Universal Robots UR10 User manual

Service Manual
Revision UR10_en_3.1.1
Robot:
UR10 with CB3-controller
valid from robot s/n 2014300001

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Contents
1. General information .................................................................................................................................. 4
1.1 Purpose.................................................................................................................................................... 4
1.2 Company details ...................................................................................................................................... 5
1.3 Disclaimer ................................................................................................................................................ 5
2. Preventive Maintenance ........................................................................................................................... 6
2.1 Controller................................................................................................................................................. 6
2.1.1 Inspection plan, Safety Functions..................................................................................................... 6
2.1.2 Visual inspection............................................................................................................................... 7
2.1.3 Cleaning and replacement of filters ................................................................................................. 7
2.2 Robot arm................................................................................................................................................ 8
2.2.1 Visual inspection............................................................................................................................... 8
3. Service and Replacement of parts............................................................................................................. 9
3.1 Robot arm................................................................................................................................................ 9
3.1.1 Robot arm configuration .................................................................................................................. 9
3.1.2 Brake release .................................................................................................................................. 10
3.1.3 General guidance to separate joint from counterpart................................................................... 11
3.1.4 Torque values ................................................................................................................................. 14
3.1.5 Base joint –Base mounting bracket ............................................................................................... 15
3.1.6 Shoulder joint –Base joint.............................................................................................................. 17
3.1.7 Upper arm –Shoulder joint............................................................................................................ 19
3.1.8 Elbow joint –Upper arm................................................................................................................. 21
3.1.9 Elbow counterpart –Elbow joint.................................................................................................... 21
3.1.10 Wrist 1 joint –Lower arm............................................................................................................. 23
3.1.11 Wrist 2 joint –Wrist 1 joint .......................................................................................................... 25
3.1.12 Wrist 3 joint –Wrist 2 joint .......................................................................................................... 27
3.1.13 Tool flange –Wrist 3 joint ............................................................................................................ 27
3.1.14 Joint calibration ............................................................................................................................ 29
3.1.15 Change joint ID ............................................................................................................................. 35
3.2 Controller............................................................................................................................................... 37
3.2.1 Handling ESD-sensitive parts.......................................................................................................... 37
3.2.2 Replacement of motherboard........................................................................................................ 41

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3.2.3 Replacement of Safety Control Board ............................................................................................ 44
3.2.4 Replacement of teach pendant ...................................................................................................... 46
3.2.5 Replacement of 48V power supply................................................................................................. 47
3.2.6 Replacement of 12V power supply................................................................................................. 50
3.2.7 Replacement of current distributor................................................................................................ 51
4. Software ...................................................................................................................................................... 52
4.1 Update software.................................................................................................................................... 52
4.2 Update joint firmware........................................................................................................................... 54
4.3 Using Magic files.................................................................................................................................... 57
5. Troubleshooting ...................................................................................................................................... 58
5.1 Error codes............................................................................................................................................. 58
5.2 LED indicators on Safety Control Board ................................................................................................ 74
5.3 Error phenomena ............................................................................................................................ 75
5.3.1 ControlBox: NO CONTROLLER displayed in Initializing................................................................... 75
5.3.2 NO CABLE displayed during power up............................................................................................ 76
5.3.3 Force limit protective stop ............................................................................................................. 77
5.3.4 Power on failure in Initializing ........................................................................................................ 78
5.3.5 Checklist after a collision ................................................................................................................ 81
5.4 Electrical documentation................................................................................................................. 82
5.4.1 Schematic overview........................................................................................................................ 82
5.4.2 E-Plan diagrams .............................................................................................................................. 87
6. Spare parts................................................................................................................................................ 100
6.1 Spare part list....................................................................................................................................... 100
6.2 Service kit............................................................................................................................................. 101
7. Packing of robot......................................................................................................................................... 102
8. Change log ............................................................................................................................................. 103
8.1 Change log ........................................................................................................................................... 103

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1. General information
1.1 Purpose
The main purpose of this manual is to help the user safely perform service related operations and
troubleshooting.
Universal Robots industrial robots are designed using high quality components designed for long lifetime.
However any improper use of robot can potentially cause failures. For example, the robot may have been
overloaded or have been dropped on the floor when relocating or have run with a load not recommended
by Universal Robots. Any improper use of the robot will invalidate the guarantee.
Universal Robots recommends that you do not attempt repair, adjustment or other intervention in the
mechanical or electrical systems of the robot unless a problem has arisen. Any unauthorized intervention
will invalidate the guarantee. Service related operations and troubleshooting should only be performed by
qualified personnel.
Before performing service related operations, always make sure to stop the robot program and disconnect
power supply to any potential dangerous tool on the robot or in the work cell.
In the event of a defect, Universal Robots recommends ordering new parts from the Universal
Robot distributor from where the robot has been purchased.
Alternatively, you can order parts from your nearest distributor, whose details you can obtain 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
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 © 2014 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.

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2. Preventive Maintenance
2.1 Controller
2.1.1 Inspection plan, Safety Functions
The safety functions of the robots must be tested at least once a year to ensure correct function. The
following tests must be performed.
Test that the Emergency Stop button on the Teach Pendant functions:
oPress the Emergency Stop button on the Teach Pendant
oObserve that the robot stops and turns off the power to the joints
oPower the robot again
Test Teach mode:
oSet the robot in Teach mode by pressing the Teach button on the Teach Pendant
oMove the robot to a position where it is stretched out horizontally
oMonitor that the robot maintains its position when not holding the robot and the teach
button still pressed
Verify safety settings:
oVerify that the safety settings of the robot comply with the Risk Assessment of the robot
installation
Test that additional safety inputs and outputs are still functioning:
oCheck which safety inputs and outputs are active and test that they can be triggered

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2.1.2 Visual inspection
Disconnect power cable from controller
Open cabinet door
Check connectors are properly inserted on printed circuit boards
Check for any dirt/dust inside of controller
If any dirt/dust is present:
» gently use a vacuum cleaner to remove particles
2.1.3 Cleaning and replacement of filters
Controller box contains two filters, one on each side of controller
Remove filters from controller box and clean them thoroughly using compressed air
» Replace filters if necessary

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2.2 Robot arm
2.2.1 Visual inspection
Move robot arm to HOME position (if possible)
Turn off and disconnect power cable from controller
Inspect cable between controller and robot arm for any damage
Inspect flat rings for wear and damage
» replace flat rings if worn out or damaged
Inspect blue lids on all joints for any cracks or damage
» replace blue lids if cracked or damaged
Inspect that screws for blue lids are in place and properly tightened
» Replace screws, tighten properly if necessary
Correct torque value for screws on blue lids are 0.4Nm
If any damage is observed on a robot within the warranty period, contact the distributor from which the
robot has been purchased.

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3. Service and Replacement of parts
3.1 Robot arm
3.1.1 Robot arm configuration
3.1.7 Upper arm –Shoulder joint
3.1.6 Shoulder joint –Base joint
3.1.5 Base joint –Base mounting bracket
3.1.8 Elbow joint –Upper arm
3.1.9 Elbow counter part –Elbow joint
3.1.13 Tool flange –Wrist 3 joint
3.1.12 Wrist 3 joint –Wrist 2 joint
3.1.11 Wrist 2 joint–Wrist 1 joint
3.1.10 Wrist 1 joint –Lower arm

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3.1.2 Brake release
If required, the brake on a joint can be released without power connected.
IMPORTANT NOTICE:
Before releasing a brake it is extremely important to dismount any dangerous tooling to avoid any
hazardous situations.
If releasing the brake on Base joint, Shoulder joint or Elbow joint, it is important to make proper
mechanical support prior to releasing the brake.
Always make sure no personnel are located under the arm when releasing the brake.
Do not move the joint more than necessary, absolute max. are 180 degrees in order for the robot
to find its original physical position.
Procedure for releasing the joint
Shut down Controller.
Remove blue lid on joint.
Push brake pin down to release, joint can then be rotated.
Brake on Base and Shoulder joints, Brake on Elbow joint, Brake on Wrist joints
Make sure to mount blue lid properly on joint before turning on Controller.

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3.1.3 General guidance to separate joint from counterpart
Disassemble:
1. Shut down the controller.
2. Move the robot to a comfortable position for disassembly. If necessary dismount entire robot arm
from work cell and place on a solid surface.
3. Remove blue lid.
4. Now screw back one of the lid screws into a pol. Clip on your ESD wristband/alligator clip as shown
below.
5. Disconnect wires.
6. Remove alignment screw.

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7. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the
joint housing.
8. Slide the grey Teflon ring back.
10 screws become visible, 5 on each side of joint.
Loosen the screws with an open-ended spanner approximately two full turns each.
9. Pull the two parts apart and gently twist them in opposite directions around 10 mm, until a
mechanical stop is met (holes are keyhole-type). They can then be completely separated.
Assemble:
1. After replacing a joint etc. do as follows to assemble the robot arm.
2. Gently insert one part with screws and washers into the other part.

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3. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)
before gently twisting the parts in opposite directions until a mechanical stop is met.
4. Gently tighten the 10 screws, and then tighten in cross order with the correct torque.
See Section 3.1.4 Torque value.
5. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon ring.
6. Mount the alignment screw and tighten with 0.4Nm.
7. Twist the communication wires before they are connected.
(To reduce electrical noise in the system)
8. Mount the blue lid on the joint and tighten with 0.4Nm.
9. Proceed to chapter 3.1.14 Joint calibration for calibrating the joint.

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3.1.4 Torque values
UR10 torque values
CONNECTION
TORQUE
HEAD SIZE
BASE PLATE
J0 BASE
8.0Nm
10 mm.
[J0] BASE
J[1] Shoulder
8.0Nm
10 mm.
[J1] SHOULDER
LOWER ARM
8.0Nm
10 mm.
LOWER ARM
[J2] ELBOW
3.0Nm
7 mm.
[J2] ELBOW
DUMMY JOINT
3.0Nm
7 mm.
DUMMY JOINT
HIGHER ARM
3.0Nm
7 mm.
HIGHER ARM
[J3] Wrist 1
1.3Nm
5.5 mm.
[J3] WRIST 1
[J4] Wrist 2
1.3Nm
5.5 mm.
[J4] WRIST 2
[J5] Wrist 3
1.3Nm
5.5 mm.
[J5] WRIST 3
Tool Flange
1.3Nm
5.5 mm.
Alignment screw
0.4Nm
Torx T10
Blue lid
0.4Nm
Torx T10
Attention: Click the torque tools 3 times before use to get the correct calibrated torque.
8.0Nm
8.0Nm
8.0Nm
3.0Nm
3.0Nm
3.0Nm
1.3Nm
1.3Nm
1.3Nm
1.3Nm

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3.1.5 Base joint –Base mounting bracket
Disassemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Shut down the controller.
2. Remove alignment screw.
3. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint
housing.
4. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen the screws
with a 7 mm. open-ended spanner about two full turns, approximately 3 mm. for each screw.
5. Pull the base plate and Base joint apart and gently twist the two parts in opposite directions around 10
mm. until a mechanical stop is met (holes are keyhole-type).
6. Pull away the base plate from Base joint.
7. Disconnect wires between base plate and Base joint.
2 x red wire = 48V DC
2 x black wire = GND
Black connector = bus cable

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Base joint –Base mounting bracket: Assemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Replace base plate and reconnect wires according to illustration:
Twist the communication wires before they are connected.
(To reduce electrical noise in the system)
2. Gently insert base plate with screws and washers into the Base joint.
3. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)
before gently twisting the parts in opposite directions until a mechanical stop is met.
4. Gently tighten the 10 screws, and then tighten in cross order with 8.0Nm.
5. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon ring.
6. Mount the alignment screw and tighten with 0.4Nm.
7. Mount blue lid on Base joint and tighten with 0.4Nm.

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3.1.6 Shoulder joint –Base joint
Disassemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Shut down the controller.
2. Remove blue lid on Base joint.
3. Connect ESD wristband
4. Disconnect wires between Base joint and Shoulder joint
2 x red wire = 48V DC
2 x black wire = GND
Black connector = bus cable (NB: polarized)
5. Remove alignment screw
6. Gently remove black flexible flat ring between Base and Shoulder with a tiny screwdriver or similar tool
and twist it around the joint housing.
7. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen the screws
with a 7 mm. open-ended spanner about two full turns, approximately 3 mm. for each screw.
8. Pull the Base joint and Shoulder joint apart and gently twist the two parts in opposite directions around
10 mm. until a mechanical stop is met (holes are keyhole-type).
9. Pull away the Base joint from Shoulder joint.

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Shoulder joint –Base joint: Assemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Gently insert Base joint with screws and washers into the Shoulder joint.
2. Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the Base joint and Shoulder joint in opposite directions until a mechanical stop is met.
3. Tighten the 10 screws lightly, and then tighten in cross order with 8.0Nm.
4. Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.
5. Mount the alignment screw and tighten with 0.4Nm.
6. Reconnect connectors as illustrated.
Twist the communication wires before they are connected.
(To reduce electrical noise in the system)
7. Mount blue lid on Base joint and tighten with 0.4Nm.
8. Proceed to chapter 3.1.14 Joint calibration for calibrating the joint.

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3.1.7 Upper arm –Shoulder joint
Disassemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Shut down the controller.
2. Remove blue lid on Shoulder joint.
3. Connect ESD wristband
4. Disconnect wires between Upper arm and Shoulder joint
1 x red wire = 48V DC
1 x black wire = GND
Black connector = bus cable (NB: polarized)
5. Remove alignment screw.
6. Gently remove black flexible gasket between Upper arm and Shoulder with a tiny screwdriver or similar
tool and twist it around the upper arm.
7. 10 screws become visible, 5 on each side of joint.
Untighten gently the screw with a 10 mm. open-ended spanner about two full rounds, approximately 3
mm. for each screw.
8. Pull the Shoulder joint and upper arm apart and gently twist the two parts in opposite directions
around 10 mm. until a mechanical stop is met (holes are keyhole-type).
9. Pull away the Shoulder joint from upper arm.

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Upper arm –Shoulder joint: Assemble
For details and photos please see: 3.1.3 General guidance to separate joint from counterpart
1. Gently insert Shoulder joint with screws and washers into the upper arm.
2. Make sure the washers are fully inserted and flush against the head of the bolt (this is important)
before gently twisting the parts in opposite directions until a mechanical stop is met.
3. Tighten the 10 screws lightly, and then tighten in cross order with 8.0Nm.
4. Gently put back the gasket.
5. Mount the alignment screw and tighten with 0.4Nm.
6. Connect ESD wristband
7. Reconnect wires correctly.
Twist the communication wires before they are connected.
(To reduce electrical noise in the system)
8. Mount blue lid on Shoulder joint and tighten with 0.4Nm.
9. Proceed to chapter 3.1.14 Joint calibration for calibrating the joint.