Universal Robots E Series User manual

Service Manual
e-Series
Original instructions (EN)
Version: 1.1.8
Robot:
UR3e, UR5e, UR10e and UR16e
Control Box:
e-Series Control box, OEM AC and OEM DC

All rights reserved 2 Service Manual e-Series (EN) 1.1.8
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. This manual is periodically reviewed and revised.
Universal Robots A/S assumes no responsibility for any errors or omissions in this document.
Copyright © 2009–2019 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.

All rights reserved 3 Service Manual e-Series (EN) 1.1.8
Contents
1. General Information ............................................................................................................................. 7
1.1 Purpose...................................................................................................................................... 7
1.2 Company Details....................................................................................................................... 8
1.3 Disclaimer.................................................................................................................................. 8
1.4 Safety message types .............................................................................................................. 9
2. Handling ESD-Sensitive Parts............................................................................................................ 10
3. Recommended Inspection activities ................................................................................................ 15
3.1 Robot Arm .............................................................................................................................. 15
3.1.1 Inspection Plan............................................................................................................... 15
3.1.2 Visual Inspection ............................................................................................................ 16
3.1.3 Functional Inspection..................................................................................................... 16
3.1.4 Cleaning........................................................................................................................... 16
3.2 Control Box and Teach Pendant........................................................................................... 17
3.2.1 Inspection Plan............................................................................................................... 17
3.2.2 Functional and safety inspection .................................................................................. 18
3.2.3 Visual Inspection ............................................................................................................ 22
3.2.4 Cleaning .......................................................................................................................... 22
4. Service and Replacement of Parts.................................................................................................... 23
4.0.1 Pre-Use Assessment ...................................................................................................... 23
4.0.2 Recommended Tools ..................................................................................................... 24
4.1 Robot Arm .............................................................................................................................. 25
4.1.1 Movement Without Drive Power.................................................................................... 26
4.1.2 General Guidance to Separate Joint from Counterpart ............................................... 27
4.1.3 Joint Connection Types.................................................................................................. 29
4.1.4 Torque values.................................................................................................................. 29
4.1.5 Power and Communication Connector Types on the Joint......................................... 30
4.1.6 Connector Location on joints......................................................................................... 31
4.1.7 Screw Connection........................................................................................................... 34
4.1.8 Bracket Connection ........................................................................................................ 39
4.1.9 Tool Flange...................................................................................................................... 44
4.1.10 Joint Verification........................................................................................................... 45
4.1.11 Zeroing of joints............................................................................................................ 47
4.1.12 Dual Robot Calibration.................................................................................................. 53
4.1.13 Program Correction by Key Waypoints ....................................................................... 53

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4.2 Control Box.............................................................................................................................. 54
4.2.1 Dismantling the Control Box .......................................................................................... 54
4.2.2 Dismantling the OEM AC and DC Control Box .............................................................. 60
4.2.3 Assembling the Control Box incl. OEM AC and OEM DC ............................................. 68
4.2.4 Replacing of Teach Pendant .......................................................................................... 72
5. Software.............................................................................................................................................. 73
5.1 Software Updates .................................................................................................................. 73
5.1.1 Update Procedure ........................................................................................................... 74
5.1.2 Update timeline............................................................................................................... 78
5.1.3 Downgrading vs. Restoring system backup ................................................................. 79
5.2 Using Support File.................................................................................................................. 80
5.3 Using Magic Files................................................................................................................... 81
5.3.1 Using Magic Files ........................................................................................................... 81
5.4 Backup of data....................................................................................................................... 82
5.4.1 Hardware Requirements................................................................................................. 82
5.4.2 Software Requirements.................................................................................................. 82
5.4.3 How to Access Linux Partition from Windows ............................................................. 82
5.4.4 Copy the data from SD card........................................................................................... 83
6. Troubleshooting ................................................................................................................................. 84
6.1 Adding external equipment for troubleshooting purpose.................................................... 84
6.2 Support Log Reader(SLR)....................................................................................................... 85
6.3 Error codes .............................................................................................................................. 86
6.4 LED indicators and Fuse on Safety Control Board .............................................................137
6.4.1 LED Indicators on Safety Control Board......................................................................137
6.4.2 Fuse ...............................................................................................................................139
6.5 Complete rebooting sequence.............................................................................................140
6.6 Protective stop ......................................................................................................................141
7. Electrical drawings...........................................................................................................................143
8. Spare Parts .......................................................................................................................................145
8.1 Robot Arm..............................................................................................................................146
Sealing ring set UR3e –103703............................................................................................147
Sealing ring set UR5e –103705............................................................................................148
Sealing ring set UR10e/UR16e –103700..............................................................................149
Lid set for UR3e –103413.....................................................................................................150
Lid set for UR5e –103405.....................................................................................................151

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Lid set for UR10e/UR16e –103410......................................................................................152
Protective cap for tool connector - 131095..........................................................................153
Tool mount with Force/Torque sensor for UR3e –124083................................................154
Tool mount with Force/Torque sensor for UR5e –124085.................................................155
Tool mount with Force/Torque sensor for UR10e/UR16e –124080.................................156
Wrist joint 3 for UR3e –124002............................................................................................157
Wrist joint 3 for UR5e –102414............................................................................................158
Wrist joint 3 for UR10e/UR16e –102412.............................................................................159
Wrist joint 2 for UR3e –124110............................................................................................160
Wrist joint 2 for UR5e –124111.............................................................................................161
Wrist joint 2 for UR10e/UR16e –124112..............................................................................162
Wrist joint 1 for UR3e –124001............................................................................................163
Wrist joint 1 for UR5e –102413.............................................................................................164
Wrist joint 1 for UR10e/UR16e –102411..............................................................................165
Lower arm assembly –N/A...................................................................................................166
Elbow joint for UR3e–124011 ..............................................................................................167
Elbow joint for UR5e –124031 ..............................................................................................168
Elbow joint for UR10e/UR16e –124031................................................................................169
Upper arm –N/A ....................................................................................................................170
Shoulder joint for UR3e –124021.........................................................................................171
Shoulder joint for UR5e –124031..........................................................................................172
Shoulder joint for UR10e/UR16e –124041...........................................................................173
Base joint for UR3e –124021 ...............................................................................................174
Base joint for UR5e –124031 ...............................................................................................175
Base joint for UR10e/UR16e –124041 .................................................................................176
Base with Robot Arm cable for UR3e –122083 ..................................................................177
Base with Robot Arm cable for UR5e –122085 ...................................................................178
Base with Robot Arm cable for UR10e/UR16e –122080 ....................................................179
8.2 Control Box............................................................................................................................180
Fan & Energy Eater assembly –122750...............................................................................181
Power Supply for UR3e –177525.........................................................................................182
Power Supply for UR5e/UR10e/UR16e/OEM AC –177526................................................182
Power Supply for OEM DC –177005....................................................................................183
Wire bundle from Power Supply to Control Board UR3e –164071....................................184
Wire bundle from PSU to Control Board UR5e/UR10e/UR16e/OEM AC –164072..........184

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Control Board Assembly –124511.......................................................................................185
Battery for Control Board PCB - 170009...............................................................................186
Terminal set for Control Board –104007.............................................................................187
Teach Pendant and Control Box mounting bolts –105202................................................188
Fuse for Control Board –170008 .........................................................................................189
SD card for Control Board –170010/170013......................................................................190
Cover plate with seal –103240.............................................................................................191
Light pipes for control box - 170007.....................................................................................192
Fan housing and filter for Control Box –104008/170020 ..................................................193
Teach Pendant - 124091........................................................................................................194
Control Box –124500/124510..............................................................................................195
8.3 Tools ...................................................................................................................................... 196
Service tool set –109011......................................................................................................197
Dual Robot Calibration Tooling - 185500..............................................................................198
Mounting plate Robot Arm UR5e(Item profile) - 131501.....................................................199
Mounting plate Robot Arm UR5e(BOSCH profile) - 131502................................................200
Mounting plate Robot Arm UR3e(Item & BOSCH profile) - 135103....................................201
Mounting plate Robot Arm UR5e/UR10e/UR16e(Item & BOSCH profile) - 131510 ..........202
Cable for tool external - 173101............................................................................................203
9. Packing and Shipping of Robot/Spare Parts..................................................................................204
10. Change log .....................................................................................................................................205

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1. General Information
1.1 Purpose
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. However, improper use of a robot or robot parts can potentially cause failures.
If, for example, the robot is overloaded, dropped during relocation, damaged by collision, or
any other improper usage, the warranty will be void.
Universal Robots recommends the user does not attempt repair, adjustment, or make other
interventions in the mechanical or electrical systems of the robot without first consulting a UR
certified service engineer. Any unauthorized intervention voids the warranty. Service-related
operations and troubleshooting should only be performed by qualified personnel.
Before performing service-related operations, stop the robot program and disconnect the main
power to any potential dangerous tool on the robot or in the surroundings.
In the event of a defect, Universal Robots recommends ordering new parts from the Universal
Robot distributor where the robot was originally purchased. Alternatively, parts can be ordered
from the nearest distributor, details of which can be obtained from Universal Robots official
website at www.universal-robots.com

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1.2 Company Details
Universal Robots A/S
Energivej 25
DK-5260 Odense Denmark
Tel.: [phone]
Fax: [phone]
1.3 Disclaimer
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 every
care that the contents of this manual are precise and correct, but takes no responsibility for
any errors or missing information.

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1.4 Safety message types
Safety messages in this document contain information that helps you avoid injuries or
equipment damage. This document contains the following safety message types.
DANGER
This safety message indicates a hazardous situation that, if not avoided, will
result in death or serious injury.
WARNING
This safety message indicates a hazardous situation that, if not avoided, could
result in death or serious injury.
CAUTION
This safety message indicates a hazardous situation that, if not avoided, could
result in minor or moderate injury.
NOTICE
This safety message indicates a situation that, if not avoided, could result in
damage to equipment or property.
This warning sign contains references to safety-related information or general safety
measures. This warning sign does not refer to individual hazards or individual
precautionary measures.
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.

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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 6.5 Complete rebooting sequence.
NOTICE
Be sure you have intact ESD Wristband and a spare ESD bag before replacing any ESD-
sensitive parts.
ESD Wristband
PCB
ESD bag
CAUTION
Static Sensitivity
Device
ALWAYS WEAR
YOUR WRIST STRAP

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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.
It discharges any static electricity in your body to ground.
NOTICE
Replacing an ESD-sensitive part in a safe way is important to avoid damage to the
part. It is important to take precautions when handling an ESD-sensitive part.

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NOTICE
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.
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.

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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.).

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NOTICE
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.

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3. Recommended Inspection activities
3.1 Robot Arm
3.1.1 Inspection Plan
Set forth below is a check list of inspections that Universal Robots recommends be performed
according to the marked time interval. If upon inspection, the referenced parts are not in an
acceptable state, please rectify immediately.
Use the following sections as guide:
3.1.1 Visual Inspection
4.0.1 Pre-Use Assessment
4.1 Robot Arm
Monthly
Semi-annually
Annually
1
Check blue lids *
V
✘
2
Check blue lid screws
F
✘
3
Check flat rings
V
✘
4
Check robot cable
V
✘
5
Check robot cable connection
V
✘
6
Check Robot Arm mounting bolts *
F
✘
7
Check Tool mounting bolts *
F
✘
8
Check screws/bolts on joints *
F
✘
V = Visual inspection F = Functional inspection *= Must also be checked after heavy collision

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3.1.2 Visual Inspection
NOTICE
Never use compressed air to clean the Robot Arm as it can damage components.
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. 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.
7. Inspect the blue lids on all the joints for any cracks or damage.
-Replace the blue lids if they cracked or damaged.
8. Inspect the screws used for the blue lids are in place and properly tightened.
-Replace or tighten screws, if necessary.
-Correct the torque value for screws on the blue lids to 0.4 Nm +0.05𝑁𝑚
−0.05𝑁𝑚
NOTICE
If any damage is observed on a robot within the warranty period, contact the
distributor where the robot was purchased.
3.1.3 Functional Inspection
The purpose of the functional inspection is to ensure that screws, bolts, tools and robot arm are
not loose. The screws/bolts mentioned in the inspection plan should be checked with a torque
wrench with the correct torque, specified in 4.1.4 Torque values.
For the robot arm mounting bolts, these specifications can be found in the User Manual under the
Mounting section.
3.1.4 Cleaning
You can wipe away any dust/dirt/oil observed on the Robot Arm using a cloth and one of the
following cleaning agents: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha. In rare
cases, very small amounts of grease can be visible from the joint. This does not affect the
function, use, or lifetime of the joint.

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3.2 Control Box and Teach Pendant
3.2.1 Inspection Plan
Set forth below is a check list of inspections that Universal Robots recommends be performed
according to the marked time interval. If upon inspection, the referenced parts are not in an
acceptable state, please rectify immediately
Use the following sections as guide:
3.2.2 Functional and safety inspection
3.2.3 Visual Inspection
4.0.1 Pre-Use Assessment
4.2 Control Box
Monthly
Semi-
annually
Annually
1
Check Emergency stop on Teach Pendant
F
✘
2
Check Backdrive mode
F
✘
3
Check Freedrive mode
F
✘
4
Check safety inputs and outputs(if
connected)
F
✘
5
Check Teach Pendant cable and connector
V
✘
6
Check and clean air filters on Control Box
V
✘
7
Check terminals in Control Box
F
✘
8
Check electrical grounding 1< Ω to Control
Box
F
✘
9
Check main power to Control Box
F
✘
V = Visual inspection F = Functional inspection

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3.2.2 Functional and safety inspection
NOTICE
Robot safety functions is highlight recommended be tested monthly to ensure correct
function.
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.

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Freedrive Mode:
1. Unmount attachment or set TCP/Payload/CoG according to tool specifications.
2. On the Teach Pendant, press the Freedrive button to set the robot to Freedrive mode.
3. Move the robot to a horizontally elongated position and release.
4. Verify the robot can maintain its position when not being held with the Freedrive button still
pressed.

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Backdrive Mode:
If the robot is close to colliding with something, you can use the Backdrive function to move the
Robot Arm to a safe position before initializing.
1. Press ON to enable power. Status changes to Robot Active
2. Press and hold Freedrive. Status changes to Backdrive