Universal Robots OEM Control Box User manual

OEM Control Box
Installation Guide
Compatible robots: UR3e, UR5e, UR10e
Original instructions (en)

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 © 2019 by UniversalRobotsA/S.
The UniversalRobots logo is a registered trademark of UniversalRobotsA/S.
OEM Control Box Installation Guide
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

Contents
1. Introduction 1
1.1. About this Document 1
1.2. What Does the Box Contain 1
1.3. Company Details 1
2. Safety 2
2.1. Safety message types 2
2.2. General Safety Precautions 2
3. Electrical Installation: AC Mains 4
3.1. Required Items 4
3.2. How to Connect Wires to the Connector 5
3.3. Power Source Wiring 5
3.4. Robot Connection 6
3.5. Circuit Breaker Installation 6
4. Electrical Installation: DC Source 8
4.1. Required Items 8
4.2. How to Connect Wires to the Connector 9
4.3. Power Source Wiring 9
4.3.1. Soft Start Circuit 10
4.4. Robot Connection 10
4.5. Circuit Breaker Installation 11
5. Mechanical Installation 12
5.1. Working Environment Guidelines 12
5.2. Mounting the OEM Control Box 12
5.2.1. Grounding 13
6. Connecting External Devices 14
6.1. Control Ports 14
6.1.1. Connecting a Mouse, Keyboard, or Monitor 14
6.1.2. Teach Pendant, Remote Control, Local Control 15
6.2. Setting up Remote ON/OFF Control and Emergency Stop 16
6.2.1. Connecting the ON/OFF Control 16
6.2.2. Connecting Remote Emergency Stop 17
Installation Guide OEM Control Box
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

7. Specifications 18
7.1. Electrical Specifications 18
7.2. Control Unit Heat Dissipation 18
7.3. Dimensions 18
7.4. Dimensional Drawings [mm] 19
8. Troubleshooting 20
8.1. OEM Control Box AC 20
8.2. OEM Control Box DC 20
9. Certificates 21
9.1. Shipping Materials 21
9.2. Certification of Quality 21
9.3. Declarations According to EU directives 21
9.4. EU Declaration of Incorporation 22
9.5. China RoHS 23
OEM Control Box Installation Guide
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

1. Introduction
1.1. About this Document
This document describes how to install the OEM Control Box.
NOTICE
UniversalRobots disclaims any liability, even if all guidelines in this document
are followed.
1.2. What Does the Box Contain
The box contains the following items:
lThe OEM Control Box
lThis document
lWAGO 831 four-pole female connector
1.3. Company Details
UniversalRobotsA/S
Energivej 25, DK-5260 Odense S
[phone]
https://www.universal-robots.com
Installation Guide 1 OEM Control Box
1. Introduction
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

2. Safety
2.1. 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.
2.2. General Safety Precautions
This section contains general safety precautions, read it before installing or operating the OEM
Control Box.
For more information on safety, refer to the Safety section in the robot User Manual.
DANGER
Performing installation or maintenance of a device connected to a power source
can lead to electric shock.
lEnsure that the OEM Control Box is disconnected from the power source
before performing installation or maintenance.
OEM Control Box 2 Installation Guide
2. Safety
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

WARNING
Incorrect connection of the power source or ground wires may result in
equipment damage or personnel injury.
Damage caused by invalid power source connection is not covered by warranty.
Before starting the operation:
lEnsure that the power source wiring is correct.
lEnsure that the grounding is correct.
CAUTION
Failure to perform installation or maintenance correctly may result in equipment
damage or personnel injury.
lOnly qualified personnel must perform installation, start-up, and
maintenance.
NOTICE
ESD can damage sensitive components in the OEM Control Box.
lAlways wear an ESD wrist strap when working with the OEM Control Box
electrical interfaces.
CAUTION
Failure to perform a risk assessment before installing and operating the OEM
Control Box may result in equipment damage or personnel injury.
lPerform a risk assessment before installing and operating the OEM Control
Box.
Installation Guide 3 OEM Control Box
2. Safety
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

3. Electrical Installation: AC Mains
This section describes how to connect the OEM Control Box to AC mains. For information on
connecting the product to the DC source, see 4. Electrical Installation: DC Source on page8.
For information on electrical specifications, see section 7.1. Electrical Specifications on page18.
DANGER
Performing installation or maintenance of a device connected to a power source
can lead to electric shock.
lEnsure that the OEM Control Box is disconnected from the power source
before performing installation or maintenance.
3.1. Required Items
You need the following items to connect the wires:
lThe WAGO 831 four-pole female connector (included with OEM Control Box).
lA flat-bladed screwdriver, blade 5.5 x 0.8 mm. For example, WAGO 210-721.
lThree wires with ferrules.
The following illustration shows the required items.
OEM Control Box 4 Installation Guide
3. Electrical Installation: AC Mains
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

3.2. How to Connect Wires to the Connector
This section describes how to connect wires to a connector with locking levers:
1. Insert the screwdriver into a flat slot next to a connector hole.
2. Push the screwdriver until the clamp inside the hole opens. Keep the screwdriver in the
slot.
3. Insert the wire ferrule into the open hole.
4. Ensure that the wire ferrule is firmly placed, remove the screwdriver to close the hole.
3.3. Power Source Wiring
Use the following scheme to attach wires to the connector.
1 Ground 2 Neutral
3 Line
To connect the OEM Control Box to the power source:
1. Connect the following three wires to the connector:
lNeutral
lLine
lGround
2. Connect the neutral, and line wires to mains. Connect the ground wire to the facility
ground.
3. Plug the connector into the power source socket on the OEM Control Box.
Installation Guide 5 OEM Control Box
3. Electrical Installation: AC Mains
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

NOTICE
Connecting wires to poles without labels may interfere with the operation of the
robot.
lDo not connect wires to poles without labels.
3.4. Robot Connection
The Robot Arm connector is next to the power supply connector. For details on connecting the
Robot Arm cable, refer to the robot user manual.
3.5. Circuit Breaker Installation
Use a double pole circuit breaker to protect the power input connector, as it can also be used as
a switch. If a fuse is used, then a two-pole switch must be installed between the fuse and power
input connector.
The following illustration shows the circuit breaker wiring scheme.
1 Power input 2 Circuit breaker
OEM Control Box 6 Installation Guide
3. Electrical Installation: AC Mains
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

CAUTION
The installation must comply with the standard IEC 60364. Installing appropriate
fuses or circuit breakers to protect the cable and system is the responsibility of
the installer.
Installation Guide 7 OEM Control Box
3. Electrical Installation: AC Mains
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

4. Electrical Installation: DC Source
This section describes how to connect the OEM Control Box to a DC source. For information on
connecting the product to the AC mains, see 3. Electrical Installation: AC Mains on page4.
For information on electrical specifications, see section 7.1. Electrical Specifications on page18.
DANGER
Performing installation or maintenance of a device connected to a power source
can lead to electric shock.
lEnsure that the OEM Control Box is disconnected from the power source
before performing installation or maintenance.
4.1. Required Items
You need the following items to connect the wires:
lThe WAGO 831 four-pole female connector (included with OEM Control Box).
lA flat-bladed screwdriver, blade 5.5 x 0.8 mm. For example, WAGO 210-721.
lThree wires with ferrules.
The following illustration shows the required items.
OEM Control Box 8 Installation Guide
4. Electrical Installation: DC Source
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

4.2. How to Connect Wires to the Connector
This section describes how to connect wires to a connector with locking levers:
1. Insert the screwdriver into a flat slot next to a connector hole.
2. Push the screwdriver until the clamp inside the hole opens. Keep the screwdriver in the
slot.
3. Insert the wire ferrule into the open hole.
4. Ensure that the wire ferrule is firmly placed, remove the screwdriver to close the hole.
4.3. Power Source Wiring
Use the following scheme to attach wires to the connector.
1 Ground 2 Negative
3 Positive
NOTICE
Reversing the DC source polarity causes permanent damage to the OEM Control
Box.
Damage caused by invalid power source connection is not covered by warranty.
lEnsure that the polarity is correct before powering up the Control Box.
Installation Guide 9 OEM Control Box
4. Electrical Installation: DC Source
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

To connect the OEM Control Box to the power source:
1. Connect the following three wires to the connector:
lNegative
lPositive
lGround (if the application supports such connection)
2. Connect the negative, and positive wires to the DC source. Ensure that the polarity is
correct.
Connect the ground wire to the facility ground if the application supports such connection.
3. Plug the connector into the power source socket on the OEM Control Box.
NOTICE
Connecting wires to poles without labels may interfere with the operation of the
robot.
lDo not connect wires to poles without labels.
4.3.1. Soft Start Circuit
NOTICE
When the OEM Control Box is connected to a DC source, the inrush current can
reach up to 400A for 200μs. This may cause damage to the DC source or shut
down other electronics connected to it.
lInstall a soft start circuit when using a DC source.
4.4. Robot Connection
The Robot Arm connector is next to the power supply connector. For details on connecting the
Robot Arm cable, refer to the robot user manual.
OEM Control Box 10 Installation Guide
4. Electrical Installation: DC Source
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

4.5. Circuit Breaker Installation
Use a double pole circuit breaker to protect the power input connector, as it can also be used as
a switch. If a fuse is used, then a two-pole switch must be installed between the fuse and power
input connector.
The following illustration shows the circuit breaker wiring scheme.
1 Power input 2 Circuit breaker
CAUTION
The installation must comply with the standard IEC 60364. Installing appropriate
fuses or circuit breakers to protect the cable and system is the responsibility of
the installer.
Installation Guide 11 OEM Control Box
4. Electrical Installation: DC Source
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

5. Mechanical Installation
5.1. Working Environment Guidelines
Follow these guidelines to ensure reliable operation of the OEM Control Box:
lKeep free from dust and dirt.
lKeep away from water, solvents, and chemicals.
lKeep ambient air temperatures flowing into the fan within 0–50°C.
lKeep the aluminum controller frame temperature within 0–65°C.
5.2. Mounting the OEM Control Box
Use the four mounting brackets to mount the OEM Control Box, see the following illustration. For
dimensional drawings, refer to section 7.4. Dimensional Drawings [mm] on page19.
For the product dimensions, refer to section 7.3. Dimensions on page18.
OEM Control Box 12 Installation Guide
5. Mechanical Installation
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

Ensure that there is enough space for cables and sufficient air circulation around the Control
Box. For information about the heat dissipation, see 7.2. Control Unit Heat Dissipation on
page18. The following illustration shows the airflow.
NOTICE
Insufficient airflow or warm air circulation can cause the OEM Control Box to
overheat and shut down.
5.2.1. Grounding
The OEM Control Box casing is electrically connected to the ground pin of the power source
connector. Any conductive mounting surface must also be connected to the ground.
Installation Guide 13 OEM Control Box
5. Mechanical Installation
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

6. Connecting External Devices
6.1. Control Ports
The bottom side of the OEM Control Box contains a bracket with ports for connecting external
devices. The following illustration shows the bracket.
1 Teach Pendant port 2 SD card slot
3 Ethernet port 4 USB ports
5 Mini DisplayPort 6 10A Mini Blade Fuse
The following table describes the ports.
Port Description
Teach
Pendant
The port for connecting the Teach Pendant (not included with OEM Control
Box).
SD card The SD card is already in the SD card port. Do not remove the card.
Ethernet Connect external devices supporting MODBUS, Ethernet/IP, or PROFINET.
USB ports Connect USB devices, for example a mouse, keyboard, a USB flash drive.
Mini
DisplayPort
Connect a monitor. The output video stream is the same as in the Teach
Pendant port. Supported connection types:
lDP (direct connection).
lActive DVI (using an active DP to DVI converter).
lActive HDMI (using an active DP to HDMI converter).
10A Mini
Blade Fuse
Connect a fuse. The fuse must be UL-marked and have a 10A current rating.
6.1.1. Connecting a Mouse, Keyboard, or Monitor
Use a USB port to connect a keyboard or a mouse.
OEM Control Box 14 Installation Guide
6. Connecting External Devices
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

Use the Mini DisplayPort to connect a monitor. The output video stream is the same as in the
Teach Pendant port.
6.1.2. Teach Pendant, Remote Control, Local Control
Connecting a Teach Pendant
1. Connect the Teach Pendant cable to the Teach Pendant port.
The Teach Pendant powers on in a fault state and the Robot Arm brakes engage.
2. Press Re-Initialize to clear the fault state and power on the Teach Pendant.
3. Once the Teach Pendant is restarted, exit the start-up screen.
4. In the Header, tap Installation and select Safety.
5. Under Safety, tap Hardware.
6. In the Teach Pendant drop-down menu, select Yes.
If you are prompted to use a password, insert the Safety Password and tap Unlock.
Installation Guide 15 OEM Control Box
6. Connecting External Devices
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.

Enabling Remote Control
1. On PolyScope, in the Header, tap the Hamburger Menu.
2. Select Settings, tap System and select Remote Control.
3. On the Remote Control screen, select Enable to activate Remote Control.
To activate Local Control, in the Header, tap the Remote Control icon and select Local Control.
NOTE
For more information, refer to the robot User Manual available on the support
website:
lhttps://www.universal-robots.com/support/
6.2. Setting up Remote ON/OFF Control and
Emergency Stop
The OEM Control Box requires a remote ON/OFF control and an emergency stop pushbutton. The
following sections describe how to install them using the I/O ports.
6.2.1. Connecting the ON/OFF Control
The table below shows how to connect a remote ON/OFF control.
State Connection
ON
OFF
NOTE
For more information, refer to the robot User Manual available on the support
website:
lhttps://www.universal-robots.com/support/
OEM Control Box 16 Installation Guide
6. Connecting External Devices
Copyright © 2019 by UniversalRobotsA/S. All rights reserved.