Universal Robots UR5 User manual

Service Manual
"Original instructions"
Revision:
UR5_en_3.2.7
Robot:
UR5 with CB3.0/3.1/3.2 - controller
CB3.0 valid from robot s/n 2014350001 to 2016351863
CB3.1 valid from robot s/n 2016351864 to 2019351625
CB3.2 valid from robot s/n 2019351626
Valid from robot s/n: 2014350001

1.Service Manual
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 © 2009–2019 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.

2.Content
1.Service Manual 2
2.Content 3
3.General Information 1
3.1. Purpose 1
3.2. Company Details 1
3.3. Disclaimer 1
3.4. Warning Symbols in this Manual 2
4.Recommended Inspection Activities 3
4.1. Controller 3
4.1.1. Inspection Plan 3
4.1.2. Safety Functions 4
4.1.3. Visual Inspection 5
4.1.4. Cleaning and Replacement of Filters 5
4.2. Robot Arm 10
4.2.1. Inspection plan 10
4.2.2. Inspection Plan 11
4.2.3. Functional Inspection 11
4.2.4. Visual Inspection 11
5.Service and Replacement of parts 13
5.1. Handling ESD Sensitive Parts 13
5.1.1. Recommended Tools 16
5.2. Robot Arm 17
5.2.1. Before returning any part to Universal Robots 17
5.2.2. Robot Arm Configuration 18
5.2.3. Brake Release 18
5.2.4. General Guidance to Separate Joint from Counterpart 19
5.2.5. Torque Values 23
5.2.6. Base Joint – Base Mounting Bracket 24
5.2.7. Shoulder joint – Base joint 25
5.2.8. Upper arm – Shoulder joint 27
5.2.9. Elbow joint – Upper arm 29
5.2.10. Elbow counterpart – Elbow joint 29
5.2.11. Wrist 1 joint – Lower arm 30
5.2.12. Wrist 2 joint – Wrist 1 joint 32
Service Manual UR5
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

5.2.13. Wrist 3 joint – Wrist 2 joint 33
5.2.14. Tool flange – Wrist 3 joint 33
5.2.15. Instructions for calibrating a joint 35
5.2.16. Dual Robot Calibration 42
5.2.17. Change joint ID 42
5.2.18. Joint Spare Part Adaptation 44
5.2.19. Wire Bundle Installation Guide 45
5.3. Controller 53
5.3.1. Replacement of Motherboard 3.0 53
5.3.2. Replacement of Motherboard 3.1 55
5.3.3. Upgrade Motherboard 3.0 To 3.1 58
5.3.4. Replacement of Safety Control Board 64
5.3.5. Replacement of Teach Pendant 67
5.3.6. Replacement of 48V power supply 70
5.3.7. Replacement of 12V power supply 77
5.3.8. Replacement of Current distributor 78
6.Software 80
6.1. Update software 80
6.2. Update joint firmware 82
6.3. Using Magic files 84
6.4. Backup of data 85
6.4.1. Hardware Requirements 85
6.4.2. Software Requirements 86
6.4.3. How to Access Linux Partition from Windows 86
6.4.4. Copy the data from CF-card to UR-USB 87
7.Troubleshooting 94
7.1. Error code 94
7.2. LED indicators and Fuses on Safety Control Board 199
7.2.1. Normal Startup Sequence for a CB3.x UR5 200
7.3. Error Phenomena 201
7.3.1. Control Box: NO CONTROLLER Displayed in Initializing 201
7.3.2. NO CABLE Displayed During Power Up 202
7.3.3. Protective Stop 202
7.3.4. Power on Failure in Initializing 204
7.3.5. Checklist After a Collision 206
7.3.6. Communication to Joints and Tool 207
7.3.7. Complete Rebooting Sequence 207
UR5 Service Manual
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

7.4. Electrical Drawing 208
7.4.1. Schematic Overview 213
7.4.2. E-Plan Diagrams 217
8.Spare Parts 224
8.1. Robot arm 224
8.2. Controller 226
8.3. Tools 227
9.Packing of Robot 229
10.Change Log 231
Service Manual UR5
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

UR5 Service Manual
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

3.General Information
3.1. 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 to ensure a long
lifetime.
However, any improper use of robot can potentially cause failures. If for example, the robot is
overloaded, run with a load not recommended by Universal Robots, dropped during relocation,
damaged by collision or any other improper usage, the warranty will be void.
Universal Robots recommends that the user does not attempt repair, adjustment or other
intervention in the mechanical or electrical systems of the robot without first consulting a UR
certified service engineer. Any unauthorized intervention will void the warranty. 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 the main power 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 where the robot was purchased from.
Alternatively, parts can be ordered from the nearest distributor, details of which can be obtained
from Universal Robots official website at www.universal-robots.com
3.2. Company Details
Universal Robots A/S
Energivej 25
DK-5260 Odense Denmark
Tel.: [phone]
Fax: [phone]
3.3. Disclaimer
Universal Robots continues to improve reliability and performance of its products, and therefore
reserves the right to upgrade the product without prior warning. Universal Robots takes every
care that the contents of this manual are precise and correct, but takes no responsibility for any
errors or missing information.
Service Manual 1 UR5
3.General Information
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

3.4. Warning Symbols in this Manual
DANGER, WARNING, CAUTION, NOTICE and SAFETY INSTRUCTION statements are used
throughout this manual to emphasize important and critical information.
You MUST read these statements to help ensure safety and to prevent product damage.
The statements are defined below.
DANGER
These warnings mean a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
These warnings mean a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
These warnings mean a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
These warnings mean damage to property may occur if no precautions are taken.
CAUTION
This warning sign contain references to safety-relevant information or general
safety measures.
This warning sign do not refer to individual hazards or individual precautionary
measures.
UR5 2 Service Manual
3.General Information
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

4.Recommended Inspection Activities
It is recommended to perform preventive maintenance on the control box and
robot at least once per year. In case of use in dirty or dusty environments it is
recommended to increase the frequency.
In case dust/dirt/oil is observed on the controller or robot arm, it can be wiped away using a cloth
with cleaning agent. Cleaning agent: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10%
Naphtha.
In very rare cases, very small amounts of grease can seep from the joint. This does not affect
the specified function or lifetime of the joint.
NOTICE
Never use compressed air to clean the controller or robot arm as it can damage
the seals and internal components
4.1. Controller
4.1.1. Inspection Plan
Set forth below is a check list of inspections that Universal Robots recommends be performed
according to the marked time interval. If upon inspection, the referenced parts are not in an
acceptable state, please rectify immediately.
Service Manual 3 UR5
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

Use the following sections as guide:
2.1.2 Safety Functional
2.1.3 Visual Inspection
3.2 Control Box
Monthly Bi-annually Annually
Check Emergency stop on Teach Pendant F X
Check Backdrive mode F X
Check Freedrive mode F X
Check safety inputs and outputs
(if connected) F X
Check Teach Pendant cable V X
Check and clean air filters on Control Box V X
Check terminals in Control Box F X
Check electrical grounding 1< Ω to Control Box F X
Check main power to Control Box F X
V = Visual inspection F = Functional inspection
4.1.2. Safety Functions
The robot safety functions must be tested at least once a year to ensure correct function. The
following tests must be performed.
• Backup data from the storage device - See section 4.4 Backup of data
• Test that the Emergency Stop button on the Teach Pendant functions:
• Press the Emergency Stop button on the Teach Pendant.
• Observe that the robot stops and turns off the power to the joints.
• Power on robot again.
• Test Freedrive mode:
• Unmount attachment or set TCP/Payload/CoG according to tool specifications.
• Set the robot in Free drive mode by holding the black Freedrive button on the back of
the Teach Pendant.
• Move the robot to a position stretched out horizontally to the edge of its workspace.
• Monitor that the robot maintains its position unsupported while the Freedrive button
is still pressed.
• Test Backdrive mode:
If the robot is close to collision, the BACKDRIVE function can be used to move the robot to
a safe position before initializing.
• Press ON to enable power, state will change to Idle.
• Press and hold Freedrive -> status will change to BACKDRIVE.
• Move the robot by hand as in Freedrive.
UR5 4 Service Manual
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

• In BACKDRIVE mode brakes will only be released on individual joints when they are
moved, and will remain released as long as the Freedrive button is pushed. Robot will
be “heavy” to move around compared to Freedrive mode.
• Be sure to test each joint individually, to ensure the brake release as expected.
• Verify safety settings:
• Verify 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:
• Check which safety inputs and outputs are active and test that they can be triggered.
4.1.3. Visual Inspection
• Disconnect power cable from controller
• Check that the terminals on the Safety Control Board are properly inserted and do not have
loose wires
• Check all connections on Motherboard and connection between Safety Control Board and
Motherboard
• Check for any dirt/dust inside of controller, clean with ESD vacuum cleaner if needed
NOTICE
Never use compressed air to clean inside the controller as it can damage
componentss
4.1.4. Cleaning and Replacement of Filters
Original control box
• Controller box has two filters, one mounted on each side of the box.
Service Manual 5 UR5
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

• Remove filters from controller box and clean them thoroughly using low pressure air.
• Replace filters if necessary.
• Gently remove the outer plastic frame and maintain the filter.
UR5 6 Service Manual
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

Merge Control Box
• Controller box has two filters, one mounted on each side of the box.
Service Manual 7 UR5
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

• Remove filters from controller box and clean them thoroughly using low pressure air.
• Replace filters if necessary.
• Gently remove the outer plastic frame and maintain the filter.
UR5 8 Service Manual
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

Cleaning the Robot in Relation to COVID
You can wipe away any dust/dirt/oil observed on the robot arm using a cloth and one of the
following cleaning agents: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha. In rare
cases, very small amounts of grease can be visible from the joint. This does not affect the
function, use, or lifetime of the joint.
Due to the added focus on cleaning your robot, UniversalRobots recommends cleaning with 70%
isopropyl alcohol (rubbing alcohol).
Service Manual 9 UR5
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

1. Wipe the robot with a hard twisted micro fiber cloth and 70% isopropyl alcohol (rubbing
alcohol).
2. Let the 70% isopropyl alcohol dwell on the robot for 5 minutes, and then clean the robot
using standard cleaning procedure.
DONOTUSEBLEACH. Do not use bleach in any diluted cleaning solution.
NOTE
The above standard cleaning recommendation is still valid with the addition of
the COVID-19 cleaning recommendation.
4.2. Robot Arm
4.2.1. Inspection plan
Set forth below is a check list of inspections that Universal Robots recommends be performed
according to the marked time interval. If upon inspection, the referenced parts are not in an
acceptable state, please rectify immediately.
Use the following sections as guide:
2.2.2 Visual Inspection
3.1 Robot Arm
Monthly Semi-annually Annually
Check blue lids* V X
Check blue lid screws F X
Check flat rings V X
Check robot cable V X
Check robot cable connection V X
Check Robot Arm mounting bolts* F X
Check Tool mounting bolts* F X
Check screws/bolts that is connecting joints* F X
V = Visual inspection F = Functional inspection * = Must also be checked after heavy
collision
UR5 10 Service Manual
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

4.2.2. Inspection Plan
Set forth below is a check list of inspections that Universal Robots recommends be performed
according to the marked time interval. If upon inspection, the referenced parts are not in an
acceptable state, please rectify immediately.
Use the following sections as guide:
2.2.2 Visual Inspection
3.1 Robot Arm
Monthly Bi-annually Annually
Check blue lids* V X
Check blue lid screws F X
Check flat rings V X
Check robot cable V X
Check robot cable connection V X
Check Robot Arm mounting bolts* F X
Check Tool mounting bolts* F X
Check screws/bolts that is connecting joints* F X
V = Visual inspection F = Functional inspection * = Must also be checked after heavy
collision
4.2.3. Functional Inspection
The purpose of the functional inspection is to ensure that screws, bolts, tools and robot arm are
not loose. The screws/bolts mentioned in the inspection plan should be checked with a torque
wrench with the correct torque, specified in 5.2.5. Torque Valueson page23
For the robot arm mounting bolts, these specifications can be found in the User Manual under
the Mounting section.
4.2.4. Visual Inspection
NOTICE
Never use compressed air to clean the robot as it can damage the seals and
internal components
• 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.
Service Manual 11 UR5
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

• 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.
UR5 12 Service Manual
4.Recommended Inspection Activities
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

5.Service and Replacement of parts
5.1. Handling ESD Sensitive Parts
To prevent damage to ESD-sensitive parts, follow the instructions below. These are in addition to
standard precautions such as turning off power before removing circuit boards.
Keep the ESD-sensitive part in its original shipping container. (a special "ESD bag") until the part
is ready to be installed.
Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This
discharges any static electricity in your body to ground.
Service Manual 13 UR5
5.Service and Replacement of parts
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.

Step 1:
Put OLD board into spare ESD bag.
Step 2:
Take NEW board out of ESD bag.
Hold the ESD-sensitive part by its edges. Do not touch its pins!
UR5 14 Service Manual
5.Service and Replacement of parts
Copyright © 2009–2021 by UniversalRobotsA/S. All rights reserved.