Universal Robots UR5 User manual

User Manual
UR5/CB3
Original instructions (en)
US version

User Manual
UR5/CB3
Version 3.1 (rev. 17782)
Original instructions (en)
US Version
Serial number UR5:
Serial number CB3:

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 © 2009-2015 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.
UR5/CB3 ii Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.

Contents
Preface ix
WhatdotheBoxesContain.......................... 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-8
1.7 RiskAssessment............................ I-8
1.8 EmergencyStop............................ I-9
1.9 Movement Without Drive Power. . . . . . . . . . . . . . . . . . . . . . I-10
2 Transportation I-11
3 Mechanical Interface I-13
3.1 Workspace of the Robot . . . . . . . . . . . . . . . . . . . . . . . . . I-13
3.2 Mounting.............................. I-13
4 Electrical Interface I-19
4.1 Introduction............................. I-19
4.2 Electrical warnings and cautions . . . . . . . . . . . . . . . . . . . . . . I-19
4.3 ControllerI/O............................ I-21
4.3.1 Common specifications for all digital I/O . . . . . . . . . . . . . . . . I-21
4.3.2 SafetyI/O........................... I-23
4.3.3 General purpose digital I/O . . . . . . . . . . . . . . . . . . . . . I-27
4.3.4 Digital input from a button . . . . . . . . . . . . . . . . . . . . . I-27
4.3.5 Communication with other machines or PLCs . . . . . . . . . . . . . . I-28
4.3.6 General purpose analog I/O. . . . . . . . . . . . . . . . . . . . . I-28
4.3.7 Remote ON/OFF control . . . . . . . . . . . . . . . . . . . . . . I-30
Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.
iii UR5/CB3

4.4 ToolI/O .............................. I-31
4.4.1 Tool Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . I-32
4.4.2 Tool Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . I-33
4.4.3 Tool Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . I-34
4.5 Ethernet............................... I-35
4.6 Mainsconnection........................... I-35
4.7 Robotconnection........................... I-36
5 Safety-related Functions and Interfaces I-39
5.1 Limiting Safety-related Functions . . . . . . . . . . . . . . . . . . . . . I-39
5.2 SafetyModes............................. I-41
5.3 Safety-related Electrical Interfaces . . . . . . . . . . . . . . . . . . . . . I-42
5.3.1 Safety-related Electrical Inputs . . . . . . . . . . . . . . . . . . . . I-42
5.3.2 Safety-related Electrical Outputs . . . . . . . . . . . . . . . . . . . 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 CATEGORY 0 stopping distances and times . . . . . . . . . . . . . . . . . . I-53
B Declarations and Certificates I-55
B.1 CE 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
C Applied Standards I-59
D Technical Specifications I-65
II PolyScope Manual II-1
10 Introduction II-3
10.1GettingStarted............................ II-3
10.1.1 Installing the Robot Arm and Control Box. . . . . . . . . . . . . . . . II-3
UR5/CB3 iv Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.

10.1.2 Turning the Control Box On and Off . . . . . . . . . . . . . . . . . . II-4
10.1.3 Turning the Robot Arm On and Off . . . . . . . . . . . . . . . . . . II-4
10.1.4QuickStart........................... II-4
10.1.5 The First Program . . . . . . . . . . . . . . . . . . . . . . . . II-5
10.2 PolyScope Programming Interface . . . . . . . . . . . . . . . . . . . . . II-6
10.3WelcomeScreen............................ II-8
10.4 Initialization Screen . . . . . . . . . . . . . . . . . . . . . . . . . . II-9
11 On-screen Editors II-11
11.1On-screenKeypad...........................II-11
11.2 On-screen Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . II-12
11.3 On-screen Expression Editor . . . . . . . . . . . . . . . . . . . . . . . II-13
11.4 Pose Editor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . II-13
12 Robot Control II-17
12.1MoveTab..............................II-17
12.1.1Robot.............................II-17
12.1.2 Feature and Tool Position . . . . . . . . . . . . . . . . . . . . . . II-18
12.1.3MoveTool...........................II-18
12.1.4MoveJoints...........................II-18
12.1.5Freedrive ...........................II-18
12.2I/OTab...............................II-19
12.3 MODBUS client I/O . . . . . . . . . . . . . . . . . . . . . . . . . . II-20
12.4AutoMoveTab............................II-21
12.5 Installation →Load/Save........................II-22
12.6 Installation →TCP Configuration . . . . . . . . . . . . . . . . . . . . . II-23
12.6.1 Adding, modifying and removing TCPs . . . . . . . . . . . . . . . . II-24
12.6.2 The default and the active TCP. . . . . . . . . . . . . . . . . . . . II-24
12.6.3 Teaching TCP position . . . . . . . . . . . . . . . . . . . . . . . II-24
12.6.4 Teaching TCP orientation . . . . . . . . . . . . . . . . . . . . . . II-25
12.6.5Payload............................II-26
12.6.6 Center of gravity . . . . . . . . . . . . . . . . . . . . . . . . . II-26
12.7 Installation →Mounting.........................II-26
12.8 Installation →I/OSetup ........................II-28
12.9 Installation →Safety..........................II-29
12.10 Installation →Variables.........................II-29
12.11 Installation →MODBUS client I/O Setup . . . . . . . . . . . . . . . . . . II-30
12.12 Installation →Features.........................II-33
12.13 Conveyor Tracking Setup . . . . . . . . . . . . . . . . . . . . . . . . II-37
12.14 Installation →DefaultProgram......................II-38
12.14.1 Loading a Default Program . . . . . . . . . . . . . . . . . . . . . II-39
12.14.2 Starting a Default Program . . . . . . . . . . . . . . . . . . . . . II-39
12.14.3 Auto Initialization . . . . . . . . . . . . . . . . . . . . . . . . II-39
Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.
vUR5/CB3

12.15LogTab...............................II-40
12.16LoadScreen.............................II-40
12.17RunTab...............................II-43
13 Programming II-45
13.1NewProgram ............................II-45
13.2ProgramTab.............................II-46
13.2.1ProgramTree..........................II-46
13.2.2 Program Execution Indication . . . . . . . . . . . . . . . . . . . . II-47
13.2.3 Undo/Redo Buttons . . . . . . . . . . . . . . . . . . . . . . . II-47
13.2.4 Program Dashboard. . . . . . . . . . . . . . . . . . . . . . . . II-48
13.3Variables..............................II-49
13.4Command:Empty...........................II-49
13.5Command:Move...........................II-50
13.6 Command: Fixed Waypoint . . . . . . . . . . . . . . . . . . . . . . . II-53
13.7 Command: Relative Waypoint. . . . . . . . . . . . . . . . . . . . . . . II-55
13.8 Command: Variable Waypoint . . . . . . . . . . . . . . . . . . . . . . II-56
13.9Command:Wait............................II-57
13.10Command:Set............................II-58
13.11Command:Popup...........................II-59
13.12Command:Halt............................II-60
13.13 Command: Comment . . . . . . . . . . . . . . . . . . . . . . . . . . II-61
13.14Command:Folder...........................II-62
13.15Command:Loop...........................II-63
13.16 Command: SubProgram . . . . . . . . . . . . . . . . . . . . . . . . . II-64
13.17 Command: Assignment . . . . . . . . . . . . . . . . . . . . . . . . . II-66
13.18Command:If.............................II-67
13.19Command:Script...........................II-68
13.20Command:Event...........................II-69
13.21Command:Thread...........................II-70
13.22 Command: Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . II-71
13.23Command:Force...........................II-72
13.24Command:Pallet...........................II-75
13.25Command:Seek............................II-76
13.26 Command: Start/Stop Conveyor Tracking . . . . . . . . . . . . . . . . . . II-80
13.27 Command: Suppress . . . . . . . . . . . . . . . . . . . . . . . . . . II-80
13.28GraphicsTab.............................II-80
13.29StructureTab.............................II-82
13.30VariablesTab.............................II-83
13.31 Command: Variables Initialization . . . . . . . . . . . . . . . . . . . . . II-84
UR5/CB3 vi Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.

14 Setup Screen II-85
14.1 Language and Units . . . . . . . . . . . . . . . . . . . . . . . . . . II-86
14.2UpdateRobot.............................II-87
14.3SetPassword.............................II-88
14.4CalibrateScreen............................II-89
14.5SetupNetwork............................II-90
14.6SetTime...............................II-91
15 Safety Configuration II-93
15.1 Changing the Safety Configuration . . . . . . . . . . . . . . . . . . . . . II-94
15.2 Safety Synchronization and Errors . . . . . . . . . . . . . . . . . . . . . II-95
15.3Tolerances..............................II-95
15.4SafetyChecksum...........................II-96
15.5SafetyModes.............................II-96
15.6FreedriveMode............................II-97
15.7PasswordLock............................II-97
15.8Apply...............................II-98
15.9GeneralLimits............................II-98
15.10JointLimits .............................II-101
15.11Boundaries..............................II-102
15.11.1 Selecting a boundary to configure. . . . . . . . . . . . . . . . . . . II-103
15.11.2 3D visualization . . . . . . . . . . . . . . . . . . . . . . . . . II-104
15.11.3 Safety plane configuration . . . . . . . . . . . . . . . . . . . . . II-104
15.11.4 Tool Boundary configuration . . . . . . . . . . . . . . . . . . . . II-108
15.12SafetyI/O..............................II-110
Glossary II-113
Index II-115
Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.
vii UR5/CB3

UR5/CB3 viii Version 3.1 (rev. 17782)
Copyright © 2009-2015 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 machines
using electrical signals. It is an arm composed of extruded aluminum tubes and joints.
Using our patented programming interface, PolyScope, it is easy to program 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 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;
• Tool cable;
• Stylus pen with laser;
• UR production test certificate;
• This manual.
Version 3.1 (rev. 17782)
Copyright © 2009-2015 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 re-
quired 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.
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 famil-
iar 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://support.universal-robots.com/), available 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 repair
of the robot.
• The Script Manual for advanced users.
UR5/CB3 xVersion 3.1 (rev. 17782)
Copyright © 2009-2015 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 under-
stood by the integrator of UR robots.
The first subsections in this chapter are more general and the later subsections contain
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.
Special attention shall be paid to text associated with warning symbols. See Chapter 5
for detailed descriptions of the safety-related functions and interfaces.
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 accor-
dance 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.
Guidance on how to find and read applicable standards and laws is provided on
http://support.universal-robots.com/
Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.
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 dam-
age to the equipment.
UR5/CB3 I-4 Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.

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 according
to the specifications and warnings found in the Chapters 3 and 4.
Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.
I-5 UR5/CB3

1.5 General Warnings and Cautions
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 configura-
tion parameters have been set up to protect both programmers,
operators and bystanders, as defined in the risk assessment.
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 emer-
gency stop, write down the conditions that led to the error, 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/back-drive) 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.
UR5/CB3 I-6 Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.

1.5 General Warnings and Cautions
11. Collisions can release high portions of kinetic energy, which are
significantly higher at high speeds and with high payloads. (Ki-
netic 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 emergency
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 hazards
that are unforeseen by the integrator. All authorized reassem-
bling shall be done according to the newest version of all rele-
vant service manuals. UNIVERSAL ROBOTS DISCLAIMS ANY
LIABILITY IF THE PRODUCT IS CHANGED OR MODIFIED
IN ANY WAY.
14. If the robot is purchased with an extra module (e.g. euromap67
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 immediately
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.
Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.
I-7 UR5/CB3

1.7 Risk Assessment
CAUTION:
1. When the robot is combined with or working with machines ca-
pable of damaging the robot, then it is highly recommended to
test all functions and the robot program separately. It is recom-
mended to test the robot program using temporary waypoints
outside the workspace of other machines. Universal Robots can-
not be held responsible for any damages caused to the robot or
to other equipment due to programming errors or malfunction-
ing of the robot.
2. Do not expose the robot to permanent magnetic fields. Very
strong magnetic fields can damage the robot.
1.6 Intended Use
UR robots are industrial and intended for handling tools and fixtures, or for processing
or transferring components or products. For details about the environmental condi-
tions under which the robot should operate, see appendices B and D.
UR robots are equipped with special safety-related features, which are purposely de-
signed 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 ap-
plication.
Any use or application deviating from the intended use is deemed to be impermissible
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 reaction times 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. The robot itself is partly completed machinery, as the safety of the robot
UR5/CB3 I-8 Version 3.1 (rev. 17782)
Copyright © 2009-2015 by Universal Robots A/S. All rights reserved.