Universal Robots UR5 User manual

Service Manual
Revision UR5_en_2.0.5
"Original instructions"
------------------------------------
Robot:
UR5 with CB2-controller
valid from robot s/n 2012208573/4

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Contents
1. General information........................................................................................................................................ 4
1.1 Purpose...................................................................................................................................................... 4
1.2 Company details........................................................................................................................................ 5
1.3 Disclaimer.................................................................................................................................................. 5
2. Preventive Maintenance ................................................................................................................................. 6
2.1 Controller .................................................................................................................................................. 6
2.1.1 Inspection plan, Safety Functions ................................................................................................ 6
2.1.2 Visual inspection .......................................................................................................................... 6
2.1.3 Cleaning and replacement of filters............................................................................................. 7
2.2 Robot arm.................................................................................................................................................. 8
2.2.1 Visual inspection .......................................................................................................................... 8
3. Service and Replacement of parts................................................................................................................... 9
3.1 Robot arm.................................................................................................................................................. 9
3.1.1 Robot arm configuration............................................................................................................ 10
3.1.2 Brake release.............................................................................................................................. 11
3.1.3 IMPORTANT - Replacing CB2 joints with CB3 sparePart joints .................................................. 12
3.1.4 Replacement of Base mounting bracket.................................................................................... 24
3.1.5 Replacement of Base joint ......................................................................................................... 27
3.1.6 Replacement of Shoulder joint .................................................................................................. 30
3.1.7 Replacement of Elbow joint....................................................................................................... 32
3.1.8 Replacement of Wrist 1 joint ..................................................................................................... 36
3.1.9 Replacement of Wrist 2 joint ..................................................................................................... 42
3.1.10 Replacement of Wrist 3 joint ................................................................................................... 46
3.1.11 Replacement of tool mounting bracket................................................................................... 50
3.1.12 Torque values........................................................................................................................... 53
3.1.13 Joint calibration........................................................................................................................ 54
3.1.14 Change joint ID......................................................................................................................... 60
3.1.15 Joint spare part adaptation CB2. ............................................................................................. 62
3.2 Controller ................................................................................................................................................ 63
3.2.1 Handling ESD-sensitive parts ..................................................................................................... 63
3.2.2 Replacement of Teach pendant................................................................................................. 64
3.2.3 Replacement of Masterboard.................................................................................................... 66
3.2.4 Replacement of Motherboard ................................................................................................... 67

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3.2.5 Replacement of 48V power supply ............................................................................................ 69
3.2.6 Replacement of 12V power supply ............................................................................................ 72
3.2.7 Replacement of current distributor........................................................................................... 73
4. Software ........................................................................................................................................................ 75
4.1 Update software...................................................................................................................................... 75
4.2 Update joint firmware............................................................................................................................. 77
4.3 Using Magic files...................................................................................................................................... 80
5. Troubleshooting ............................................................................................................................................ 81
5.1 Error codes .............................................................................................................................................. 81
5.2 Normal startup procedure on a CB2 UR5................................................................................................ 88
5.3 Error phenomena .................................................................................................................................... 89
5.3.1 ControlBox: NO CONTROLLER displayed in Initializing .............................................................. 89
5.3.2 NO CABLE displayed during power up ....................................................................................... 90
5.3.3 Force limit protective stop......................................................................................................... 91
5.3.4 Power on failure in Initializing ................................................................................................... 92
5.3.5 Checklist after a collision ........................................................................................................... 95
5.4 Schematic drawing .................................................................................................................................. 96
5.4.1 Tool connector ........................................................................................................................... 97
6. Spare parts .................................................................................................................................................... 98
6.1 Spare part list .......................................................................................................................................... 98
6.2 Tool part list ............................................................................................................................................ 99
7. Packing of robot .......................................................................................................................................... 100
8. Changelog.................................................................................................................................................... 101
8.1 Changelog.............................................................................................................................................. 101

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1. General information
1.1 Purpose
The main purpose of this manual is to help the user safely perform service related operations and
troubleshooting.
Universal Robots industrial robots are designed using high quality components designed for long lifetime.
However any improper use of robot can potentially cause failures on the robot. For example, the robot may
have been overloaded on an overrun or it may have been dropped on the floor when relocating or have run
with a load not recommended by Universal Robots. Any improper use of the robot will invalidate the guarantee.
Universal Robots recommends that you do not attempt repair, adjustment or other intervention in the
mechanical or electrical systems of the robot unless a problem has arisen. Any unauthorized intervention will
invalidate the guarantee. Service related operations and troubleshooting should only be performed by qualified
personnel.
Before performing service related operations, always make sure to stop the robot program and disconnect
supply to any potential dangerous tool attached on the robot arm and in the work cell.
In the event of a defect, Universal Robots recommends ordering new parts from the Universal
Robot distributor from where the robot has been purchased.
Alternatively, you can order parts from your nearest distributor, whose details you can obtain from Universal
Robots official website at www.universal-robots.com

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1.2 Company details
Universal Robots A/S
Energivej 25
DK-5260 Odense Denmark
Tel.: [phone]
Fax [phone]
1.3 Disclaimer
The information contained herein is the property of Universal Robots A/S and shall not be reproduced in whole
or in part without prior written approval of Universal Robots A/S. The information herein is subject to change
without notice and should not be construed as a commitment by Universal Robots A/S. This
Manual is periodically reviewed and revised.
Universal Robots A/S assumes no responsibility for any errors or omissions in this document.
Copyright © 2016 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.

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2. Preventive Maintenance
2.1 Controller
2.1.1 Inspection plan, Safety Functions
At least once in a year, the correct functioning of all safety functions should be tested.
2.1.2 Visual inspection
Disconnect power cable from controller.
Open cabinet door.
Check connectors are properly inserted on printed circuit boards.
Check for any dirt/dust inside of controller.
If any dirt/dust is present:
ogently use vacuum cleaning for removing particles
oUse a soft cloth. You can add: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha

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2.1.3 Cleaning and replacement of filters
Controller box contains two filters, one on each side of controller.
Remove filters from controller box and clean them thoroughly using compressed air.
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
Move robot arm to HOME position (if possible).
Turn off and disconnect power cable from controller.
Inspect cable between controller and robot arm for any damages.
Inspect flat rings for wear and damages.
oreplace flat rings if worn out or damaged.
Inspect blue lids on all joints for any cracks or damages.
oreplace blue lids if cracked or damaged.
Inspect that screws for blue lids are in place and properly tightened.
oReplace screws, tighten properly if necessary.
Correct torque value for screws on blue lids are 0.4Nm
If any damages are observed on a robot within the warranty period, contact the distributor from where the
robot has been purchased.

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3. Service and Replacement of parts
3.1 Robot arm
Before returning any part to Universal Robots check:
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 notice:
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.

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3.1.1 Robot arm configuration
J1
Shoulder
J0
Base
J5
Wrist 3
J3
Wrist 1
J2
Elbow
J4
Wrist 2
Upper arm
Lower arm
Baseplate
mounting
bracket
Tool
mounting
bracket

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3.1.2 Brake release
If required, the brake on a joint can be released without power connected.
IMPORTANT NOTICE:
Before releasing a brake it is extremely important to dismount any dangerous tooling for avoiding any
hazardous situations.
If releasing the brake on Base joint, Shoulder joint or Elbow joint, it is important to make proper
mechanical support prior to releasing the brake.
Always make sure no personnel are located under the arm when releasing the brake.
Do not move the joint more than necessary, absolute max. is 180 degrees in order for the robot to find
its original physical position.
Procedure for releasing the joint
Shut down Controller.
Remove blue lid on joint.
Push pin brake down for releasing, joint can then be rotated.
Brake on Base, Shoulder and Elbow joint Brake on Wrist joints
Make sure to mount blue lid properly on joint before turning on Controller.

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3.1.3 IMPORTANT - Replacing CB2 joints with CB3 sparePart joints
PLEASE READ AND UNDERSTAND THE COMPLETE CHAPTER BEFORE REPLACING THE JOINT
Universal Robots A/S assumes no responsibility for incorrect use of this procedure.
Only special CB3 sparePart parts can be used on CB2.
Reason is the firmware on these parts.
All parts are listed below.
122031
Joint Size 3 Base kit UR5
122032
Joint Size 3 Shoulder kit UR5
122033
Joint Size 3 Elbow kit UR5
122011
Joint Size 1 Wrist 1 kit UR5
122012
Joint Size 1 Wrist 2 kit UR5
122013
Joint Size 1 Wrist 3 kit UR5
122039
Tool Mounting Bracket kit UR5
122042
Joint Size 4 Base kit UR10
122043
Joint Size 4 Shoulder kit UR10
122034
Joint Size 3 Elbow kit UR10
122021
Joint Size 2 Wrist 1 kit UR10
122022
Joint Size 2 Wrist 2 kit UR10
122023
Joint Size 2 Wrist 3 kit UR10
122059
Tool Mounting Bracket kit UR10
122092
Teach Pendant incl. Touch Screen & power cable UR5 & UR10

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3.1.3.1 Criteria for using CB3 spareParts on CB2 robot and controller
Important
Polyscope software must be minimum 1.8.23117
Do not attempt to load sparePart revision firmware on a CB2 joint. This will result in the joint no
longer working and need to be re-coded by Universal Robots in Denmark.
Only the CB3 sparePart parts listed on previous page can be used

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3.1.3.2 How to find software version on PolyScope
Press the About button on the main Polyscope page and a popup will show the software version.
Information on how to update the Polyscope software can be found in the chapter 4.

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3.3.1.3 How to tell the difference between a CB2 and CB3 sparePart joint
It is very important to select the correct revision for each joint but also, if not more important, correct revision
for CB2 joints and CB3 sparePart.
Below two photos shows the difference.
CB2 has green coloured PCB
CB3 sparePart has blue coloured PCB

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3.1.3.4 How to select the correct revision for the joint
Purpose of this guide:
When replacing a CB2 joint with a CB3 sparePart joint, it is necessary to select the correct revision so that it
matches the hardware configuration.
On the previous pages it’s shown how to find the hardware revision.
1. Navigate to the Low Level Control section in Expert mode –see below how.
Drag the finger or pointer across the logo from left to right
2. Enter password lightbot and press OK
lightbot

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3. Press Low Level Control
4. Select the Firmware tab,
IMPORTANT - mark the replaced joint,
select Current Joint and press UPDATE Firmware
Do not attempt to load sparePart revision firmware on a CB2 joint. This will result in the joint no longer
working and need to be re-coded by Universal Robots in Denmark.

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5. A popup will appear where you have to confirm if the selected joint is the one that needs updating.
Press OK to continue.
6. A new popup will appear where you have two options:
Yes (recommended) - you get a window where you have to select the correct revision
No (just upgrade the firmware) –this will not change the robot configuration/revision so if a CB2 joint
have been replaced with a CB3 sparePart joint it is important to click Yes (recommended). See step 8

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7. When Yes (recommended) has been selected a window will show. Here a drop-down, for the joint, can
be used to select the correct revision. For CB3 sparePart joints,
select the one ending on _sparePart_rev1.conf and select Confirm
8. The process of updating the firmware will now begin. See next steps.

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9. If a popup appears saying Your configuration is corrupt and could not be loaded your configuration file
is not as expected by the software.
Please contact your Universal Robots representative.
10. Verify that the firmware has been updated successfully. This can be seen in the status field,
then press Back and Return to Normal
11. Verify that the robot is moving as expected. If not, check that the correct firmware has been selected.