Universal Robots UR5 User manual

Service Manual
Revision UR5_en_3.2.0
"Original instructions"
Robot:
UR5 with CB3.0/CB3.1-controller
CB3.0 valid from robot s/n 2014350001 to 2016351863
CB3.1 valid from robot s/n 2016351864

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Contents
1. General information..................................................................................................................................... 4
1.1 Purpose.............................................................................................................................................. 4
1.2 Company details................................................................................................................................ 5
1.3 Disclaimer.......................................................................................................................................... 5
1.4 Warning Symbols in this Manual....................................................................................................... 6
2. Preventive Maintenance .............................................................................................................................. 7
2.1 Controller .......................................................................................................................................... 7
2.1.1 Inspection plan, Safety Functions ........................................................................................ 7
2.1.2 Visual inspection .................................................................................................................. 9
2.1.3 Cleaning and replacement of filters................................................................................... 10
2.2 Robot arm........................................................................................................................................ 11
2.2.1 Visual inspection ................................................................................................................ 11
3. Service and Replacement of parts............................................................................................................... 12
3.0.0 Handling ESD-sensitive parts ............................................................................................. 12
3.0.1 Recommended Tools ........................................................................................................ 15
3.1 Robot arm........................................................................................................................................ 16
3.1.1 Before returning any part to Universal Robots.................................................................. 16
3.1.2 Robot arm configuration.................................................................................................... 17
3.1.3 Brake release...................................................................................................................... 18
3.1.4 General guidance to separate joint from counterpart ...................................................... 19
3.1.5 Torque values..................................................................................................................... 23
3.1.6 Base joint –Base mounting bracket .................................................................................. 24
3.1.7 Shoulder joint –Base joint................................................................................................. 26
3.1.8 Upper arm –Shoulder joint ............................................................................................... 28
3.1.9 Elbow joint –Upper arm .................................................................................................... 30
3.1.10 Elbow counterpart –Elbow joint ..................................................................................... 30
3.1.11 Wrist 1 joint –Lower arm ................................................................................................ 32
3.1.12 Wrist 2 joint –Wrist 1 joint.............................................................................................. 34
3.1.13 Wrist 3 joint –Wrist 2 joint.............................................................................................. 36
3.1.14 Tool flange –Wrist 3 joint................................................................................................ 36
3.1.15 Instructions for calibrating a joint.................................................................................... 38
3.1.16 Dual Robot Calibration..................................................................................................... 46
3.1.17 Change joint ID................................................................................................................. 47
3.1.18 Joint spare part adaptation.............................................................................................. 48
3.1.19 Wire bundle installation guide......................................................................................... 50

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3.2 Controller....................................................................................................................................... 58
3.2.1 Replacement of Motherboard 3.0 ..................................................................................... 58
3.2.2 Replacement of Motherboard 3.1 ..................................................................................... 61
3.2.3 Upgrading of Motherboard 3.0 to 3.1 ............................................................................... 64
3.2.4 Replacement of Safety Control Board ............................................................................... 71
3.2.5 Replacement of Teach Pendant......................................................................................... 74
3.2.6 Replacement of 48V power supply .................................................................................... 76
3.2.7 Replacement of 12V power supply .................................................................................... 79
3.2.8 Replacement of Current distributor................................................................................... 80
4. Software ...................................................................................................................................................... 82
4.1 Update software.............................................................................................................................. 82
4.2 Update joint firmware..................................................................................................................... 84
4.3 Using Magic files.............................................................................................................................. 87
4.4 Backup of data................................................................................................................................. 88
4.4.1 Hardware requirements..................................................................................................... 88
4.4.2 Software requirements ...................................................................................................... 89
4.4.3 How to access Linux partition from Windows ................................................................... 89
4.4.4 Copy the data from CF-card to UR-USB ............................................................................. 90
5. Troubleshooting .......................................................................................................................................... 94
5.1 Error codes ...................................................................................................................................... 94
5.2 LED indicators and Fuses on Safety Control Board ....................................................................... 126
5.2.1 Normal startup sequence for a CB3.x UR5 ...................................................................... 127
5.3 Error phenomena .......................................................................................................................... 128
5.3.1 Control Box: NO CONTROLLER displayed in Initializing ................................................... 128
5.3.2 NO CABLE displayed during power up ............................................................................. 129
5.3.3 Protective stop................................................................................................................. 130
5.3.4 Power on failure in Initializing ......................................................................................... 131
5.3.5 Checklist after a collision ................................................................................................. 132
5.3.6 Communication to joints and tool ................................................................................... 133
5.3.7 Complete rebooting sequence......................................................................................... 134
5.4 Electrical drawing .......................................................................................................................... 135
5.4.1 Schematic overview ......................................................................................................... 135
5.4.2 E-Plan diagrams................................................................................................................ 141
6. Spare parts................................................................................................................................................. 154
7. Packing of robot......................................................................................................................................... 157
8. Change log ................................................................................................................................................. 158

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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 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
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 that 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

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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 © 2018 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.

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1.4 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 that it is curtain or high probable that death or
severe injuries will occur, if no precautions are taken.
WARNING:
These warning mean that dead or severe injuries may occur, if no
precautions are taken.
CAUTION:
These warning mean that minor injuries may occur, if no precautions
are taken.
NOTICE:
These warning mean that damage to property may occur, if no
precautions are taken.
These warning signs contain references to safety-relevant information or
general safety measures.
These warnings do not refer to individual hazards or individual
precautionary measures.
This warning draws attention to procedures which serve to prevent or remedy emergencies or
malfunctions:
SAFETY INFORMATION:
Procedure marked with this warning must be followed exactly.

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2. Preventive Maintenance
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.
2.1 Controller
2.1.1 Inspection plan, 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

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•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.
•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.

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2.1.2 Visual inspection
•Disconnect power cable from controller
•Check terminals are properly inserted on Safety Control Board and check for loose wires in the
terminals
•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 components

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2.1.3 Cleaning and replacement of filters
•Controller box has two filters, one mounted on each side of the box
•Remove filters from controller box and clean them thoroughly using low pressure air
oReplace filters if necessary
oGently remove the outer plastic frame and maintain the filter

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2.2 Robot arm
2.2.1 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
•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
3.0.0 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 logic cards.
.
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.
Keep the ESD-sensitive part in its
original shipping container.
(a special "ESD bag") until the part is ready to be
installed

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Hold the ESD-sensitive part by its edges;
do not touch its pins.
Step 1:
Put OLD board into spare ESD bag.
Step 2:
Take NEW board out of ESD bag.

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Do not place the ESD-sensitive part on
nonconductive material or on a metal table.
If the ESD-sensitive part needs to be put down for
any reason, then first put it into its special ESD
bag
Machine covers and metal tables are
electrical grounds. They increase the risk of
damage because they make a discharge path
from your body through the ESD-sensitive part.
(Large metal objects can be discharge paths
without being grounded.)

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Prevent ESD-sensitive parts from being accidentally touched by other personnel and do not put unprotected ESD-
sensitive parts on a table.
Be extra careful in working with ESD-sensitive parts when cold-weather and heating is used,
because low humidity increases static electricity.
3.0.1 Recommended Tools
Robot arm:
•Service kit –part no.: 109010
Control box:
Below tool should be ESD safe tools.
•Slotted screwdriver
0.5 (For terminals on Current Distributor)
•Philips screwdriver
PH2 (For terminals on power supplies)
•Torx screwdriver
TX10 (For external connections i.e. main power connection)
TX20 (For shield in front of PCB’s)
TX45 (For Control box handle)
•Hex screwdriver
Size 4 (For Safety Control Board and Motherboard)
•Spanner
Size 7 (for energy eater)
•Socket screwdriver
Size 10 (For component bracket and grounding nuts)
Bit extinction (To access nuts that are hard to reach)
•Other
Flathead Plier (for removing terminals on Safety Control Board and Current Distributor)

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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 INSTRUCTION:
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.
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.
•You will find packing down procedure in section - 7. Packing of robot

3.1.2 Robot arm configuration
J1
Shoulder
J0
Base
J5
Wrist 3
J3
Wrist 1
J2
Elbow
J4
Wrist 2
Upper arm
Elbow
counterpart
and lower
arm
Base mounting bracket
Tool flange
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

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3.1.3 Brake release
If required, the brake on a joint can be released without power connected.
CAUTION:
•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 is necessary.
Not more than 160 degrees to ensure the robot can 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, Shoulder and Elbow joints, Brake on Wrist joints
4. Make sure to replace blue lid onto joint correctly and fasten screws before turning on Controller.
5. Correct torque value for screws on blue lids are 0.4Nm

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3.1.4 General guidance to separate joint from counterpart
Disassemble:
1. Ensure that the necessary tools and documentation are available before starting the repair.
1.1. Service kit with torque tools, ESD Wristband, etc.
1.2. 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, and connect the Alligator Clip from the ESD wristband to
it, as shown below.
6. Gently unplug the cable connectors without bending the printed circuit board.
Some connectors have a lock that must be engaged before it is pulled out of the printed circuit board.
Example below.

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7. Disconnect wires.
8. Remove alignment screw (Not present on newer joint housings).
9. Gently remove black flexible flat ring with a small flathead screwdriver or similar tool and pull it back
over joint housing away from its original position.
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 anti-clockwise around 5 degrees, until a mechanical stop
is met (holes are keyhole-type). They can then be completely separated.