Universal Robots e Series User manual

e-Series
Compatible robots: UR3e, UR5e, UR10e, UR16e
Control Box: e-Series Control box, OEM Control Box
Original instructions (en)

Contents
1.Introduction 1
1.1. About This Document 1
1.2. Company Details 1
1.3. Copyright and disclaimers 1
1.4. Safety Message Types 2
2.Handling ESD-Sensitive Parts 4
3.Recommended Inspection Activities 9
3.1. Robot Arm 9
3.1.1. Inspection Plan 9
3.1.2. Visual Inspection: Robot arm 9
3.1.3. Functional Inspection 10
3.1.4. Cleaning Your Robot 11
3.2. Control Box and Teach Pendant 11
3.2.1. Inspection Plan 11
3.2.2. Functional and Safety Inspection 12
3.2.3. Visual Inspection: Control Box 15
3.2.4. Cleaning 17
4.Service and Replacement of Parts 18
4.1. Pre-Use Assessment 18
4.1.1. Recommended Tools 18
4.2. Robot Arm 20
4.2.1. Movement Without Drive Power 21
4.2.2. General Guidance to Separate Joint from Counterpart 21
4.2.3. Joint Connection Types 23
4.2.4. Torque Values 23
4.2.5. Power and Communication Connector Types on the Joint 24
4.2.6. Connector Location on joints 27
4.2.7. Screw Connection 31
4.2.8. Clamp Connection 35
4.2.9. Tool Flange 38
4.2.10. Joint Verification 39
4.2.11. Zeroing of Joints 41
4.2.12. Dual Robot Calibration 44
4.2.13. Program Correction by Key Waypoints 45
4.2.14. Important Notice about Size 3 Joint on UR10e 45
4.3. Robot Cable 45

4.3.1. Replacing Robot Cable 45
4.4. Control Box 47
4.4.1. Dismantling the Control Box 47
4.4.2. Dismantling the OEM AC and DC Control Box 51
4.4.3. Torque Values 57
4.4.4. Replacing the Teach Pendant:Standard TP 60
4.4.5. Replacing the Teach Pendant: 3PE TP 62
4.4.6. Replacement of Teach Pendant Cable 64
5.Software 69
5.1. Long Term Support 69
5.2. Software Updates 69
5.2.1. Update Procedure 70
5.2.2. Update timeline 73
5.2.3. Downgrading vs. Restoring system backup 73
5.3. Using Support File 74
5.4. Using Magic Files 75
5.4.1. Using Magic Files 76
5.5. Backup of data 76
5.5.1. Hardware Requirements 76
5.5.2. Software Requirements 77
5.5.3. How to Access Linux Partition from Windows 77
5.5.4. Copy the data from SD card 77
6.Troubleshooting 79
6.1. Adding External Equipment for Troubleshooting Purpose 79
6.2. Log Viewer 79
6.2.1. Generel Purpose 79
6.2.2. Log Viewer Requirements 80
6.2.3. Installation Log Viewer 80
6.2.4. How to Use The UR Log Viewer 81
6.2.5. Loading the Data 81
6.2.6. Log Reader Tab 83
6.2.7. Flight Records 84
6.2.8. Log Start 86
6.2.9. Log Analysis Tab 88
6.2.10. Record Data Tab 89
6.2.11. Export From Robot Tab 90
6.2.12. Types of Messages 91
6.3. Support Log Reader (SLR) 91
6.4. LED indicators and Fuse on Safety Control Board 93

6.4.1. LED Indicators on Safety Control Board 93
6.4.2. Fuse 93
6.5. Complete Rebooting Sequence 95
6.6. Protective stop 97
7.Electrical drawings 99
8.Spare Parts 100
9.Packing and Shipping of Robot/Spare Parts 101
9.1. Transport Without Packaging 102
10.Change log 104

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. 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
1.2. Company Details
Universal Robots A/S
Energivej 25
DK-5260 Odense Denmark
Tel.: [phone]
Fax: [phone]
1.3. Copyright and disclaimers
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 document is periodically reviewed and revised.
UniversalRobotsA/S assumes no responsibility for any errors or omissions in this document.
Copyright © 2009–2024 by UniversalRobotsA/S.
The UniversalRobots logo is a registered trademark of UniversalRobotsA/S.
Service Manual 1 e-Series
1.Introduction
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

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.
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.
Safety messages and statements are used throughout this manual to emphasize important
information.
Read all messages and statements to help ensure safety and to prevent injury to personnel and
product damage.
The safety message types are defined below.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
WARNING: ELECTRICITY
Indicates a hazardous electrical situation which, if not avoided, could result in
death or serious injury.
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.
e-Series 2 Service Manual
1.Introduction
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

GROUND
Indicates grounding.
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.
Service Manual 3 e-Series
1.Introduction
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

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
ESD-sensitive parts.
e-Series 4 Service Manual
2.Handling ESD-Sensitive Parts
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

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.
NOTICE
Hold the ESD-sensitive part by its edges. Do not touch its pins or hold directly on
any exposed prints.
Service Manual 5 e-Series
2.Handling ESD-Sensitive Parts
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

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.
e-Series 6 Service Manual
2.Handling ESD-Sensitive Parts
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

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
wristband and the ESD wristband is attached to the system grounding point.
Service Manual 7 e-Series
2.Handling ESD-Sensitive Parts
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

NOTICE
Be extra careful in working with ESD-sensitive parts when cold-weather and heating
is used, because low humidity increases static electricity.
e-Series 8 Service Manual
2.Handling ESD-Sensitive Parts
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

3.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.
See the following sections for detailed guidance:
•3.1.2. Visual Inspection: Robot armbelow
•4.1. Pre-Use Assessmenton page18
•4.2. Robot Armon page20
Inspection action type Timeframe
Monthly Biannually 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
3.1.2. Visual Inspection: Robot arm
NOTICE
Using compressed air to clean the robot arm can damage the robot arm
components.
•Never use compressed air to clean the robot arm.
Service Manual 9 e-Series
3.Recommended Inspection Activities
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

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
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
Do functional inspections to ensure the robot arm and its screws, bolts and tools are not loose.
Use a correctly calibrated torque wrench, specified in Torque Values
to check the screws and bolts listed in the inspection plan.
For the robot arm mounting bolts specifications, see the Hardware Installation Manual, chapter
Mechanical Interface: Mounting.
e-Series 10 Service Manual
3.Recommended Inspection Activities
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

3.1.4. Cleaning Your Robot
Everyday Cleaning
You can wipe away any dust/dirt/oil observed on the robot arm and/or Teach Pendant 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.
Additional Cleaning
Due to the added focus on cleaning your robot, UniversalRobots recommends cleaning with 70%
isopropyl alcohol (rubbing alcohol).
1. Wipe the robot with a hard twisted micro fiber cloth and 70% isopropyl alcohol (rubbing
alcohol).
2. Let the 70% isopropyl alcohol dwell on the robot for 5 minutes, and then clean the robot
using standard cleaning procedure.
DONOTUSEBLEACH. Do not use bleach in any diluted cleaning solution.
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.
See the following sections for detailed guidance:
•3.2.2. Functional and Safety Inspectionon the next page
•3.1.2. Visual Inspection: Robot armon page9
•4.1. Pre-Use Assessmenton page18
•Control Box
Inspection action type Timeframe
Monthly Biannually Annually
1 Check Emergency stop on Teach
Pendant
F✘
Service Manual 11 e-Series
3.Recommended Inspection Activities
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

Inspection action type Timeframe
Monthly Biannually Annually
2 & 3
On a standard TP: check the freedrive
button by pressing it gently.
On a 3PE TP: check the 3PE buttons
pressing them gently.
F✘
Check Backdrive mode F ✘
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 &9 Check electrical grounding 1< Ω to
Control Box
F✘
Check main power to Control Box F ✘
V = Visual inspection F = Functional inspection
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:
e-Series 12 Service Manual
3.Recommended Inspection Activities
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

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
1. Unmount attachment or set TCP/Payload/CoG according to tool specifications.
2. To move the robot arm in Freedrive:
•On a standard Teach Pendant, press and hold the Freedrive button.
•On a 3PE Teach Pendant, rapidly light-press, then light-press-and-hold the 3PE button.
Standard TP 3PE TP
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 pressing the
Freedrive, or 3PE button.
Service Manual 13 e-Series
3.Recommended Inspection Activities
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

Backdrive
If the robot arm is close to colliding with something, you can use the Backdrive function to move
the robot arm to a safe position before (re)initializing it.
1. Press ON to enable power. Status changes to Robot Active
2. Press and hold Freedrive. Status changes to Backdrive
Standard TP 3PE TP
3. Move robot as in Freedrive. Joint brakes are released where needed once the Freedrive
button is activated.
NOTICE
The robot arm is “heavy” to move around in Backdrive, so efort is required to move
the joints.
e-Series 14 Service Manual
3.Recommended Inspection Activities
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

MANDATORY ACTION
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
Check which safety inputs and outputs are active and that they can be triggered via PolyScope or
external devices.
Backup data
See section Backup of data
3.2.3. Visual Inspection: Control Box
1. Disconnect the power cable from Control Box.
2. Check the Control Board terminals are properly inserted.Do not ignore loose wires.
3. Check for any dirt/dust inside Control Box. Clean with ESD vacuum cleaner if needed.
NOTICE
Using compressed air to clean the Control Box can cause damage to the Control
Box components.
•Never use compressed air to clean the Control Box.
Service Manual 15 e-Series
3.Recommended Inspection Activities
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.

e-Series 16 Service Manual
3.Recommended Inspection Activities
Copyright © 2009–2024 by UniversalRobotsA/S. All rights reserved.