Universal Robots ur3 User manual

Service Manual
Revision UR3_en_3.1.2
"Original instructions"
Robot:
UR3 with CB3-controller
Valid from robot s/n 2014330001

All rights reserved 2 Servicemanual_UR3_en_rev3.1.2
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 of controller.......................................................................................................... 7
2.1.3 Cleaning and replacement of filters ................................................................................................. 7
2.2 Robot arm................................................................................................................................................ 8
2.2.1 Visual inspection of robot arm ......................................................................................................... 8
3. Service and Replacement of parts................................................................................................................ 9
3.1 Robot arm................................................................................................................................................ 9
3.1.1 Before returning any part to Universal Robots check:..................................................................... 9
3.1.2 Robot arm configuration ................................................................................................................ 10
3.1.3 Brake release .................................................................................................................................. 11
3.1.4 General guidance to separate joint from counterpart................................................................... 12
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............................................................................................................ 21
3.1.9 Elbow joint –Upper arm................................................................................................................. 22
3.1.10 Elbow counterpart –Elbow joint.................................................................................................. 23
3.1.11 Wrist 1 joint –Lower arm............................................................................................................. 25
3.1.12 Wrist 2 joint –Wrist 1 joint .......................................................................................................... 27
3.1.13 Wrist 3 joint –Wrist 2 joint .......................................................................................................... 29
3.1.14 Tool flange –Wrist 3 joint ............................................................................................................ 29
3.1.15 Dual Robot Calibration and Joint calibration................................................................................ 31
3.1.16 Instructions for calibrating a joint ................................................................................................ 32
3.1.17 Change joint ID ............................................................................................................................. 40
3.1.18 Joint spare part adaptation .......................................................................................................... 42

All rights reserved 3 Servicemanual_UR3_en_rev3.1.2
3.1.19 Modify wrist 3 to Wrist 1 or wrist2 .............................................................................................. 43
3.2 Controller............................................................................................................................................... 45
3.2.1 Handling ESD-sensitive parts.......................................................................................................... 45
3.2.2 Replacement of motherboard 3.1 .................................................................................................. 49
3.2.3 Replacement of Safety Control Board (SCB)................................................................................... 52
3.2.4 Replacement of teach pendant ...................................................................................................... 55
3.2.5 Replacement of 48V power supply................................................................................................. 56
3.2.6 Replacement of 12V power supply................................................................................................. 59
3.2.7 Replacement of current distributor................................................................................................ 60
4. Software .................................................................................................................................................. 61
4.1 Update software.................................................................................................................................... 61
4.2 Update joint firmware........................................................................................................................... 63
4.3 Using Magic files.................................................................................................................................... 63
5. Troubleshooting ...................................................................................................................................... 64
5.1 Error codes............................................................................................................................................. 64
5.2 LED indicators and Fuses on Safety Control Board.......................................................................... 86
5.3 Error phenomena .................................................................................................................................. 88
5.3.1 ControlBox: NO CONTROLLER displayed in Initializing................................................................... 88
5.3.2 NO CABLE displayed during power up............................................................................................ 89
5.3.3 Force limit protective stop ............................................................................................................. 90
5.3.4 Power on failure in Initializing ........................................................................................................ 91
5.3.5 Checklist after a collision ................................................................................................................ 94
5.4 Electrical drawing ............................................................................................................................ 95
5.4.1 Schematic overview........................................................................................................................ 95
5.4.2 E-Plan diagrams ............................................................................................................................ 100
6 Spare parts............................................................................................................................................. 113
6.1 Spare part list....................................................................................................................................... 113
6.2 Service kit............................................................................................................................................. 114
7 Packing of robot..................................................................................................................................... 115
8 Changelog .............................................................................................................................................. 116
8.1 Changelog ............................................................................................................................................ 116

All rights reserved 4 Servicemanual_UR3_en_rev3.1.2
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_UR3_en_rev3.1.2
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 © 2015 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.

All rights reserved 6 Servicemanual_UR3_en_rev3.1.2
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 Free drive mode:
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:
oIf 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 for the joints - Do NOT release the brakes.
oPress and hold Freedrive -> status will change to BACKDRIVE
oPull joint away from collision area -> brake is released for only this joint as long as freedrive
is 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.

All rights reserved 7 Servicemanual_UR3_en_rev3.1.2
2.1.2 Visual inspection of controller
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
» 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 8 Servicemanual_UR3_en_rev3.1.2
2.2 Robot arm
2.2.1 Visual inspection of robot arm
Of safety reasons confirm that the 4 rubber covers over the mounting screws are present on the
Base mounting bracket.
If you observe oil on the robot arm you simply clean it with a cloth.
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.
Flat rings

All rights reserved 9 Servicemanual_UR3_en_rev3.1.2
3. Service and Replacement of parts
3.1 Robot arm
3.1.1 Before returning any part to Universal Robots check:
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 customers expense.

All rights reserved 10 Servicemanual_UR3_en_rev3.1.2
3.1.2 Robot arm configuration
Elbow counter part
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
3.1.10 Elbow counterpart –Elbow joint
3.1.9 Elbow joint –Upper arm
3.1.8 Upper arm –Shoulder joint
3.1.7 Shoulder joint –Base joint
3.1.6 Base joint –Base mounting bracket
Size 0
Size 0
Size 0
Size 1
Size 2
Size 2

All rights reserved 11 Servicemanual_UR3_en_rev3.1.2
3.1.3 Brake release
In an urgent situation the brake on Base, Shoulder and Elbow joints can be released without power
connected. It is not possible to release the brakes on Wrist 1, 2 and 3 manually.
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, Not more than about 160 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.
On the Wrist 1, 2 and 3 it is not possible to release the brakes manually.
Brake on Base and Shoulder joints, Brake on Elbow joints
Make sure to mount blue lid properly on joint before turning on Controller.
Correct torque value for screws on blue lids are 0.4Nm

All rights reserved 12 Servicemanual_UR3_en_rev3.1.2
3.1.4 General guidance to separate joint from counterpart
Disassemble:
1. Check if you have the necessary tools before you start to repair the robot.
1.1. Service kit with torque tools, ESD Wristband, etc.
1.2. If you have to disassemble the robot arm you need: new flat rings, M3 and M4 tap tool for
threads, pre coated screws or Loctite and normal.
1.3. Check the guide in this manual in details before you continue.
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. Now reattach one of the screws for the blue lids to connect an alligator Clip on your ESD wristband as
shown below.
6. Gently unplug the cable connectors without bending the printed circuit board.
The power supply connector for the size 0 and the size 1 has a lock that has to be engaged before it
is pulled out of the printed circuit board.

All rights reserved 13 Servicemanual_UR3_en_rev3.1.2
7. After disconnecting the wires gently remove black flexible flat ring with a tiny screwdriver and twist it
around the joint housing.
8. Slide back the black teflon ring. (Marked with red)
6, 8 or 10 screws become visible
Loosen the screws.
9. Pull the two parts gently apart.

All rights reserved 14 Servicemanual_UR3_en_rev3.1.2
Assemble:
1. Important note: remove residues of old Loctite in screw holes with a M3 or M4 tap tool for threads
before assembling the joint to get the correct torque on the new screws.
2. Important note: Always use new pre-coated screws when it is possible. If you have to assemble with
old screws carefully clean the screws and attach Loctite 648 on the screws before assembly.
3. Important note: Always replace the black flexible flat ring to maintain the IP classification.
4. Orientate the joints according to the marks and gently push the two joints together. (In the below
drawing the marks are indicated with red)
5. Gently tighten the 6, 8 or 10 screws, and then tighten in cross order with the correct torque.
See 3.1.5 Torque values
Example: The screws from 1 to 6 should be tightened like this:
1, 4, 2, 5, 3, 6 and again
1, 4, 2, 5, 3 and 6
6
3
1
2
4
5

All rights reserved 15 Servicemanual_UR3_en_rev3.1.2
6. Slide the black teflon ring (Indicated with red) into place and gently put the new flat ring back on top of
the teflon ring.

All rights reserved 16 Servicemanual_UR3_en_rev3.1.2
7. Connect the cables:
Size 0 joint.
Size 1 joint.
Size 2 joint.
8. Twist the communication cable 1.5 to 2 full rounds before connection.
(To reduce electrical noise in the system)
9. Mount the blue lid on the joint and tighten with 0.4Nm.
10. Proceed to 3.1.15 Dual Robot Calibration and Joint calibration. for calibrating the Robot.
Twist the communication cable 1.5 to 2 full
rounds before connection
Twist the communication cable 1.5 to 2 full
rounds before connection
Twist the communication cable 1.5 to 2 full
rounds before connection

All rights reserved 17 Servicemanual_UR3_en_rev3.1.2
3.1.5 Torque values
UR3 torque values
CONNECTION
TORQUE
HEAD SIZE
Base mounting bracket
J0 Base
3.0Nm
Torx T20
[J0] Base
J[1] Shoulder
3.0Nm
Torx T20
[J1] Shoulder
Upper arm
3.0Nm
Torx T20
Upper arm
[J2] Elbow
1.3Nm
Torx T10
[J2] Elbow
Lower arm
1.3Nm
Torx T10
Lower arm
[J3] Wrist 1
1.3Nm
Torx T10
[J3] Wrist 1
[J4] Wrist 2
1.3Nm
Torx T10
[J4] Wrist 2
[J5] Wrist 3
1.3Nm
Torx T10
[J5] Wrist 3
Tool mounting bracket
1.3Nm
Torx T10
Tool/ Gripper M6
10Nm
Blue lid: Base, Shoulder and Elbow
0.4Nm
Torx T10
Blue lid: Wrist 1, Wrist 2 and Wrist 3
0.4Nm
Torx T8
Attention: Click the torque tools 3 times before use to get the correct calibrated torque.
1.3Nm
Nm
1.3Nm
1.3Nm
1.3Nm
1.3Nm
1.3Nm
3.0Nm
3.0Nm
3.0Nm
10.0Nm
Nm

All rights reserved 18 Servicemanual_UR3_en_rev3.1.2
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 black flexible flat ring with a tiny screwdriver and twist it around the joint housing.
3. Slide back the black teflon ring. 10 screws become visible. Loosen the screws.
4. Pull the Base mounting bracket and Base joint gently apart.
5. Disconnect wires from the EMC filter in the Base mounting bracket.

All rights reserved 19 Servicemanual_UR3_en_rev3.1.2
Base joint –Base mounting bracket: Assemble
For details and photos please see: 3.1.4 General guidance to separate joint from counterpart
1. Important note: remove residues of old Loctite in screw holes with a M4 tap tool for threads before
assembling the joint to get the correct torque on the new screws.
2. Important note: Always use new pre-coated screws when it is possible. If you have to assemble with
old screws carefully clean the screws and attach Loctite 648 on the screws before assembly.
3. Replace Base mounting bracket and reconnect wires to the EMC filter.
Twist the communication cable 1.5 to 2 full rounds before it is connected.
(To reduce electrical noise in the system)
1 x red wire = 48V DC
1 x black wire = GND
White and black = bus connector
4. Orientate the joint and Base mounting bracket according to the marks and gently push them together.
5. Press gently the base and base mounting bracket together to align the screw holes in the two parts
before attaching the screws.
6. Gently tighten the 10 screws, and then tighten in cross order with 3.0Nm.
7. Slide the black teflon ring into place and gently put the flat ring back on top of the teflon ring.
8. Proceed to chapter 3.1.15 Dual Robot Calibration and Joint calibration. for calibrating the robot.
Align the screw holes in the two
parts

All rights reserved 20 Servicemanual_UR3_en_rev3.1.2
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 and connect ESD wristband.
3. Disconnect wires between Base joint and Shoulder joint.
Without bending the printed circuit board.
4. After disconnecting the wires gently remove black flexible flat ring with a tiny screwdriver and twist it
around the joint housing.
5. Slide back the black teflon ring. 10 screws become visible. Loosen the screws.
6. Pull the Base joint and Shoulder joint gently apart.
Shoulder joint –Base joint: Assemble
For details and photos please see: 3.1.4 General guidance to separate joint from counterpart
1. Important note: remove residues of old Loctite in screw holes with a M4 tap tool for threads before
assembling the joint to get the correct torque on the new screws.
2. Important note: Always use new pre-coated screws when it is possible. If you have to assemble with
old screws carefully clean the screws and attach Loctite 648 on the screws before assembly.
3. Orientate the Base joint and Shoulder joint according to the marks and gently push them together.
4. Gently tighten the 10 screws, and then tighten in cross order with 3.0Nm.
5. Slide the black teflon ring into place and gently put the flat ring back on top of the teflon ring.
6. Connect ESD wristband.
7. Twist the communication cable 1.5 to 2 full rounds before it is
connected. (To reduce electrical noise in the system)
1 x red wire = 48V DC
1 x black wire = GND
White and black = bus connector
8. After connection of the wires then mount the blue lid and tighten with 0.4Nm.
9. Proceed to chapter 3.1.15 Dual Robot Calibration and Joint calibration. for calibrating the robot.