Universal Robots UR5 User manual

User Manual
UR5/CB3
Original instructions (en)

User Manual
UR5/CB3
Euromap67
Version 3.4.5
Original instructions (en)

The information contained herein is the property of Universal Robots A/S and shall not be repro-
duced in whole or in part without prior written approval of Universal Robots A/S. The informa-
tion 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 © 2009–2017 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.
UR5/CB3 ii Version 3.4.5
Copyright © 2009–2017 by Universal Robots A/S. All rights reserved.

Contents
Preface ix
What Do the Boxes Contain . . . . . . . . . . . . . . . . . . . . . . . . ix
ImportantSafetyNotice......................... x
HowtoReadThisManual........................ x
Where to Find More Information . . . . . . . . . . . . . . . . . . . . . . x
I Hardware Installation Manual I-1
1 Safety I-3
1.1 Introduction........................... I-3
1.2 Validity and Responsibility . . . . . . . . . . . . . . . . . . . . . . I-3
1.3 Limitation of Liability. . . . . . . . . . . . . . . . . . . . . . . . I-4
1.4 Warning Symbols in this Manual . . . . . . . . . . . . . . . . . . . . I-4
1.5 General Warnings and Cautions . . . . . . . . . . . . . . . . . . . . I-5
1.6 IntendedUse........................... I-7
1.7 RiskAssessment.......................... I-7
1.8 EmergencyStop.......................... I-9
1.9 Movement Without Drive Power . . . . . . . . . . . . . . . . . . . . I-9
2 Safety-related Functions and Interfaces I-11
2.1 Introduction........................... I-11
2.2 Stopping times of the Safety System . . . . . . . . . . . . . . . . . . I-12
2.3 Limiting Safety-related Functions . . . . . . . . . . . . . . . . . . . I-12
2.4 SafetyModes........................... I-13
2.5 Safety-related Electrical Interfaces . . . . . . . . . . . . . . . . . . . I-15
2.5.1 Safety-related Electrical Inputs . . . . . . . . . . . . . . . . . . I-15
2.5.2 Safety-related Electrical Outputs . . . . . . . . . . . . . . . . . I-16
3 Transportation I-19
4 Mechanical Interface I-21
4.1 Introduction........................... I-21
4.2 Workspace of the Robot . . . . . . . . . . . . . . . . . . . . . . . I-21
4.3 Mounting............................ I-21
4.4 MaximumPayload......................... I-25
5 Electrical Interface I-27
5.1 Introduction........................... I-27
5.2 Electrical warnings and cautions . . . . . . . . . . . . . . . . . . . . I-27
5.3 ControllerI/O.......................... I-29
5.3.1 Common specifications for all digital I/O . . . . . . . . . . . . . . I-29
5.3.2 SafetyI/O......................... I-31
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iii UR5/CB3

5.3.3 General purpose digital I/O. . . . . . . . . . . . . . . . . . . I-34
5.3.4 Digital input from a button . . . . . . . . . . . . . . . . . . . I-35
5.3.5 Communication with other machines or PLCs . . . . . . . . . . . . I-35
5.3.6 General purpose analog I/O. . . . . . . . . . . . . . . . . . . I-35
5.3.7 Remote ON/OFF control . . . . . . . . . . . . . . . . . . . . I-37
5.4 ToolI/O ............................ I-38
5.4.1 Tool Digital Outputs . . . . . . . . . . . . . . . . . . . . . I-39
5.4.2 Tool Digital Inputs . . . . . . . . . . . . . . . . . . . . . . I-40
5.4.3 Tool Analog Inputs . . . . . . . . . . . . . . . . . . . . . . I-41
5.5 Ethernet............................. I-42
5.6 Mainsconnection......................... I-42
5.7 Robotconnection......................... I-43
6 Maintenance and Repair I-45
6.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . I-45
7 Disposal and Environment I-47
8 Certifications I-49
8.1 Third Party Certifications . . . . . . . . . . . . . . . . . . . . . . I-49
8.2 Declarations According to EU directives . . . . . . . . . . . . . . . . . I-49
9 Warranties I-51
9.1 ProductWarranty......................... I-51
9.2 Disclaimer............................ I-51
A Stopping Time and Stopping Distance I-53
A.1 Stop Category 0 stopping distances and times . . . . . . . . . . . . . . . I-53
B Declarations and Certificates I-55
B.1 CE/EU Declaration of Incorporation (original). . . . . . . . . . . . . . . I-55
B.2 Safety System Certificate. . . . . . . . . . . . . . . . . . . . . . . I-56
B.3 Environmental Test Certificate. . . . . . . . . . . . . . . . . . . . . I-57
B.4 EMC Test Certificate . . . . . . . . . . . . . . . . . . . . . . . . I-58
B.5 Cleanroom Test Certificates. . . . . . . . . . . . . . . . . . . . . . I-59
C Applied Standards I-61
D Technical Specifications I-69
II PolyScope Manual II-1
10 Safety Configuration II-3
10.1Introduction........................... II-3
10.2 Changing the Safety Configuration . . . . . . . . . . . . . . . . . . . II-4
10.3 Safety Synchronization and Errors . . . . . . . . . . . . . . . . . . . II-5
10.4Tolerances............................ II-6
10.5SafetyChecksum......................... II-6
10.6SafetyModes........................... II-6
UR5/CB3 iv Version 3.4.5
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10.7FreedriveMode.......................... II-7
10.7.1Backdrive......................... II-7
10.8PasswordLock.......................... II-8
10.9Apply............................. II-8
10.10GeneralLimits.......................... II-9
10.11JointLimits ........................... II-11
10.12Boundaries............................ II-12
10.12.1 Selecting a boundary to configure. . . . . . . . . . . . . . . . . II-13
10.12.2 3D visualization . . . . . . . . . . . . . . . . . . . . . . . II-14
10.12.3 Safety plane configuration . . . . . . . . . . . . . . . . . . . II-14
10.12.4 Tool Boundary configuration . . . . . . . . . . . . . . . . . . II-17
10.13SafetyI/O............................ II-19
10.13.1 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . II-19
10.13.2 Output Signals . . . . . . . . . . . . . . . . . . . . . . . II-21
11 Begin programming II-23
11.1Introduction........................... II-23
11.2GettingStarted.......................... II-23
11.2.1 Installing the Robot Arm and Control Box. . . . . . . . . . . . . . II-24
11.2.2 Turning the Control Box On and Off . . . . . . . . . . . . . . . . II-24
11.2.3 Turning the Robot Arm On and Off . . . . . . . . . . . . . . . . II-24
11.2.4QuickStart......................... II-25
11.2.5 The First Program . . . . . . . . . . . . . . . . . . . . . . II-25
11.3 PolyScope Programming Interface . . . . . . . . . . . . . . . . . . . II-26
11.4WelcomeScreen.......................... II-28
11.5 Initialization Screen . . . . . . . . . . . . . . . . . . . . . . . . II-29
12 On-screen Editors II-31
12.1 On-screen Expression Editor . . . . . . . . . . . . . . . . . . . . . II-31
12.2 Pose Editor Screen . . . . . . . . . . . . . . . . . . . . . . . . . II-31
13 Robot Control II-35
13.1MoveTab............................ II-35
13.1.1Robot........................... II-35
13.1.2 Feature and Tool Position. . . . . . . . . . . . . . . . . . . . II-36
13.1.3MoveTool......................... II-36
13.1.4MoveJoints......................... II-36
13.1.5Freedrive ......................... II-36
13.2I/OTab............................. II-37
13.3 MODBUS client I/O . . . . . . . . . . . . . . . . . . . . . . . . II-38
13.4AutoMoveTab.......................... II-38
13.5 Installation →Load/Save...................... II-40
13.6 Installation →TCP Configuration . . . . . . . . . . . . . . . . . . . II-41
13.6.1 Adding, modifying and removing TCPs . . . . . . . . . . . . . . II-41
13.6.2 The default and the active TCP . . . . . . . . . . . . . . . . . . II-41
13.6.3 Teaching TCP position . . . . . . . . . . . . . . . . . . . . . II-42
13.6.4 Teaching TCP orientation . . . . . . . . . . . . . . . . . . . . II-43
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vUR5/CB3

13.6.5Payload.......................... II-43
13.6.6 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . II-43
13.7 Installation →Mounting....................... II-44
13.8 Installation →I/OSetup ...................... II-45
13.8.1 I/O Signal Type . . . . . . . . . . . . . . . . . . . . . . . II-46
13.8.2 Assigning User-defined Names . . . . . . . . . . . . . . . . . II-46
13.8.3 I/O Actions and I/O Tab Control . . . . . . . . . . . . . . . . . II-46
13.9 Installation →Safety........................ II-46
13.10 Installation →Variables....................... II-47
13.11 Installation →MODBUS client I/O Setup . . . . . . . . . . . . . . . . II-48
13.12 Installation →Features....................... II-51
13.12.1 Using a feature . . . . . . . . . . . . . . . . . . . . . . . II-52
13.12.2NewPoint......................... II-54
13.12.3NewLine......................... II-54
13.12.4NewPlane......................... II-55
13.12.5 Example: Manually updating a feature to adjust a program . . . . . . . II-56
13.12.6 Example: Dynamically updating a feature pose . . . . . . . . . . . . II-57
13.13 Conveyor Tracking Setup . . . . . . . . . . . . . . . . . . . . . . II-58
13.14 Installation →Default Program . . . . . . . . . . . . . . . . . . . . II-59
13.14.1 Loading a Default Program . . . . . . . . . . . . . . . . . . . II-59
13.14.2 Starting a Default Program . . . . . . . . . . . . . . . . . . . II-60
13.14.3 Auto Initialization . . . . . . . . . . . . . . . . . . . . . . II-60
13.15LogTab............................. II-60
13.16LoadScreen........................... II-61
13.17RunTab............................. II-63
14 Programming II-65
14.1NewProgram .......................... II-65
14.2ProgramTab........................... II-66
14.2.1 Program Tree . . . . . . . . . . . . . . . . . . . . . . . . II-66
14.2.2 Program Execution Indication . . . . . . . . . . . . . . . . . . II-67
14.2.3 Search Button . . . . . . . . . . . . . . . . . . . . . . . . II-67
14.2.4 Undo/Redo Buttons . . . . . . . . . . . . . . . . . . . . . II-68
14.2.5 Program Dashboard. . . . . . . . . . . . . . . . . . . . . . II-68
14.3Variables............................ II-69
14.4Command:Empty......................... II-69
14.5Command:Move......................... II-70
14.6 Command: Fixed Waypoint . . . . . . . . . . . . . . . . . . . . . II-73
14.7 Command: Relative Waypoint. . . . . . . . . . . . . . . . . . . . . II-78
14.8 Command: Variable Waypoint . . . . . . . . . . . . . . . . . . . . II-79
14.9Command:Wait.......................... II-80
14.10Command:Set.......................... II-80
14.11 Command: Popup . . . . . . . . . . . . . . . . . . . . . . . . . II-81
14.12Command:Halt.......................... II-82
14.13 Command: Comment . . . . . . . . . . . . . . . . . . . . . . . . II-82
14.14 Command: Folder . . . . . . . . . . . . . . . . . . . . . . . . . II-83
14.15Command:Loop......................... II-83
UR5/CB3 vi Version 3.4.5
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14.16 Command: SubProgram . . . . . . . . . . . . . . . . . . . . . . . II-84
14.17 Command: Assignment . . . . . . . . . . . . . . . . . . . . . . . II-85
14.18Command:If........................... II-86
14.19 Command: Script . . . . . . . . . . . . . . . . . . . . . . . . . II-87
14.20 Command: Event . . . . . . . . . . . . . . . . . . . . . . . . . II-88
14.21 Command: Thread . . . . . . . . . . . . . . . . . . . . . . . . . II-89
14.22 Command: Switch . . . . . . . . . . . . . . . . . . . . . . . . . II-89
14.23 Command: Pattern . . . . . . . . . . . . . . . . . . . . . . . . . II-90
14.24 Command: Force . . . . . . . . . . . . . . . . . . . . . . . . . II-91
14.25 Command: Pallet . . . . . . . . . . . . . . . . . . . . . . . . . II-95
14.26Command:Seek.......................... II-96
14.27 Command: Conveyor Tracking . . . . . . . . . . . . . . . . . . . . II-99
14.28 Command: Suppress . . . . . . . . . . . . . . . . . . . . . . . . II-100
14.29GraphicsTab........................... II-100
14.30StructureTab........................... II-101
14.31VariablesTab........................... II-102
14.32 Command: Variables Initialization . . . . . . . . . . . . . . . . . . . II-103
15 Setup Screen II-105
15.1 Language and Units . . . . . . . . . . . . . . . . . . . . . . . . II-106
15.2UpdateRobot........................... II-107
15.3SetPassword........................... II-108
15.4 Calibrate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . II-109
15.5SetupNetwork.......................... II-109
15.6SetTime............................. II-110
15.7URCapsSetup.......................... II-111
III EUROMAP 67 Interface III-1
16 Introduction III-3
16.1 EUROMAP 67 standard . . . . . . . . . . . . . . . . . . . . . . . III-4
16.2 Statutory notice . . . . . . . . . . . . . . . . . . . . . . . . . . III-4
17 Robot and IMM integration III-7
17.1 Emergency stop and safeguard stop. . . . . . . . . . . . . . . . . . . III-7
17.2 Connecting a MAF light guard . . . . . . . . . . . . . . . . . . . . III-7
17.3 Mounting the robot and tool . . . . . . . . . . . . . . . . . . . . . III-8
17.4 Using the robot without an IMM . . . . . . . . . . . . . . . . . . . . III-8
17.5 EUROMAP 12 to EUROMAP 67 conversion . . . . . . . . . . . . . . . . III-8
18 GUI III-11
18.1 EUROMAP 67 program template . . . . . . . . . . . . . . . . . . . III-11
18.2 I/O overview and troubleshooting . . . . . . . . . . . . . . . . . . . III-12
18.2.1Control.......................... III-13
18.2.2 Manufacturer dependent . . . . . . . . . . . . . . . . . . . . III-14
18.2.3Safety........................... III-14
18.2.4Status........................... III-14
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vii UR5/CB3

18.3 Program structure functionality . . . . . . . . . . . . . . . . . . . . III-14
18.3.1 Startup Check . . . . . . . . . . . . . . . . . . . . . . . . III-15
18.3.2 Free to Mould . . . . . . . . . . . . . . . . . . . . . . . . III-16
18.3.3 Wait for Item . . . . . . . . . . . . . . . . . . . . . . . . III-17
18.3.4 Ejector Forward . . . . . . . . . . . . . . . . . . . . . . . III-17
18.3.5 Ejector Back. . . . . . . . . . . . . . . . . . . . . . . . . III-18
18.3.6 Core Pullers In . . . . . . . . . . . . . . . . . . . . . . . III-18
18.3.7 Core Pullers Out . . . . . . . . . . . . . . . . . . . . . . . III-19
18.4 I/O action and wait . . . . . . . . . . . . . . . . . . . . . . . . III-20
19 Installing and uninstalling the interface III-21
19.1Installing............................ III-21
19.2Uninstalling........................... III-22
20 Electrical characteristics III-25
20.1 MAF light guard interface . . . . . . . . . . . . . . . . . . . . . . III-25
20.2 Emergency stop, safety devices and MAF signals . . . . . . . . . . . . . . III-25
20.3DigitalInputs........................... III-26
20.4 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . III-26
Glossary III-27
Index III-29
UR5/CB3 viii Version 3.4.5
Copyright © 2009–2017 by Universal Robots A/S. All rights reserved.

Preface
Congratulations on the purchase of your new Universal Robot, UR5.
The robot can be programmed to move a tool, and communicate with other ma-
chines using electrical signals. It is an arm composed of extruded aluminum tubes
and joints. Using our patented programming interface, PolyScope, it is easy to pro-
gram the robot to move the tool along a desired trajectory.
What Do the Boxes Contain
When you order a complete robot, you receive two boxes. One contains the robot
arm and the following items are included in the other one:
• Control box with teach pendant;
• Mounting bracket for the control box;
• Mounting bracket for the teach pendant;
• Key for opening the control box;
• Mains cable compatible with your region;
• EUROMAP 67 cable;
• Stylus pen with laser;
• UR production test certificate;
• This manual.
Version 3.4.5
Copyright © 2009–2017 by Universal Robots A/S. All rights reserved.
ix UR5/CB3

Where to Find More Information
Important Safety Notice
The robot is partly completed machinery (see 8.2) and as such a risk assessment is
required for each installation of the robot. It is particularly important that all of the
safety instructions in chapter 1 are followed.
How to Read This Manual
This manual contains instructions for installing and using the robot. It consists of
the following parts:
Hardware Installation Manual: The mechanical and electrical installation of the robot.
PolyScope Manual: Programming of the robot.
EUROMAP 67 Interface: Using the EUROMAP 67 interface.
This manual is intended for the integrator who is expected to have a basic level of
mechanical and electrical training. It is also helpful, though not necessary, to be
familiar with elementary concepts of programming. No special knowledge about
robots in general or Universal Robots in particular is required.
Where to Find More Information
The support website (http://www.universal-robots.com/support), avail-
able to all UR distributors, contains additional information, such as:
• Other language versions of this manual;
• PolyScope Manual updates after the PolyScope is upgraded to a new version.
• The Service Manual with instructions for troubleshooting, maintenance and re-
pair of the robot.
• The Script Manual for advanced users.
• The URCAPS where capabilities can be purchased.
UR5/CB3 xVersion 3.4.5
Copyright © 2009–2017 by Universal Robots A/S. All rights reserved.

Part I
Hardware Installation Manual

1 Safety
1.1 Introduction
This chapter contains important safety information, which must be read and un-
derstood by the integrator of UR robots before the robot is powered on for the first
time.
The first subsections in this chapter are more general and the later subsections con-
tain more specific engineering data relevant for setting up and programming the
robot.
It is essential that all assembly instructions and guidance provided in other chapters
and parts of this manual are observed and followed.
Chapter 2 describes and defines safety-related functions particularly relevant for
collaborative applications. Instructions and guidance provided in that chapter and
in section 1.7 is particularly important.
Special attention shall be paid to text associated with warning symbols.
1.2 Validity and Responsibility
The information does not cover how to design, install and operate a complete robot
application, nor does it cover all peripheral equipment that can influence the safety
of the complete system. The complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the robot is installed.
The integrators of UR robots are responsible for ensuring that the applicable safety
laws and regulations in the country concerned are observed and that any significant
hazards in the complete robot application are eliminated.
This includes, but is not limited to:
• Making a risk assessment for the complete system;
• Interfacing other machines and additional safety devices if defined by the risk
assessment;
• Setting up the appropriate safety settings in the software;
• Ensuring that the user will not modify any safety measures;
• Validating that the total system is designed and installed correctly;
• Specifying instructions for use;
• Marking the robot installation with relevant signs and contact information of
the integrator;
• Collecting all documentation in a technical file; including the risk assessment
and this manual.
Guidance on how to find and read applicable standards and laws is provided on
http://universal-robots.com/support/
Version 3.4.5
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I-3 UR5/CB3

1.4 Warning Symbols in this Manual
1.3 Limitation of Liability
Any information given in this manual regarding safety must not be construed as
a warranty by UR that the industrial manipulator will not cause injury or damage
even if all safety instructions are complied with.
1.4 Warning Symbols in this Manual
The table below defines the captions specifying the danger levels used throughout
this manual. The same warning signs are used on the product.
DANGER:
This indicates an imminently hazardous electrical situation which,
if not avoided, could result in death or serious injury.
DANGER:
This indicates an imminently hazardous situation which, if not
avoided, could result in death or serious injury.
WARNING:
This indicates a potentially hazardous electrical situation which, if
not avoided, could result in injury or major damage to the equip-
ment.
WARNING:
This indicates a potentially hazardous situation which, if not
avoided, could result in injury or major damage to the equipment.
WARNING:
This indicates a potentially hazardous hot surface which, if
touched, could result in injury.
CAUTION:
This indicates a situation which, if not avoided, could result in
damage to the equipment.
UR5/CB3 I-4 Version 3.4.5
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1.5 General Warnings and Cautions
1.5 General Warnings and Cautions
This section contains some general warnings and cautions. Some of which are re-
peated or explained in different parts of the manual. Other warnings and cautions
are present throughout the manual.
DANGER:
Make sure to install the robot and all electrical equipment accord-
ing to the specifications and warnings found in the Chapters 4 and
5.
WARNING:
1. Make sure the robot arm and tool are properly and securely
bolted in place.
2. Make sure the robot arm has ample space to operate freely.
3. Make sure that safety measures and/or robot safety configu-
ration parameters have been set up to protect both program-
mers, operators and bystanders, as defined in the risk assess-
ment.
4. Do not wear loose clothing or jewellery when working with
the robot. Make sure long hair is tied back when working
with the robot.
5. Never use the robot if it is damaged.
6. If the software prompts a fatal error, immediately activate
emergency stop, write down the conditions that led to the er-
ror, find the corresponding error codes on the log screen, and
contact your supplier.
7. Do not connect any safety equipment to normal I/O. Use
safety-related interfaces only.
8. Make sure to use the correct installation settings (e.g. Robot
mounting angle, weight in TCP, TCP offset, safety configura-
tion). Save and load the installations file along with the pro-
gram.
9. The freedrive function (Impedance/Backdrive) shall only be
used in installations where the risk assessment allows it.
Tools and obstacles shall not have sharp edges or pinch
points. Make sure that all people keep their heads and faces
outside the reach of the robot.
10. Be aware of robot movement when using the teach pendant.
11. Do not enter the safety range of the robot or touch the robot
when the system is in operation.
Version 3.4.5
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I-5 UR5/CB3

1.5 General Warnings and Cautions
11. Collisions can release high levels of kinetic energy, which are
significantly higher at high speeds and with high payloads.
(Kinetic Energy = 1
2Mass ·Speed2)
12. Combining different machines might increase hazards or cre-
ate new hazards. Always make an overall risk assessment for
the complete installation. When different safety and emer-
gency stop performance levels are needed, always choose the
highest performance level. Always read and understand the
manuals for all equipment used in the installation.
13. Never modify the robot. A modification might create haz-
ards that are unforeseen by the integrator. All authorized
reassembling shall be done according to the newest version
of all relevant service manuals. UNIVERSAL ROBOTS DIS-
CLAIMS ANY LIABILITY IF THE PRODUCT IS CHANGED
OR MODIFIED IN ANY WAY.
14. If the robot is purchased with an extra module (e.g. eu-
romap67 interface) then look up that module in the respective
manual.
WARNING:
1. The robot and controller box generate heat during operation.
Do not handle or touch the robot while in operation or imme-
diately after operation. To cool the robot down, power off the
robot and wait one hour.
2. Never stick fingers behind the internal cover of the controller
box.
CAUTION:
1. When the robot is combined with or working with machines
capable of damaging the robot, then it is highly recom-
mended to test all functions and the robot program sepa-
rately. It is recommended to test the robot program using tem-
porary waypoints outside the workspace of other machines.
Universal Robots cannot be held responsible for any damages
caused to the robot or to other equipment due to program-
ming errors or malfunctioning of the robot.
2. Do not expose the robot to permanent magnetic fields. Very
strong magnetic fields can damage the robot.
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1.6 Intended Use
1.6 Intended Use
UR robots are industrial and intended for handling tools and fixtures, or for pro-
cessing or transferring components or products. For details about the environmen-
tal conditions under which the robot should operate, see appendices B and D.
UR robots are equipped with special safety-related features, which are purposely
designed for collaborative operation, where the robot operates without fences and/or
together with a human.
Collaborative operation is only intended for non-hazardous applications, where
the complete application, including tool, work piece, obstacles and other machines,
is without any significant hazards according to the risk assessment of the specific
application.
Any use or application deviating from the intended use is deemed to be impermis-
sible misuse. This includes, but is not limited to:
• Use in potentially explosive environments;
• Use in medical and life critical applications;
• Use before performing a risk assessment;
• Use where the rated performance levels are insufficient;
• Use where the performance of the safety functions are insufficient;
• Use as a climbing aid;
• Operation outside the permissible operating parameters.
1.7 Risk Assessment
One of the most important things that an integrator needs to do is to make a risk
assessment. In many countries this is required by law. The robot itself is partly
completed machinery, as the safety of the robot installation depends on how the
robot is integrated (E.g. tool, obstacles and other machines).
It is recommended that the integrator uses guidelines in ISO 12100 and ISO 10218-2
to conduct the risk assessment. Additionally the integrator can choose to use the
Technical Specification ISO/TS 15066 as additional guidance.
The risk assessment that the integrator conducts shall consider all work procedures
throughout the lifetime of the robot application, including but not limited to:
• Teaching the robot during set-up and development of the robot installation;
• Troubleshooting and maintenance;
• Normal operation of the robot installation.
A risk assessment must be conducted before the robot arm is powered on for the
first time. A part of the risk assessment conducted by the integrator is to identify
the proper safety configuration settings, as well as the need for additional emer-
gency stop buttons and/or other protective measures required for the specific robot
application.
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I-7 UR5/CB3

1.7 Risk Assessment
Identifying the correct safety configuration settings is a particularly important part
of developing collaborative robot applications. See chapter 2 and Part II for detailed
information.
Some safety-related features are purposely designed for collaborative robot appli-
cations. These features are configurable though the safety configuration settings
and are particularly relevant when addressing specific risks in the risk assessment
conducted by the integrator:
•Force and power limiting: Used to reduce clamping forces and pres-
sures exerted by the robot in the direction of movement in case of collisions
between the robot and the operator.
•Momentum limiting: Used to reduce high transient energy and impact forces
in case of collisions between robot and operator by reducing the speed of the
robot.
•Joint and TCP position limiting: Particularly used to reduce risks
associated with certain body parts. E.g. to avoid movement towards head and
neck during set-up and programming.
•TCP and tool orientation limiting: Particularly used to reduce risks
associated with certain areas and features of the tool and work-piece. E.g. to
avoid sharp edges to be pointed towards the operator.
•Speed limitation: Particularly used to ensure a low speed of the robot
arm. E.g. to provide time for the operator to avoid contact with the robot arm.
Applying the correct safety configuration settings is considered equivalent to bolt-
ing the robot into place and connecting safety-related equipment to safety-related
I/Os. The integrator must prevent unauthorized persons from changing the safety
configuration, e.g. by use of password protection.
When assessing risks in a collaborative robot application, it is particularly impor-
tant to cover:
• Severity of individual potential collisions;
• Likeliness of occurrence of individual potential collisions;
• Possibility to avoid individual potential collisions;
If the robot is installed in a non-collaborative robot application where hazards can-
not be reasonably eliminated or risks cannot be sufficiently reduced by use of the
built-in safety-related functions (e.g. when using a hazardous tool), then the risk
assessment conducted by the integrator must conclude that the integrator needs to
add additional protective measures (e.g. an enabling device to protect the integra-
tor during set-up and programming).
Universal Robots has identified the potential significant hazards listed below as
hazards which must be considered by the integrator. Note that other significant
hazards might be present in a specific robot installation.
1. Entrapment of fingers between robot foot and base (joint 0).
2. Entrapment of fingers between wrist 1 and wrist 2 (joint 3 and joint 4).
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