Universal Robots UR5/CB3 User manual

User Manual
UR5/CB3
Original instructions (en)

User Manual
UR5/CB3
Version 3.0 (rev. 15965)
Original instructions (en)
Serial number UR5:
Serial number CB3:

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 © 2009-2014 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.
UR5/CB3 ii Version 3.0 (rev. 15965)
Copyright © 2009-2014 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-8
1.9 Movement Without Drive Power . . . . . . . . . . . . . . . . . . . . I-8
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-17
4.1 Introduction........................... I-17
4.2 Electrical warnings and cautions . . . . . . . . . . . . . . . . . . . . I-17
4.3 ControllerI/O.......................... I-19
4.3.1 Common specifications for all digital I/O . . . . . . . . . . . . . . I-19
4.3.2 SafetyI/O......................... I-20
4.3.3 General purpose digital I/O. . . . . . . . . . . . . . . . . . . I-24
4.3.4 Digital input from a button . . . . . . . . . . . . . . . . . . . I-24
4.3.5 Communication with other machines or PLCs . . . . . . . . . . . . I-25
4.3.6 General purpose analog I/O. . . . . . . . . . . . . . . . . . . I-25
4.3.7 Remote ON/OFF control . . . . . . . . . . . . . . . . . . . . I-27
4.4 ToolI/O ............................ I-28
4.4.1 Tool Digital Outputs . . . . . . . . . . . . . . . . . . . . . I-29
4.4.2 Tool Digital Inputs . . . . . . . . . . . . . . . . . . . . . . I-30
4.4.3 Tool Analog Inputs . . . . . . . . . . . . . . . . . . . . . . I-30
Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.
iii UR5/CB3

4.5 Ethernet............................. I-31
4.6 Mainsconnection......................... I-32
4.7 Robotconnection......................... I-33
5 Safety-related Functions and Interfaces I-35
5.1 Limiting Safety-related Functions . . . . . . . . . . . . . . . . . . . I-35
5.2 SafetyModes........................... I-37
5.3 Safety-related Electrical Interfaces . . . . . . . . . . . . . . . . . . . I-37
5.3.1 Safety-related Electrical Inputs . . . . . . . . . . . . . . . . . . I-37
5.3.2 Safety-related Electrical Outputs . . . . . . . . . . . . . . . . . I-39
6 Maintenance and Repair I-41
6.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . I-41
7 Disposal and Environment I-43
8 Certifications I-45
8.1 Third Party Certifications . . . . . . . . . . . . . . . . . . . . . . I-45
8.2 Declarations According to EU directives . . . . . . . . . . . . . . . . . I-45
9 Warranties I-47
9.1 ProductWarranty......................... I-47
9.2 Disclaimer............................ I-47
A Stopping Time and Stopping Distance I-49
A.1 CATEGORY 0 stopping distances and times. . . . . . . . . . . . . . . . I-49
B Declarations and Certificates I-51
B.1 CE Declaration of Incorporation (original) . . . . . . . . . . . . . . . . I-51
B.2 Safety System Certificate. . . . . . . . . . . . . . . . . . . . . . . I-52
B.3 Environmental Test Certificate. . . . . . . . . . . . . . . . . . . . . I-53
B.4 EMC Test Certificate . . . . . . . . . . . . . . . . . . . . . . . . I-54
C Applied Standards I-55
D Technical Specifications I-61
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
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
UR5/CB3 iv Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.

11 On-screen Editors II-11
11.1 On-screen Keypad . . . . . . . . . . . . . . . . . . . . . . . . . II-11
11.2 On-screen Keyboard . . . . . . . . . . . . . . . . . . . . . . . . II-12
11.3 On-screen Expression Editor . . . . . . . . . . . . . . . . . . . . . II-12
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
12.1.5Teach........................... II-18
12.2I/OTab............................. II-19
12.3 MODBUS client I/O . . . . . . . . . . . . . . . . . . . . . . . . II-20
12.4AutoMoveTab.......................... II-20
12.5 Installation →Load/Save...................... II-22
12.6 Installation →TCP Configuration . . . . . . . . . . . . . . . . . . . II-23
12.7 Installation →Mounting....................... II-24
12.8 Installation →I/OSetup ...................... II-25
12.9 Installation →Safety........................ II-25
12.10 Installation →Variables....................... II-26
12.11 Installation →MODBUS client I/O Setup . . . . . . . . . . . . . . . . II-27
12.12 Installation →Features....................... II-30
12.13 Installation →Default Program . . . . . . . . . . . . . . . . . . . . II-34
12.13.1 Loading a Default Program . . . . . . . . . . . . . . . . . . . II-34
12.13.2 Starting a Default Program . . . . . . . . . . . . . . . . . . . II-34
12.13.3 Auto Initialization . . . . . . . . . . . . . . . . . . . . . . II-35
12.14LogTab............................. II-35
12.15LoadScreen........................... II-36
12.16RunTab............................. II-38
13 Programming II-39
13.1NewProgram .......................... II-39
13.2ProgramTab........................... II-40
13.3Variables............................ II-41
13.4Command:Empty......................... II-42
13.5Command:Move......................... II-42
13.6 Command: Fixed Waypoint . . . . . . . . . . . . . . . . . . . . . II-45
13.7 Setting the waypoint . . . . . . . . . . . . . . . . . . . . . . . . II-45
13.8 Command: Relative Waypoint. . . . . . . . . . . . . . . . . . . . . II-47
13.9 Command: Variable Waypoint . . . . . . . . . . . . . . . . . . . . II-48
13.10Command:Wait.......................... II-49
13.11Command:Set.......................... II-49
13.12 Command: Popup . . . . . . . . . . . . . . . . . . . . . . . . . II-50
13.13Command:Halt.......................... II-51
13.14 Command: Comment . . . . . . . . . . . . . . . . . . . . . . . . II-51
Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.
vUR5/CB3

13.15 Command: Folder . . . . . . . . . . . . . . . . . . . . . . . . . II-52
13.16Command:Loop......................... II-52
13.17 Command: SubProgram . . . . . . . . . . . . . . . . . . . . . . . II-53
13.18 Command: Assignment . . . . . . . . . . . . . . . . . . . . . . . II-54
13.19Command:If........................... II-55
13.20 Command: Script . . . . . . . . . . . . . . . . . . . . . . . . . II-56
13.21 Command: Event . . . . . . . . . . . . . . . . . . . . . . . . . II-57
13.22 Command: Thread . . . . . . . . . . . . . . . . . . . . . . . . . II-58
13.23 Command: Pattern . . . . . . . . . . . . . . . . . . . . . . . . . II-58
13.24 Command: Force . . . . . . . . . . . . . . . . . . . . . . . . . II-60
13.25 Command: Pallet . . . . . . . . . . . . . . . . . . . . . . . . . II-63
13.26Command:Seek.......................... II-64
13.27 Command: Suppress . . . . . . . . . . . . . . . . . . . . . . . . II-67
13.28GraphicsTab........................... II-68
13.29StructureTab........................... II-69
13.30VariablesTab........................... II-70
13.31 Command: Variables Initialization . . . . . . . . . . . . . . . . . . . II-71
14 Setup Screen II-73
14.1 Language and Units . . . . . . . . . . . . . . . . . . . . . . . . II-74
14.2UpdateRobot........................... II-75
14.3SetPassword........................... II-76
14.4 Calibrate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . II-77
14.5SetupNetwork.......................... II-77
14.6SetTime............................. II-78
15 Safety Configuration II-79
15.1 Changing the Safety Configuration . . . . . . . . . . . . . . . . . . . II-80
15.2 Safety Synchronization and Errors . . . . . . . . . . . . . . . . . . . II-80
15.3Tolerances............................ II-81
15.4 Safety Checksum . . . . . . . . . . . . . . . . . . . . . . . . . II-82
15.5SafetyModes........................... II-82
15.6TeachMode........................... II-83
15.7PasswordLock.......................... II-83
15.8Apply............................. II-83
15.9GeneralLimits.......................... II-84
15.10JointLimits ........................... II-87
15.11Boundaries............................ II-88
15.11.1 Selecting a boundary to configure. . . . . . . . . . . . . . . . . II-89
15.11.2 3D visualization . . . . . . . . . . . . . . . . . . . . . . . II-89
15.11.3 Safety plane configuration . . . . . . . . . . . . . . . . . . . II-90
15.11.4 Tool Boundary configuration . . . . . . . . . . . . . . . . . . II-93
15.12SafetyI/O............................ II-95
UR5/CB3 vi Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.

Glossary II-97
Index II-99
Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.
vii UR5/CB3

UR5/CB3 viii Version 3.0 (rev. 15965)
Copyright © 2009-2014 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 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 3.0 (rev. 15965)
Copyright © 2009-2014 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.
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://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 re-
pair of the robot.
• The Script Manual for advanced users.
UR5/CB3 xVersion 3.0 (rev. 15965)
Copyright © 2009-2014 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.
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.
Special attention shall be paid to text associated with warning symbols. See Chap-
ter 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
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.
Guidance on how to find and read applicable standards and laws is provided on
http://support.universal-robots.com/
Version 3.0 (rev. 15965)
Copyright © 2009-2014 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
damage to the equipment.
UR5/CB3 I-4 Version 3.0 (rev. 15965)
Copyright © 2009-2014 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 accord-
ing to the specifications and warnings found in the Chapters 3 and
4.
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 (e.g. guardrail, rope or safety
screen) have been set up around the robot operating area to
protect both the operator and bystanders.
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 teach 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.
Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.
I-5 UR5/CB3

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 pay-
loads. (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.
UR5/CB3 I-6 Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.

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 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 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.
The risk assessment shall consider two scenarios:
• Teaching the robot while developing the robot installation;
• Normal operation of the robot installation.
If the robot is installed in a non-collaborative installation (E.g. when using a haz-
ardous tool) the risk assessment might conclude that the integrator needs to connect
additional safety devices (E.g. an enable device) to protect him while program-
ming.
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.
Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.
I-7 UR5/CB3

1.9 Movement Without Drive Power
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).
3. Penetration of skin by sharp edges and sharp points on tool or tool connector.
4. Penetration of skin by sharp edges and sharp points on obstacles near the
robot track.
5. Bruising due to stroke from the robot.
6. Sprain or bone fracture due to strokes between a heavy payload and a hard
surface.
7. Consequences due to loose bolts that hold the robot arm or tool.
8. Items falling out of tool, e.g. due to a poor grip or power interruption.
9. Mistakes due to different emergency stop buttons for different machines.
Information on stopping times and stopping distances are found in appendix A.
1.8 Emergency Stop
Activate the emergency stop button to immediately stop all robot motion.
Emergency stop shall not be used as a risk reduction measure, but as a secondary
protective device.
The risk assessment of the robot application shall conclude if more emergency
stop buttons must be connected. Emergency stop buttons should comply with IEC
60947-5-5, see more in section 4.3.2.
1.9 Movement Without Drive Power
In the unlikely event of an emergency situation where one or more robot joints
need to be moved and robot power is either not possible or unwanted, there are
two different ways to force movements of the robot joints:
1. Forced back-driving: Force a joint to move by pulling hard (500 N) on the robot
arm. Each joint brake has a friction clutch which enables movement during
high forced torque.
2. Manual brake release: Remove the joint cover by removing the few M3 screws
that fix it. Release the brake by pushing the plunger on the small electromag-
net as shown in the picture below.
WARNING:
1. Moving the robot arm manually is intended for urgent emer-
gencies only and might damage the joints.
2. If the brake is released manually, gravitational pull can cause
the robot arm to fall. Always support the robot arm, tool and
work item when releasing the brake.
UR5/CB3 I-8 Version 3.0 (rev. 15965)
Copyright © 2009-2014 by Universal Robots A/S. All rights reserved.