Universal Robots UR10 User manual

Service Manual
Revision UR10_en_3.1.3
"Original instructions"
Robot:
UR10 with CB3.0/3.1-controller
CB3.0 valid from robot s/n 2014300001 to 2016301178
CB3.1 valid from robot s/n 2016301179

All rights reserved 2 Servicemanual_UR10_en_3.1.3
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 .................................................................................................................. 8
2.1.3 Cleaning and replacement of filters..................................................................................... 8
2.2 Robot arm.......................................................................................................................................... 9
2.2.1 Visual inspection .................................................................................................................. 9
3. Service and Replacement of parts............................................................................................................... 10
3.1 Robot arm........................................................................................................................................ 10
3.1.1 Before returning any part to Universal Robots.................................................................. 10
3.1.2 Robot arm configuration................................................................................................... 11
3.1.3 Brake release...................................................................................................................... 12
3.1.4 General guidance to separate joint from counterpart ...................................................... 13
3.1.5 Torque values..................................................................................................................... 17
3.1.6 Base joint –Base mounting bracket .................................................................................. 18
3.1.7 Shoulder joint –Base joint................................................................................................. 20
3.1.8 Upper arm –Shoulder joint ............................................................................................... 22
3.1.9 Elbow joint –Upper arm .................................................................................................... 24
3.1.11 Wrist 1 joint –Lower arm ................................................................................................ 26
3.1.12 Wrist 2 joint –Wrist 1 joint.............................................................................................. 28
3.1.13 Wrist 3 joint –Wrist 2 joint.............................................................................................. 30
3.1.14 Tool flange –Wrist 3 joint................................................................................................ 30
3.1.15 Instructions for calibrating a joint.................................................................................... 32
3.1.16 Dual Robot calibration ..................................................................................................... 40
3.1.17 Change joint ID................................................................................................................. 41
3.1.18 Joint spare part adaptation.............................................................................................. 42
3.2 Controller ........................................................................................................................................ 44

All rights reserved 3 Servicemanual_UR10_en_3.1.3
3.2.1 Handling ESD-sensitive parts ............................................................................................. 44
3.2.2 Replacement of motherboard 3.0 ..................................................................................... 48
3.2.3 Replacement of motherboard 3.1 ..................................................................................... 51
3.2.4 Replacement of Safety Control Board ............................................................................... 54
3.2.5 Replacement of teach pendant.......................................................................................... 57
3.2.6 Replacement of 48V power supply .................................................................................... 59
3.2.7 Replacement of 12V power supply .................................................................................... 62
3.2.8 Replacement of current distributor ................................................................................... 63
4. Software ...................................................................................................................................................... 64
4.1 Update software.............................................................................................................................. 64
4.2 Update joint firmware..................................................................................................................... 66
4.3 Using Magic files.............................................................................................................................. 69
5. Troubleshooting .......................................................................................................................................... 70
5.1 Error codes ...................................................................................................................................... 70
5.2 LED indicators and Fuses on Safety Control Board ......................................................................... 92
5.3 Error phenomena ............................................................................................................................ 94
5.3.1 ControlBox: NO CONTROLLER displayed in Initializing ...................................................... 94
5.3.2 NO CABLE displayed during power up ............................................................................... 95
5.3.3 Protective stop................................................................................................................... 96
5.3.4 Power on failure in Initializing ........................................................................................... 97
5.3.5 Checklist after a collision ................................................................................................. 100
5.4 Electrical documentation .............................................................................................................. 101
5.4.1 Schematic overview ......................................................................................................... 101
5.4.2 E-Plan diagrams................................................................................................................ 107
6. Spare parts................................................................................................................................................ 120
6.1 Spare part list ................................................................................................................................ 120
6.2 Service kit ...................................................................................................................................... 121
7. Packing of robot......................................................................................................................................... 122
8. Change log ................................................................................................................................................. 123

All rights reserved 4 Servicemanual_UR10_en_3.1.3
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

All rights reserved 5 Servicemanual_UR10_en_3.1.3
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 © 2016 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.

All rights reserved 6 Servicemanual_UR10_en_3.1.3
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 on robot again
Test Free drive mode:
oUnmount attachment or set TCP/Payload/CoG according to tool specifications
oSet the robot in Free drive mode by pressing the Free drive 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 Free
drive button still pressed.
Test Back drive mode:
If robot is close to collision, the BACKDRIVE function can be used to move robot arm to safe
position before initializing.
oPress ON to enable power, state will change to Idle.
oPress and hold Freedrive -> status will change to BACKDRIVE
oMove the robot as done in Freedrive, brakes will be released on the joints where it’s
needed but only as long as the Freedrive button is activated. Robot will be “heavy” to move
around.
oBe sure to test this so that all joints have been tested.

All rights reserved 7 Servicemanual_UR10_en_3.1.3
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.

All rights reserved 8 Servicemanual_UR10_en_3.1.3
2.1.2 Visual inspection
Disconnect power cable from controller
Check terminals are properly inserted on Safety Control Board
Check all connections on Motherboard and connection between Safety Control Board and
Motherboard
Check for any dirt/dust inside of controller, clean with vacuum cleaner if needed
» Use a soft cloth. You can add: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha
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
oReplace filters if necessary
oGently remove the outer plastic frame and maintain the filter

All rights reserved 9 Servicemanual_UR10_en_3.1.3
2.2 Robot arm
2.2.1 Visual inspection
If you observe dirt/oil on the robot arm you simply clean it with a soft cloth.
Cleaning agent: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha
In very rare cases the grease is from the inside of the joint. There is still enough grease in the gear
for life time you just clean the joint with a cloth.
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.

All rights reserved 10 Servicemanual_UR10_en_3.1.3
3. Service and Replacement of parts
3.1 Robot arm
3.1.1 Before returning any part to Universal Robots
Remove all external non-UR equipment such as grippers, hoses, cables and so on.
Universal Robots cannot be held responsible for damage caused to non-UR equipment mounted on
the robot.
Backup all relevant files before sending the robot/part to UR. Universal Robots cannot be held
responsible for loss of programs, data or files stored in the robot.
Safety notice:
If the robot/part has been in contact with, or working in environments, where dangerous chemicals
or materials are present, the robot must be cleaned before shipment.
If this is not possible, the shipment must be accompanied by an MSDA (Material Safety Data Sheet)
in English and instructions for cleaning the chemicals.
The amount of labor hours needed for cleaning will be billed at the standard rate.
If UR finds the robot/part unsafe to service, UR reserve the right to get the robot/part cleaned or
decline the case and send the part back, at customer’s expense.
Note: Please note that the robot will be updated to newest software/firmware when repaired. New parts
will also be updated to newest version (hardware/software). Therefore, updating PolyScope may be
necessary when new parts are mounted.

All rights reserved 11 Servicemanual_UR10_en_3.1.3
3.1.2 Robot arm configuration
3.1.8 Upper arm –Shoulder joint
3.1.7 Shoulder joint –Base joint
3.1.6 Base joint –Base mounting bracket
3.1.9 Elbow joint –Upper arm
Error! Reference source not found.
3.1.14 Tool flange –Wrist 3 joint
3.1.13 Wrist 3 joint –Wrist 2 joint
3.1.12 Wrist 2 joint –Wrist 1 joint
3.1.11 Wrist 1 joint –Lower arm

All rights reserved 12 Servicemanual_UR10_en_3.1.3
3.1.3 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 parts 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 personnel are in no risk when releasing the brake.
Do not move the joint more than necessary.
No more than about 160 degrees in order for the robot to find its original physical position.
Procedure for releasing the joint
1. Shut down Controller.
2. Remove blue lid on joint.
3. 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
4. Make sure to mount blue lid properly on joint before turning on Controller.
5. Correct torque value for screws on blue lids are 0.4Nm

All rights reserved 13 Servicemanual_UR10_en_3.1.3
3.1.4 General guidance to separate joint from counterpart
Disassemble:
1. Check if the necessary tools and documentation are available before starting a repair.
a. Service kit with torque tools, ESD Wristband, etc.
b. Thoroughly read and understand this guide.
2. Move the robot to a comfortable position for disassembly or if necessary dismount entire robot
arm from work cell and place on a solid surface.
3. Shut down the controller.
4. Remove blue lid.
5. Reattach one of the screws from the blue lids, in order to connect an alligator Clip on the ESD
wristband as shown below.
6. Gently unplug the cable connectors without bending the printed circuit board.
The power supply connector for the size 1 has a lock that has to be engaged before it is pulled out
of the printed circuit board.

All rights reserved 14 Servicemanual_UR10_en_3.1.3
7. Disconnect wires
8. Remove alignment screw.
9. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the
joint housing.
10. 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.
11. 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.

All rights reserved 15 Servicemanual_UR10_en_3.1.3
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.
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, tighten in cross order with the correct torque. When shorter bolts are
used (marked with red) drawing on the right shows where they are mounted.
See 3.1.5 Torque values
Tighten in numeric order.

All rights reserved 16 Servicemanual_UR10_en_3.1.3
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 cable 1.5 to 2 full rounds before it is 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 3.1.16 Dual Robot calibration for calibrating the robot.

All rights reserved 17 Servicemanual_UR10_en_3.1.3
3.1.5 Torque values
UR10 torque values
CONNECTION
TORQUE
HEAD SIZE
Base mounting bracket
J0 BASE
8.0Nm
10 mm.
[J0] Base
[J1] Shoulder
8.0Nm
10 mm.
[J1] Shoulder
Upper arm
8.0Nm
10 mm.
Upper arm
[J2] Elbow
2.6-3.0Nm
7 mm.
[J2] Elbow
Elbow counter part
2.6-3.0Nm
7 mm.
Elbow counter part
Lower arm
2.6-3.0Nm
7 mm.
Lower 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 mounting bracket
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 used to get the correct calibrated torque.
8.0Nm
8.0Nm
8.0Nm
2.6-3.0Nm
1.3Nm
1.3Nm
1.3Nm
1.3Nm
2.6-3.0Nm
2.6-3.0Nm

All rights reserved 18 Servicemanual_UR10_en_3.1.3
3.1.6 Base joint –Base mounting bracket
Disassemble
For details and photos please see: 3.1.4 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 mounting bracket 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 mounting bracket from Base joint.
7. Disconnect wires between base mounting bracket and Base joint.
2 x red wire = 48V DC
2 x black wire = GND
Black connector = bus cable

All rights reserved 19 Servicemanual_UR10_en_3.1.3
Base joint –Base mounting bracket: Assemble
For details and photos please see: 3.1.4 General guidance to separate joint from counterpart
1. Replace base mounting bracket and reconnect wires according to illustration:
2. Twist the communication cable 1.5 to 2 full rounds before it is connected.
(To reduce electrical noise in the system)
3. Gently insert base mounting bracket with screws and washers into the Base joint.
4. 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.
5. Gently tighten the 10 screws, and then tighten in cross order with 8.0Nm.
6. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon ring.
7. Mount the alignment screw and tighten with 0.4Nm.
8. Mount blue lid on Base joint and tighten with 0.4Nm.
9. Proceed to chapter 3.1.16 Dual Robot calibration for calibrating the robot.

All rights reserved 20 Servicemanual_UR10_en_3.1.3
3.1.7 Shoulder joint –Base joint
Disassemble
For details and photos please see: 3.1.4 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.