Universal Robots UR5 User manual

Service Manual
Revision UR5_en_3.0.2
Robot:
UR5 with CB3-controller
valid from robot s/n 2014350001

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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............................................................................................................................... 6
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 Replacement of base plate............................................................................................................. 11
3.1.4 Replacement of Base joint.............................................................................................................. 14
3.1.5 Replacement of Shoulder joint....................................................................................................... 17
3.1.6 Replacement of Elbow joint ........................................................................................................... 19
3.1.6 Replacement of Wrist 1 joint.......................................................................................................... 23
3.1.7 Replacement of Wrist 2 joint.......................................................................................................... 29
3.1.8 Replacement of Wrist 3 joint.......................................................................................................... 33
3.1.9 Replacement of tool flange ............................................................................................................ 37
3.1.10 Torque values ............................................................................................................................... 40
3.1.11 Joint calibration ............................................................................................................................ 41
3.2 Controller............................................................................................................................................... 47
3.2.1 Handling ESD-sensitive parts.......................................................................................................... 47
3.2.2 Replacement of motherboard........................................................................................................ 48
3.2.3 Replacement of Safety Control Board ............................................................................................ 51
3.2.4 Replacement of teach pendant ...................................................................................................... 53
3.2.5 Replacement of 48V power supply................................................................................................. 54

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3.2.6 Replacement of 12V power supply................................................................................................. 57
3.2.7 Replacement of current distributor................................................................................................ 58
4. Software .................................................................................................................................................. 60
4.1 Update software.................................................................................................................................... 60
4.2 Update joint firmware........................................................................................................................... 62
4.3 Using Magic files.................................................................................................................................... 65
5. Troubleshooting ...................................................................................................................................... 66
5.1 Error codes............................................................................................................................................. 66
5.2 Error phenomena .................................................................................................................................. 78
5.2.1 ControlBox: NO CONTROLLER displayed in Initializing................................................................... 78
5.2.2 NO CABLE displayed during power up............................................................................................ 79
5.2.3 Force limit protective stop ............................................................................................................. 80
5.2.4 Power on failure in Initializing ........................................................................................................ 81
5.2.5 Checklist after a collision ................................................................................................................ 84
5.3 Schematic drawing ................................................................................................................................ 85
6. Spare parts............................................................................................................................................... 86
6.1 Spare part list......................................................................................................................................... 86
6.2 Tool part list........................................................................................................................................... 87
7. Packing of robot....................................................................................................................................... 88
8. Changelog ................................................................................................................................................ 89
8.1 Changelog .............................................................................................................................................. 89

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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 on the robot. For example, the robot may
have been overloaded on an overrun or it may 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
supply to any potential dangerous tool attached on the robot arm and 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
At least once in a year, the correct functioning of all safety functions should be tested.
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 vacuum cleaning for removing particles.

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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 damages.
Inspect flat rings for wear and damages.
» replace flat rings if worn out or damaged.
Inspect blue lids on all joints for any cracks or damages.
» 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 0.5Nm
If any damages are observed on a robot within the warranty period, contact the distributor from where 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
J1
Shoulder
J0
Base
J5
Wrist 3
J3
Wrist 1
J2
Elbow
J4
Wrist 2
Upper arm
Lower arm
Baseplate
Tool flange

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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 for avoiding
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. is 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 pin brake down for releasing, joint can then be rotated.
Brake on Base, Shoulder and Elbow joints, and on all Wrist joints
Make sure to mount blue lid properly on joint before turning on Controller.

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3.1.3 Replacement of base plate
How to replace base plate
Move robot to a comfortable position for replacing the base. If necessary dismount entire robot
arm from work cell and place arm on solid surface.
Shut down the controller.
Remove grease plug.
Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the
joint housing.

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Slide the grey Teflon ring apart.
10 screws become visible, 5 on each side of joint.
Untighten gently the screw with a 7 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.
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).
Pull away the base plate from Base joint.
Disconnect wires between base plate and Base joint.
1 x red wire = 48V DC
1 x black wire = GND
Black connector = bus cable (NB: polarized)

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Replace base plate and reconnect wires according to illustration:
Gently insert base plate with screws and washers into the Base joint.
Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the base plate and Base joint in opposite directions until a mechanical stop is met.
Tighten the 10 screws lightly, then tighten in cross order with 3.0Nm.
Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.
Mount the grease plug and tighten with 0.8Nm.

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3.1.4 Replacement of Base joint
How to replace Base joint
Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.
Shut down the controller.
For separating base plate from Base joint, consult chapter 3.1.3 Replacement of base plate.
Remove blue lid on Base joint.
Disconnect wires between Base joint and Shoulder joint
1 x red wire = 48V DC
1 x black wire = GND
Black connector = bus cable
Remove grease plug at Shoulder joint.

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Gently remove black flexible flat ring between Base and Shoulder with a tiny screwdriver or similar
tool and twist it around the joint housing.
Slide the grey Teflon ring apart.
10 screws become visible, 5 on each side of joint.
Untighten gently the screw with a 7 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.
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).

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•Pull away the Base joint from Shoulder joint.
Replace Base joint and gently insert Base joint with screws and washers into the Shoulder joint.
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.
Tighten the 10 screws lightly, then tighten in cross order with 3.0Nm.
Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.
Mount the grease plug and tighten with 0.8Nm.
Reconnect connectors as illustrated.
Mount blue lid on Base joint and tighten with 0.5Nm.
Proceed to chapter 3.1.11 Joint calibration for calibrating the joint.

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3.1.5 Replacement of Shoulder joint
How to replace Shoulder joint
Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.
Shut down the controller.
For separating Base joint from Shoulder joint, consult chapter 3.1.4 Replacement of Base joint.
Remove blue lid on Shoulder joint.
Disconnect wires between Shoulder joint and upper arm
1 x red wire = 48V DC
1 x black wire = GND
Black connector = bus cable

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Unmount screws around the upper arm as indicated on the illustration:
•Pull away the Shoulder joint from upper arm.
Replace Shoulder joint and mount screws into shoulder joint.
Tighten screws lightly, then tighten in cross order with 3.0Nm.
Reconnect wires as illustrated
Mount blue lid on Base joint and tighten with 0.5Nm.
Proceed to chapter 3.1.11 Joint calibration for calibrating the joint.

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3.1.6 Replacement of Elbow joint
How to replace Elbow joint
Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.
Shut down the controller.
Remove grease plug at Elbow joint.
Gently remove black flexible flat ring between Elbow and lower arm with a tiny screwdriver or
similar tool and twist it around the joint housing.
Slide the grey Teflon ring apart.
10 screws become visible, 5 on each side of joint.
Untighten gently the screw with a 7 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

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Pull Elbow joint and lower arm apart and gently twist the two parts in opposite directions around
10 mm. until a mechanical stop is met (holes are keyhole-type).
•Pull away the Elbow joint from lower arm.
Disconnect wires between Elbow joint and lower arm
1 x red wire = 48V DC
1 x black wire = GND
Green connector = bus cable
Replace Elbow joint and reconnect wires between Elbow joint and lower arm accordingly.
Gently insert lower arm with screws and washers into the Elbow joint.
Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the Elbow joint and lower arm in opposite directions until a mechanical stop is met.
Tighten the 10 screws lightly, then tighten in cross order with respectively 3.0Nm.
Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.
Mount the grease plug and tighten with 0.8Nm.