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Service Manual

Revision UR10_en_2.0.5
"Original instructions"
------------------------------------
Robot:
UR10 with CB2-controller

valid from robot s/n 2012200015/6


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 ..................................................................................................... 35
3.1.9 Replacement of Wrist 2 joint ..................................................................................................... 40
3.1.10 Replacement of Wrist 3 joint ................................................................................................... 44
3.1.11 Replacement of tool flange ...................................................................................................... 48
3.1.12 Torque values ........................................................................................................................... 52
3.1.13 Joint calibration........................................................................................................................ 53
3.1.14 Change joint ID ......................................................................................................................... 59
3.1.15 Joint spare part adaptation CB2. ............................................................................................. 61
3.2 Controller ................................................................................................................................................ 62
3.2.1 Handling ESD-sensitive parts ..................................................................................................... 62
3.2.2 Replacement of teach pendant.................................................................................................. 63
3.2.3 Replacement of Masterboard .................................................................................................... 65
3.2.4 Replacement of Motherboard ................................................................................................... 66

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3.2.5 Replacement of 48V power supply ............................................................................................ 68
3.2.6 Replacement of 12V power supply ............................................................................................ 71
3.2.7 Replacement of current distributor ........................................................................................... 72
4. Software ........................................................................................................................................................ 74
4.1 Update software...................................................................................................................................... 74
4.2 Update joint firmware ............................................................................................................................. 76
4.3 Using Magic files...................................................................................................................................... 79
5. Troubleshooting ............................................................................................................................................ 80
5.1 Error codes .............................................................................................................................................. 80
5.2 Normal startup procedure on a CB2 UR10.............................................................................................. 87
5.3 Error phenomena .................................................................................................................................... 88
5.3.1 ControlBox: NO CONTROLLER displayed in Initializing .............................................................. 88
5.3.2 NO CABLE displayed during power up ....................................................................................... 89
5.3.3 Force limit protective stop ......................................................................................................... 90
5.3.4 Power on failure in Initializing ................................................................................................... 91
5.3.5 Checklist after a collision ........................................................................................................... 94
5.4 Schematic drawing .................................................................................................................................. 95
5.4.1 Tool connector ........................................................................................................................... 96
6. Spare parts .................................................................................................................................................... 97
6.1 Spare part list .......................................................................................................................................... 97
6.2 Tool part list ............................................................................................................................................ 98
7. Packing of robot ............................................................................................................................................ 99
8. Changelog .................................................................................................................................................... 100
8.1 Changelog .............................................................................................................................................. 100

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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.: +45 89 93 89 89
Fax +45 38 79 89 89

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:
o gently use vacuum cleaning for removing particles
o Use 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.
o Replace filters if necessary.

o Gently 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.
o replace flat rings if worn out or damaged.
Inspect blue lids on all joints for any cracks or damages.
o replace blue lids if cracked or damaged.
Inspect that screws for blue lids are in place and properly tightened.
o Replace 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

J5
Tool flange Wrist 3

J3
Wrist 1

J4
Wrist 2

Lower arm

J2 Elbow
Elbow counterpart

Upper arm

J0
Base

J1
Shoulder

Baseplate

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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 Wrist joints Brake on Elbow joint

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 its 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.

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3.1.3.5 Connecting a CB3 teach pendant to CB2 masterboard

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3.1.3.6 Adapters cables

There are used 3 different adaptor cables when mounting a CB3 joint onto a CB2 robot arm.

Communications cable CB2 to CB3 power cable CB3 to CB2 power cable

Communication cable

An extension cable is needed on the communication side. This is only an extension and should be used on Size 1
and 4 joints only.
Its important that the cable connections are colour correct.
White <-> White
Brown <-> Black

When plugging in the connectors onto the printed circuit boards its recommended to mount the plug with the
tap facing out from the house. The two plugs are recommended to swap places. This is so the pins on the print
board are not getting bend.
Photo below shows recommended and not recommended.

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Power cable

An adaptor plug is needed for the 48V power. There are two versions.

One plug is for CB2->CB3 and one for CB3->CB2.

CB2 to CB3 looks like below CB3 to CB2 looks like below

Important when replacing a size 1 joint: The connectors need to lay flat, on the connectors lowest side,
when mounting the blue lid. If not, it can cause issues when mounting the lid but also effect the sensor in
the size 1 joint as the plug is pushing onto the setup.
3.1.4 Replacement of base mounting bracket

How to replace base mounting bracket

Move robot to a comfortable position for replacing the base. If necessary dismount entire robot
arm from work cell and place arm on solid surface.

Shut down the controller.

Remove grease plug.

Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the
joint housing.

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Slide the grey Teflon ring apart.
10 screws become visible, 5 on each side of joint.
Untighten gently the screw with a 7 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull the base mounting bracket and Base joint apart and gently twist the two parts in opposite
directions around 10 mm. until a mechanical stop is met (holes are keyhole-type).

Pull away the base mounting bracket from Base joint.

Disconnect wires between base mounting bracket and Base joint.


2 x red wire = 48V DC
2 x black wire = GND
Black/green conn. = bus cable

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Replace base mounting bracket and reconnect wires according to illustration - remember to twist
the communications wires:

Gently insert base mounting bracket with screws and washers into the Base joint.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the base mounting bracket and Base joint in opposite directions until a mechanical
stop is met.
Tighten the 10 screws lightly, then tighten in cross order with 8.0Nm.
Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

Mount the grease plug and tighten with 0.8Nm.


Mount blue lid on Base joint and tighten with 0.4Nm.

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3.1.5 Replacement of Base joint

How to replace Base joint

Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.

Shut down the controller.

For separating base mounting bracket from Base joint, consult chapter 3.1.3 Replacement of base
mounting bracket.

Remove blue lid on Base joint.

Disconnect wires between Base joint and Shoulder joint


2 x red wire = 48V DC
2 x black wire = GND
Green connector = bus cable

Remove grease plug at Shoulder joint.

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Gently remove black flexible flat ring between Base and Shoulder with a tiny screwdriver or similar
tool and twist it around the joint housing.

Slide the grey Teflon ring apart.


10 screws become visible, 5 on each side of joint.
Untighten gently the screw with a 7 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull the Base joint and Shoulder joint apart and gently twist the two parts in opposite directions
around 10 mm. until a mechanical stop is met (holes are keyhole-type).

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Pull away the Base joint from Shoulder joint.

Replace Base joint and gently insert Base joint with screws and washers into the Shoulder joint.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the Base joint and Shoulder joint in opposite directions until a mechanical stop is
met.

Tighten the 10 screws lightly, then tighten in cross order with 8.0Nm.

Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

Mount the grease plug and tighten with 0.8Nm.

Reconnect connectors as illustrated - remember to twist the communications wires:

Mount blue lid on Base joint and tighten with 0.4Nm.

Proceed to chapter 3.1.11 Joint calibration for calibrating the joint.

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3.1.6 Replacement of Shoulder joint

How to replace Shoulder joint

Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.

Shut down the controller.

For separating Base joint from Shoulder joint, consult chapter 3.1.4 Replacement of Base joint.

Remove blue lid on Shoulder joint.

Disconnect wires between Shoulder joint and upper arm


1 x red wire = 48V DC
1 x black wire = GND
Green connector = bus cable

Gently remove black flexible gasket between Shoulder and upper arm with a tiny screwdriver or
similar tool and twist it around the upper arm.

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10 screws become visible, 5 on each side of joint.
Untighten gently the screw with a 10 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull the Shoulder joint and upper arm apart and gently twist the two parts in opposite directions
around 10 mm. until a mechanical stop is met (holes are keyhole-type).

Pull away the Shoulder joint from upper arm.

Replace Shoulder joint and gently insert Shoulder joint with screws and washers into the upper
arm.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the Shoulder joint and upper arm in opposite directions until a mechanical stop is
met.

Tighten the 10 screws lightly, then tighten in cross order with 8.0Nm.

Gently put back the gasket.

Mount the grease plug and tighten with 0.8Nm.

Reconnect wires correctly.

Mount blue lid on Shoulder joint and tighten with 0.4Nm.

Proceed to chapter 3.1.11 Joint calibration for calibrating the joint.

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3.1.7 Replacement of Elbow joint

How to replace Elbow joint

Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.

Shut down the controller.

Procedure for separating upper arm from Elbow joint is similar to separation of upper arm and
Shoulder joint, consult chapter 3.1.5 Replacement of Shoulder joint.

Remove blue lid on elbow counterpart.

Disconnect wires between Elbow joint and elbow counterpart


1 x red wire = 48V DC
1 x black wire = GND
Green connector = bus cable

Remove grease plug at Elbow joint.

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Gently remove black flexible flat ring between Elbow and elbow counterpart with a tiny screwdriver
or similar tool and twist it around the joint housing.

Slide the grey Teflon ring apart.


10 screws become visible, 5 on each side of joint.
Untighten gently the screw with a 7 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull Elbow joint and elbow counterpart apart and gently twist the two parts in opposite directions
around 10 mm. until a mechanical stop is met (holes are keyhole-type).

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Pull away the Elbow joint from elbow counterpart.

Replace Elbow joint and gently insert Elbow joint with screws and washers into the elbow
counterpart.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the Elbow joint and elbow counterpart in opposite directions until a mechanical
stop is met.

Tighten the 10 screws lightly, then tighten in cross order with respectively 3.0Nm.

Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

Mount the grease plug and tighten with 0.8Nm.

Reconnect connectors as illustrated - remember to twist the communications wires:

Mount blue lid on Elbow joint and tighten with 0.4Nm.

Proceed to chapter 3.1.11 Joint calibration for calibrating the joint.

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3.1.8 Replacement of Wrist 1 joint

How to replace Wrist 1 joint

Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.

Shut down the controller.

Remove blue lid on Wrist 1 joint.

Disconnect wires between lower arm and Wrist 1 joint.


1 x red wire = 48V DC
1 x black wire = GND
Green connector = bus cable

Gently remove black flexible gasket between lower arm and Wrist 1 joint with a tiny screwdriver or
similar tool and twist it around the lower arm.

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10 screws become visible, 5 on each side of joint.
Untighten gently the screws with a 5.5 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull the lower arm and Wrist 1 joint apart and gently twist the two parts in opposite directions
around 8 mm. until a mechanical stop is met (holes are keyhole-type).

Pull away the lower arm from Wrist 1 joint.

Lower arm and Wrist 1 joint has now been separated, proceed for separating Wrist 1 from Wrist 2.

Remove blue lid on Wrist 2 joint.

Disconnect wires between Wrist 1 joint and Wrist 2 joint


1 x red wire = 48V DC
1 x black wire = GND
Green connector = bus cable

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Gently remove black flexible flat ring between Wrist 1 and Wrist 2 with a tiny screwdriver or similar
tool and twist it around the joint housing.

Slide the grey Teflon ring apart.


10 screws become visible, 5 on each side of joint.
Untighten gently the screws with a 5.5 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull Wrist 1 joint and Wrist 2 joint apart and gently twist the two parts in opposite directions
around 8 mm. until a mechanical stop is met (holes are keyhole-type).

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Pull away Wrist 1 joint from Wrist 2 joint.

Wrist 1 joint and Wrist 2 joint has now been separated, proceed for assembling new Wrist 1 joint
with Wrist 2 joint.

Replace Wrist 1 and gently insert Wrist 1 joint with screws and washers into Wrist 2 joint.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting Wrist 1 joint and Wrist 2 joint in opposite directions until a mechanical stop is met.

Tighten the 10 screws lightly, then tighten in cross order with 1.3Nm.

Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

Mount the grease plug and tighten with 0.8Nm.

Replace Wrist 1 and reconnect connectors as illustrated into Wrist 2 - remember to twist the
communications wires:

Mount blue lid on Wrist 2 joint and tighten with 0.4Nm.

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New Wrist 1 joint and Wrist 2 joint has now been assembled, proceed for assembling new Wrist 1
joint and lower arm.

Gently insert Wrist 1 joint with screws and washers into the lower arm.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting Wrist 1 joint and lower arm in opposite directions until a mechanical stop is met.

Tighten the 10 screws lightly, then tighten in cross order with 1.3Nm.

Gently put back the gasket.

Mount the grease plug and tighten with 0.8Nm.

Reconnect wires between lower arm and Wrist 1 joint correctly.

Mount blue lid on Wrist 1 joint and tighten with 0.4Nm.

Proceed to chapter 3.1.11 Joint calibration for calibrating the joint.

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3.1.9 Replacement of Wrist 2 joint

How to replace Wrist 2 joint

Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.

Shut down the controller.

Remove blue lid on Wrist 2 joint.

Disconnect wires between Wrist 1 joint and Wrist 2 joint


2 x red wire = 48V DC
2 x black wire = GND
Green connector = bus cable

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Gently remove black flexible flat ring between Wrist 1 and Wrist 2 with a tiny screwdriver or similar
tool and twist it around the joint housing.

Slide the grey Teflon ring apart.


10 screws become visible, 5 on each side of joint.
Untighten gently the screws with a 5.5 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull Wrist 1 joint and Wrist 2 joint apart and gently twist the two parts in opposite directions
around 8 mm. until a mechanical stop is met (holes are keyhole-type).

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Pull away Wrist 1 joint from Wrist 2 joint.

Wrist 1 joint and Wrist 2 joint has now been separated. Perform same procedure for separating
Wrist 2 joint and Wrist 3 joint and proceed when done.

Replace Wrist 2 and gently insert Wrist 1 joint with screws and washers into Wrist 2 joint.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the Wrist 1 joint and Wrist 2 joint in opposite directions until a mechanical stop is
met.

Tighten the 10 screws lightly, then tighten in cross order with 1.3Nm.

Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

Mount the grease plug and tighten with 0.8Nm.

Reconnect connectors as illustrated into Wrist 2 - remember to twist the communications wires:

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Mount blue lid on Wrist 2 joint and tighten with 0.4Nm.

Wrist 1 joint and Wrist 2 joint has now been assembled. Perform same procedure for assembling
Wrist 2 joint and Wrist 3 joint.

Proceed to chapter 3.1.11 Joint calibration for calibrating the joint.

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3.1.10 Replacement of Wrist 3 joint

How to replace Wrist 3 joint

Move robot to a comfortable position for replacing the joint. If necessary dismount entire robot
arm from work cell and place arm on solid surface.

Shut down the controller.

Remove blue lid on Wrist 3 joint.

Disconnect wires between Wrist 2 joint and Wrist 3 joint


2 x red wire = 48V DC
2 x black wire = GND
Green connector = bus cable

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Gently remove black flexible flat ring between Wrist 2 and Wrist 3 with a tiny screwdriver or similar
tool and twist it around the joint housing.

Slide the grey Teflon ring apart.


10 screws become visible, 5 on each side of joint.
Untighten gently the screws with a 5.5 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull Wrist 2 joint and Wrist 3 joint apart and gently twist the two parts in opposite directions
around 8 mm. until a mechanical stop is met (holes are keyhole-type).

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Pull away Wrist 2 joint from Wrist 3 joint.

Wrist 2 joint and Wrist 3 joint has now been separated.

For separating Wrist 3 joint from tool flange, consult chapter 3.1.9 Replacement of tool flange.

Replace Wrist 3 and gently insert Wrist 2 joint with screws and washers into Wrist 3 joint.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the Wrist 2 joint and Wrist 3 joint in opposite directions until a mechanical stop is
met.

Tighten the 10 screws lightly, then tighten in cross order with 1.3Nm.

Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

Mount the grease plug and tighten with 0.8Nm.

Reconnect connectors as illustrated into Wrist 3 - remember to twist the communications wires:

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Mount blue lid on Wrist 3 joint and tighten with 0.4Nm.

Wrist 2 joint and Wrist 3 joint has now been assembled.

For assembling Wrist 3 joint and tool flange, consult chapter 3.1.9 Replacement of tool flange.

Proceed to chapter 3.1.11 Joint calibration for calibrating the joint.

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3.1.11 Replacement of tool flange

How to replace tool flange

Move robot to a comfortable position for replacing the tool flange. If necessary dismount entire
robot arm from work cell and place arm on solid surface.

Shut down the controller.

Remove grease plug.

Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the
joint housing.

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Slide the grey Teflon ring apart.
10 screws become visible, 5 on each side of joint.
Untighten gently the screws with a 5.5 mm. open-ended spanner about two full rounds,
approximately 3 mm. for each screw.

Pull the tool flange and Wrist 3 joint apart and gently twist the two parts in opposite directions
around 8 mm. until a mechanical stop is met (holes are keyhole-type).

Pull away the tool from Wrist 3 joint.

Disconnect the two connectors.

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Assembly of replacement tool flange.

Cover O-ring Tool Plate

Insert carefully O-ring into the Tool Plate and place cover on top

Final assembly of replacement tool flange.

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Replace tool flange and reconnect connectors as illustrated - remember to twist the
communications wires:

Replace tool mounting bracket and reconnect wires correctly.

Gently insert tool flange with screws and washers into the Wrist 3 joint.

Make sure the washers are fully inserted and located on the correct side (this is important) before
gently twisting the tool flange and Wrist 3 joint in opposite directions until a mechanical stop is
met.

Tighten the 10 screws lightly, then tighten in cross order with 1.3Nm.

Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.

Mount the grease plug and tighten with 0.8Nm.

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3.1.12 Torque values

UR10 torque values


CONNECTION TORQUE HEAD SIZE
Base mounting bracket J0 Base 8.0Nm 10 mm.
[J0] Base J[1] Shoulder 8.0Nm 10 mm.
[J1] Shoulder Upper arm 8.0Nm 10 mm.
Upper arm [J2] Elbow 3.0Nm 7 mm.
[J2] Elbow Elbow counterpart 3.0Nm 7 mm.
Elbow counterpart Lower arm 3.0Nm 7 mm.
Lower arm [J3] Wrist 1 1.3Nm 5.5 mm.
[J3] Wrist 1 [J4] Wrist 2 1.3Nm 5.5 mm.
[J4] Wrist 2 [J5] Wrist 3 1.3Nm 5.5 mm.
[J5] Wrist 3 Tool mounting bracket 1.3Nm 5.5 mm.
Tool/ Gripper M6 9.0Nm
Alignment screw 0.4Nm Torx T10
Blue lid 0.4Nm Torx 10

1.3N
m
1.3N
m

1.3N
m
1.3N
m

3.0N
m

3.0N 3.0N
m m

8.0Nm 8.0Nm

8.0
Nm
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3.1.13 Joint calibration

After replacement of joint it is required to calibrate the new joint in order to find the correct zero position
of joint.

Instruction for calibrating a joint

Jog robot to HOME position

Illustration shows the HOME position, which is defined as zero position of all joints.

Drag a finger from left to right across the UNIVERSAL-sign on main screen of PolyScope.

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Enter password lightbot and press OK.

lightbot

You are now in Expert Mode, press Low Level Control.

Select Power On/Off tab and press Turn power on for enabling power to motors.

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Select General tab, and select the desired joint by either using the dropdown list or directly press
on the joint state line.

Press Arm current joint for releasing the brake on the selected joint.

Select Move tab and press either Up or Down for the joint to find its index mark.
For every time the button is pressed, the velocity of joint will be increased.

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Await that state of the joint changes to OK, then press STOP.
Index mark has now been found (index mark is not the same position as zero position).

Use the Up and Down buttons for navigating the joint to the correct zero position according to the
following illustrations.
Press STOP when the joint is in the correct position.

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Zero position illustrations

Base: Shoulder, Elbow, Wrist 1:

Base zero position is aligned to Shoulder, Elbow and Wrist 1 zero positions are
connector in back of robot base. Vertical aligned (if Base if horizontal).
Make sure that base of robot is positioned
horizontal, use leveler for aligning joints.

Wrist 2: Wrist 3:

Wrist 2 zero position is aligned similar Wrist 3 zero position is aligned so tool connector
to Base joint. is pointing upward.
Mount two bolts in tool holes and use leveler for
aligning joint.

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Select Calibration tab and press Zero current joint position for calibrating the joint.

Press Back for exiting Low Level Control.

Back in Expert Mode, press Return to Normal.

Verify zero position by moving the robot to HOME.


If not satisfied with the zero position, perform the procedure once again.

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3.1.14 Change joint ID

Each joint has a unique ID no. It is NOT possible to have two joints with the same ID no. on the same robot.

ID Joint
J0 Base
J1 Shoulder
J2 Elbow
J3 Wrist 1
J4 Wrist 2
J5 Wrist 3

Example:

Wrist 1 (J3) has to be replaced. Spare joint is a Wrist 3 (J5)

Disconnect the joint with correct ID no.


Enter Low Level Control
Go to Power on/off tap
Press Turn power on and the connected joints turn into READY

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Select Joint ID
Select J5 (The one to be changed)
Uncheck Exchange IDs box
In dropdown box, select ID no. 3
Press Set it
Confirm Change ID

After you have turned power on you can see the joint J5 has changed to J3.

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3.1.15 Joint spare part adaptation CB2.

The UR5 and UR10 are constructed of 4 joint sizes and have to be setup on the robot:

Recommended spare joints for UR5 and UR10 are marked with:

Robot: UR5 UR10

Wrist 3: ID =5 Size 1 Size 2

Alignment screw

Power connector UR10 Wrist 3

Wrist 2: ID =4 Size 1 Size 2

Wrist 1: ID =3 Size 1 Size 2

Power connector UR10


Wrist 1 & 2

Elbow: ID =2 Size 3 Size 3


NB
!

Shoulder: ID =1 Size 3 Size 4

Base: Communication
cable with double isolation

Base: ID =0 Size 3 Size 4

NB! To use UR5 base as UR5 Elbow it is necessary to change ID and then connect the joints electrically then
turn the joint 180 degree in low level control, before mechanical assemble joint.

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3.2 Controller

3.2.1 Handling ESD-sensitive parts

To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before removing logic cards:

Keep the ESD-sensitive part in its original shipping container (a special "ESD bag") until the part is
ready to be installed.

Make the least-possible body movements to prevent an increase of static electricity from clothing
fibers, carpets, and furniture.

Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point .
This discharges any static electricity in your body to ground.

Hold the ESD-sensitive part by its edges; do not touch its pins. If a pluggable module is being removed,
then use the correct tool.

Do not place the ESD-sensitive part on insulating or on a metal table; if the ESD-sensitive part needs to be put
down for any reason, then first put it into its special bag.

Machine covers and metal tables are electrical grounds. They increase the risk of damage
because they make a discharge path from your body through the ESD-sensitive part. (Large metal
objects can be discharge paths without being grounded.)

Prevent ESD-sensitive parts from being accidentally touched by other personnel and do not put
unprotected ESD-sensitive parts on a table.

If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case).

Be extra careful in working with ESD-sensitive parts when cold-weather heating is used,
because low humidity increases static electricity

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3.2.2 Replacement of teach pendant

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace Teach Pendant on Controller

Shut down the controller and disconnect the power cable, open the controller cabinet and loosen
the 5 Torx screws and remove the alu cover plate.

Remove black USB plug from motherboard and push the alu cover to the right and pull out alu
cover for removal.

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Disconnect 4 cables:
Red plug with black cable
Black USB cable
Black DVI cable
Black cable for RS232-connection to touchscreen

Remove the bracket (foot of the controller box) that holds the cable inlet and pull out the cables
and plugs through this hole.

Replace teach pendant with new, insert cable in cable inlet and perform reconnection of all plugs
and mounting of alu cover in reversed order of the above description.
Connect power and verify that teach pendant works properly.

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3.2.3 Replacement of Masterboard

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace Masterboard in Controller box

Note: use the same procedure for power down and removing the alu cover plate as in chapter 3.2.2
Replacement of Teach pendant

Carefully remove all plugs and connectors (it is recommended to mark the cable positions or take a
picture of them).

Remove 15 screws holding the Masterboard.

Replace Masterboard with new and tighten the 15 screws to hold the board

Insert all connectors and plugs in correct positions.

Carefully put back the grey alu cover plate, make sure to mount it correct and fix it with the 5
screws.

Connect power and verify that teach pendant works properly.

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3.2.4 Replacement of Motherboard

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace motherboard in Controller box

Note: use the same procedure for power down and removing the alu cover plate as in chapter 3.2.2
Replacement of Teach pendant
Remove Flash card and RAM block.

Disconnect cable connections from motherboard:


2x RJ45 network cables
Black USB cable
DVI-cable
Black cable for RS232-connection
White plug with white, brown, yellow and green wires

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Remove the 4 screws of the 2 holding brackets in the side of the mother board
Remove the 4 screws that fix the DVI connector and the RS232 connector.
The board can now be removed. There might be some glue on the back side of the mother board
that sticks to the aluminum. That means you have to use a little force to remove the mother board.

Replace Motherboard with new.

If controller is equipped with long-hole brackets, make sure to replace them with circular-hole
brackets. Tighten the 4 screws gently.

Insert the 6 cables in correct positions.

Re-install Flash card and RAM block.

Carefully put back the grey aluminum cover plate, make sure to mount it correct and fix it with the
5 screws.

Connect power and verify that teach pendant works properly.

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3.2.5 Replacement of 48V power supply

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace 48V power supply in Controller box

Note: use the same procedure for power down and removing the alu cover plate and cables for teach
pendant as in chapter 3.2.2 Replacement of Teach pendant

Remove the handle on Controller box by loosen the 2 screws holding it.

Removes the 2 wires for the fan.

Remove the 2 nuts in the bottom of Controller module.

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Gently take out the controller module from the Controller box without disconnecting the robot
cable and power cable.

Power supply is located in the rack under the controller module, the 48V power supply is the lower
one in the rack.
Before dismounting the 48V power supply, mark and disconnect the cables from that supply.

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Remove the screws respectively of the defective 48V power supply from the side of the rack.

Replace 48V power supply with new.

Reconnect the wires for the 48V power supply.

Re-install Controller module in reverse order and connect the 2 wires for the fan and cables for the
teach pendant.

Carefully put back the grey alu cover plate, make sure to mount it correct and fix it with the 5
screws.

Connect power and verify that teach pendant works properly.

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3.2.6 Replacement of 12V power supply

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace 12V power supply in Controller box

Note: use the same procedure for power down and removing the alu cover plate and cables for teach
pendant as in chapter 3.2.2 Replacement of Teach pendant

For replacing the 12V power supply follow exactly the same steps as for the procedure in chapter 3.2.5
Replacement of 48V power supply

The 12V power supply is placed in top of rack. The screws holding it in the frame are placed on the
sides.

Replace 12V power supply with new.

Reconnect the wires for the 12V power supply.

Re-install Controller module in reverse order and connect the 2 wires for the fan and cables for the
teach pendant.

Carefully put back the grey alu cover plate, make sure to mount it correct and fix it with the 5
screws.

Connect power and verify that teach pendant works properly.

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3.2.7 Replacement of current distributor

Take care of ESD handling 3.2.1 Handling ESD-sensitive parts

How to replace current distributor in Controller box

Note: use the same procedure for power down and removing the alu cover plate and cables for teach
pendant as in chapter 3.2.2 Replacement of Teach pendant

For replacing the current distributor follow exactly the same steps as for the procedure in chapter 3.2.5
Replacement of 48V power supply

Current distributor is placed on top of rack.

Before dismounting the current distributor, mark and disconnect the cables from the circuit board.

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Replace current distributor with new.

Reconnect the wires for the current distributor.

Re-install Controller module in reverse order and connect the 2 wires for the fan and cables for the
teach pendant.

Carefully put back the grey alu cover plate, make sure to mount it correct and fix it with the 5
screws.

Connect power and verify that teach pendant works properly.

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4. Software

4.1 Update software

Universal Robots software is named PolyScope.


This software can be updated, when new releases of software become available.

When updating software on robot with older version, it is required to install each update in sequence, i.e. if
robot using software v1.5 must be updated to v1.7, it is required to first update to v1.6 and then update to
v1.7.

If it aint broken, dont fix it:


If a robot is operating in an existing application, Universal Robots do not recommend updating software,
unless the use of new functions in a newer software release is required for this application.

IMPORTANT NOTICE:
Software should only be updated after consulting Distributor from where the robot has been
purchased or if representing a Distributor after consulting Universal Robots.
Universal Robots do not recommend updating software without proper instruction in how to
update software.
When updating firmware it is strictly forbidden to turn off controller during update.
Universal Robots can be no means be held responsible for any failed update caused by improper
operation.

Go to http://www.universal-robots.com/support/ for downloading software updates.


Login is not required.

Please note: If representing an end customer, contact the Distributor from where the robot has been
purchased before updating the software.

Instruction for updating software


Download software update. Carefully read requirements on support site relating to which software
must be installed on robot prior to updating to the downloaded version.
Save it in the root folder on a USB-stick.
Insert USB-stick into USB-connector on right-hand side of teach pendant.
Go to main screen of PolyScope.

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Press button SETUP Robot.
In left side menu, select UPDATE Robot.

Press button Search for searching after software update on USB-stick.

Mark the found software update and press UPDATE.


Press YES for updating the software.
Await robot update software, after successful update controller will automatically shut power off.
Remove USB-stick and boot robot.

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4.2 Update joint firmware

Each joint on robot arm is provided with firmware for controlling the joint.

For normal operation firmware update is not required. Software can be updated on robot without updating
the firmware.

Special procedure is needed when replacing a CB2 joint with a CB3 special joint. Please see chapter 3.1.3
Replacing CB2 joint with CB3 special joint

IMPORTANT NOTICE:
Firmware should only be updated after consulting Distributor from where the robot has been
purchased or if representing a Distributor after consulting Universal Robots.
Universal Robots do not recommend updating firmware without proper instruction in how to
update firmware.
When updating firmware it is strictly forbidden to turn off controller or to remove cable between
controller and robot arm during update.
Universal Robots can be no means be held responsible for any failed update caused by improper
operation.

Instruction for updating firmware


Prior to updating firmware, it is required to update the robot software.
Please refer to chapter 4.1 for updating software. When updating robot software, the firmware will
automatically be copied to a folder on the controller.

Drag a finger from left to right across the UNIVERSAL-sign on main screen of PolyScope.

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Enter password lightbot and press OK.

lightbot

You are now in Expert Mode, press Low Level Control.

Select the Firmware tab, mark All joints and press UPDATE firmware.

Firmware update is being processed, await message that robot firmware updated successfully.
It is strictly forbidden to turn off controller during this update.
After successful update, press Back.

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Back in Expert Mode, press Return to Normal.

Firmware has now been updated.

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4.3 Using Magic files

For easy backup, Universal Robots provides Magic files for automatic copy of data from controller to USB-
stick.

These files are available: Function:


URmagic log file copies the entire log history file to USB-stick
URmagic backup programs copies all programs and installation files to USB-stick
URmagic configuration files copies all configuration files to USB-stick
URmagic upload programs copies all programs and installation files from USB-stick
URmagic screenshot generates a screenshot of GUI when USB-stick is inserted

Go to http://www.universal-robots.com/support/ support for downloading Magic files.


Login is not required.

Instruction for using Magic files


Download Magic file.
Save it in the root folder on a USB-stick.
Insert USB-stick into USB-connector on right-hand side of teach pendant.
After a few seconds a red ! USB ! -sign will appear on the screen, this is a warning not to remove
the USB-stick, while the file will do its magic.
Await a green <- USB -sign appears on the screen, then you can safely remove the USB-stick.
Remove USB-stick and youre done.

The Magic file creates a folder on USB-stick named after the serial number of robot.

If more than one magic file is on USB-stick, they will be run in sequence, the warnings will then appear for
each file. Do not remove the USB-stick before after the last file has been run. Multiple folders will be
created and named after serial number added with a sequential no, like 201220xxx4_0, 201220xxx4_1 etc.

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5. Troubleshooting
5.1 Error codes
Note: In some software version, the wording of the error code may be different.

Code Error description Issue concerning error How to fix


C4 Broken communication error Serial communication Check green 2-wire connectors
problem with one or more and wires in joints
joints
C4A1 Broken communication error Communication with PC Check connection between
lost. masterboard and motherboard,
replace Masterboard and/or
motherboard if needed
C4A2 Broken communication error Communication with Check connection between
primary MASTERBOARD uP masterboard and motherboard,
lost replace Masterboard
C4A3 Broken communication error Communication with Check connection between
secondary MASTERBOARD masterboard and motherboard,
uP lost replace Masterboard
C4A4 Broken communication error Communication with Check connection between
primary SCREEN uP lost controller and teach pendant,
replace if needed
C4A5 Broken communication error Communication with Check connection between
secondary SCREEN uP lost controller and teach pendant,
replace if needed
C4A6 Broken communication error
C4A7 Broken communication error
C4A8 Broken communication error
C4A9 Broken communication error
C4A10 Broken communication error
C4A65 Broken communication error
C4A66 Broken communication error
C4A67 Broken communication error
C4A68 Broken communication error
C4A69 Broken communication error
C5 Heavy processor load Simplify program, minimize
warning numbers of Modbus I/Os by
using registers, use sync() see
script manual
C6 Motor encoder index Update firmware,If seen once,
mounting or interrupt drift check program for hard accl and
error detected high speed, If see several times,
replace joint
C7 Joint encoder index interrupt Mechanical problem or Update firmware or replace
drift error detected firmware in joint joint
C10 Broken PC communication Check connection between
error masterboard and motherboard,
replace Masterboard and/or
motherboard if needed
C11 Bad CRC error Serial communication Update firmware, check green 2-

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problem with joint wire connectors and wires in
joints

C15 Master sniffed message Serial communication Check green 2-wire connectors
addressed to invalid node ID problem with joint and wires in joints

C17 In buffer overflow error in Communication error Check connection between


Master from PC between Masterboard and masterboard and motherboard,
Motherboard replace Masterboard and/or
motherboard if needed
C19 Master had no data to send Possible CPU-overload due Update firmware on joint,
to joints to structure of user program restructure user program
C21Axx Joint Encoder Interrupt Update firmware,If seen once,
without bit change error check program for hard accl and
high speed, If see several times,
replace joint
C22 Encoder joint interrupt with Replace joint
two step change error
C23 Encoder motor interrupt Replace joint
without change error
C24 Encoder motor interrupt with
two step error
C25 Joint Encoder index drift Problem with reading Replace joint
detected encoder position in joint
C26 Motor Encoder index drift Joint mechanical problem Replace joint
detected
C29 Ethernet package loss Possible CPU-overload due Restructure user program
detected from PC to robot to structure of user program
C31 Caught wrong message (not Serial communication Check green 2-wire connectors
from master) problem with joint and wires in joints
C37 In buffer parse error Serial communication Check green 2-wire connectors
problem with joint and wires in joints
C40 AD-Converter hit high limit EMC issue external or Check grounding and shielding
electronics internal for EMC problems

C43 Could not track target External blocking, encoder, Use Teach Mode for checking
position brake, gear, acceleration too manual jog with joint
high, payload too high Open blue lid on joint and check
brake pin, consult chapter 3.1.2
Reduce acceleration in user
program
Verify payload is correct
Replace joint if necessary
C44 CRC error, likely from joint Serial communication Check green 2-wire connectors
problem with joint and wires in joints
C46 Loose gearbox or bad Mechanical problem in gear Replace joint
encoder mounting related to encoder
mounting
C47 AD-Converter hit low limit EMC issue external or Check grounding and shielding
electronics internal for EMC problems

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C48 Powerbus voltage drop Error on 48V powerbus Check 48V output from PSU
detected Check Current Distributor pcb
Replace 48V PSU or Curernt
Distributor is necessary
C50 Robot power up failure Electrical error control box Remove all external connections
to I/O-interface of Masterboard
Check for short circuit
Argument of error code specifies
in details what causes the error
C50A1 The 24V I/O has voltage, but
24V regulator is off
C50A2 Voltage present at
unpowered robot
C50A4 Robot is not stopped, this is
an error
C50A5 48V PSU voltage to low after
powerup
C50A6 48V PSU voltage to high after
powerup
C50A11 Voltage not detected at 24V
rail after startup
C50A15 Warning, Waiting for
secondary masterboard
processor
C50A16 Comm. Error with Teach Check connection to Teach
Pendant under start up Pendand, check that correct type
Teach Pendent is connected.
Replace Teach Pendant if
needed.
C50A17 Warning, Waiting for Check ribbon cable
euromap67 interface
C50A18 Warning, Waiting for primary
masterboard processor
C50A19 Warning, Waiting for a valid
"euromap67 activated"
status bit from secondary
masterbaord processor
C50A20 5V measured too high, 5V,
3V3 or ADC malfunction
C50A21 5V measured too low, 5V,
3V3 or ADC malfunction
C50A22 Robot current sensor output
too high for offset calibration
C50A23 Robot current sensor output
too low for offset calibration
C50A24 Robot Power up failure: 48V Check internal connection Check Error phenomena in this
not present service manual
C50A25 Robot voltage preset when Transistors ON/OFF function
the 48V PSU is powered up might be short circuited
C50A26 Voltage present on
unpowered 48V PSU

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C50A27 12V measured too high, 12V,
3V3 or ADC malfunction
C50A28 12V measured too low, 12V,
3V3 or ADC malfunction
C50A29 -12V measured too high,
Analog I/O malfunction
C50A30 -12V measured too low,
Analog I/O malfunction
C50A31 The other SafetySys will not Euromap67, one or both Check that the correct type
initialize masterboard uP will not Teach Pendent has been
initialize connected.
C50A99 Wrong software on PCB
C50A100 Cable not connected
C50A101 Short Circuit in robot
C50A102 Voltage rising too slow
C50A103 Voltage did not reach
appropriate level
C51 Emergency relay failure Masterboard error Replace Masterboard
C53 IO, Master or Tool Too high current Remove all external connections
overcurrent consumption to I/O-interface of Masterboard
Check for short circuit
C55 Safety system error Safety system malfunction Check Motherboard,
Masterboard, Screenboard,
Current distributor
( Euromap, if installed )
Bypass safety connections to
I/O-interface of Masterboard
C55A23 Safety relay error minus connction
C55A24 Safety relay error plus connction
C55A33 Safety relay error a relay is stuck
C55A34 Safety relay error relays are not on
C55A50 Voltage present at
unpowered robot
C55A51 Voltage will not disappear
from robot
C55A52 5V, 3V3 or ADC error 5V too low
C55A53 5V, 3V3 or ADC error 5V too high
C55A90 Bootloader error, robot
voltage too low or current
too high
C55A91 Bootloader error, robot
voltage too high
C55A100 Safety violation
C55A101 Safety Channel Error In
Masterboard
C55A120 Safety Channel Error In
Screen
C55A103 Safety Channel Error In
Euromap67 Interface
C55A109 Received fault message from
PC

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C55A110 Safety State is changing too
often
C55A111 On/Off State is changing too
often
C55A112 Robot current sensors
readings differ
C55A120 Robot current is too high
while emergency stopped
C55A121 Robot current is too high
while safeguard stopped
C56 Overvoltage shutdown Voltage exceeded 55V Check Energy Eaters
Replace Energy Eater
C57 Joint speed deviation External blocking, encoder, Use Teach Mode for checking
brake, gear, acceleration too manual jog with joint
high, payload too high Open blue lid on joint and check
brake pin, consult chapter 3.1.2
Reduce acceleration in user
program
Verify payload is correct
C58A0 Motor Encoder Not Never calibrated
Calibrated
C58A1 Motor Encoder Not Wrongly calibrated, or joint
Calibrated could not decelerate well
enough after motor init.
C59 Overcurrent shutdown Overcurrent in joint Check for short circuit
Check program for singularity
issues
Replace joint if necessary
C61 Missed joint index mark Encoder too far off shaft Adjust encoder with appropriate
tool
Replace joint if necessary
C62A1 Thermal shutdown Joint temperature exceeded Reduce acceleration in user
80 deg. C program
Check ambient temperature
Replace joint if necessary
C62A3 Static load too high
C62A11 Thermal shutdown Joint at 85 C Reduce acceleration in user
program
Check ambient temperature
Replace joint if necessary
C62A13 Static load too high
C64A1 Interface connection error Safety error: Auto is active
but reset is not.
C64A2 Interface connection error Safety error: Reset button is
stock
C64A3 Interface connection error I/O overcurrent at 24V, max
is 1200mA
C64A4 Interface connection error I/O overcurrent at 24V, max
is 2A
C66 Version mismatch error Masterboard version not Edit config file, contact
matching config file info distributor

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C70 Close to gearbox shear limit Acceleration / deceleration Reduce acceleration in user
to high Mechanical problem program
in gear related to encoder Replace joint if necessary
mounting
C71A1 Joint Startup check error Joint hardware is size 1 but Edit config file, contact
software is not distributor

C71A2 Joint Startup check error Joint hardware is size 2 but Edit config file, contact
software is not distributor

C71A3 Joint Startup check error Joint hardware is size 3 but Edit config file, contact
software is not distributor

C71A4 Joint Startup check error Joint hardware is size 4 but Edit config file, contact
software is not distributor

C71A5 Joint Startup check error Wrong hardware size read Edit config file, contact
distributor

C100 Robot changed mode Status warning, general Check preceding errors in log
modus change history
C107 Joint has too many errors in a After 3 consecutive errors, Check preceding errors in log
row result of preceding errors history
Replace joint if necessary
C109 Security Stop Generated by controller Check preceding errors in log
safety system. history
Security limit exceeded
C110 Joint Security Stop Generated by controller Check preceding errors in log
safety system history
Security limit exceeded
C113 Force limit protective stop Robot movement blocked Use Teach Mode for checking
Collision or mechanical manual jog with joint
failure Open blue lid on joint and check
Acceleration too high in user brake pin, consult chapter 3.1.2
program Reduce acceleration in user
TCP and payload settings program
incorrect Verify payload is correct
C114 High Measured Force Warning prior to error code Use Teach Mode for checking
Warning 113: Force Limit Protective manual jog with joint
Stop Reduce acceleration in user
program
Verify payload is correct
C115 Wrong robot type Can be related to different Check settings in config file
causes: Replace 48V PSU, Masterboard,
a. Wrong setting in Current Distributor pcb or Teach
urcontrol.conf file pendant if necessary
b. Defective 48V PSU
c. Defective Masterboard
d. Defective Current

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Distributor pcb
e. Fault on the teach
pendant
C116 Real time part warning Possible CPU-overload due Restructure user program
to structure of user program
C150 SECURITY CHECK: Position Incorrect TCP and payload Verify TCP and payload settings
change too large setting Reduce acceleration in user
Too high acceleration, program
typically when running
robot in positions with full
reach and full payload
C151 SECURITY CHECK: Joint limit Incorrect TCP and payload Verify TCP and payload settings
violation setting Reduce acceleration in user
Too high acceleration, program
typically when running
robot in positions with full
reach and full payload
C153 SECURITY CHECK: Speed limit Incorrect TCP and payload Verify TCP and payload settings
violation setting Reduce speed or modify
Too high velocity, typically positions in user program
in linear movements close
to singularity
C156 SECURITY CHECK: Torque Incorrect TCP and payload Verify TCP, payload and
limit violation setting Mounting settings
Incorrect Mounting setting Reduce acceleration in user
Too high acceleration program

C190 Modbus error Incorrect setting of Modbus Verify settings and


addr. or comm. lost communication
between robot and device
C191 Force mode error Incorrect setting of Force Verify settings
Mode
Robot TCP close to
singularity
C194 Conveyor speed too high Conveyor speed higher than Adjust conveyor tick count
robot is able to run accordingly
C195 MoveP speed too high Too high speed in relation to Reduce speed or increase blend
blend radius radius in user program

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5.2 Normal startup procedure on a CB2 UR10

1. When you only have the power plug connected and the robot is not turned on the 12 V LED is
on.(On the Master board)
2. When you press the power on button on the TP the power up sequence starts
3. In this sequence The 48 V LED indicator and the "R" LED indicator is on in about 1 second (Master
board) it is for testing if the 48V power supply is working and to check if the robot arm is
connected.

If the 48V LED indicator is off all the time in the start up sequence you should measure the voltage.

1. Measure the 48V on the Master board where the 48V comes from the Current distributor. And check
this 1 second pulse.
1.1. Voltage on the Master board. It should be the master board that is defect
1.2. No voltage on the Master board 48V then measure the output 48V on the power supply.
1.3. No voltage on the 48 V Power supply output. Check the 230 V input to the 48V power supply. It is
either the Power supply that is defect or the 240 V.
1.4. Voltage on the Output of the 48V Power supply. Then measure on both sides of the current
distributor. It should be the Current distributor that is defect.

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5.3 Error phenomena

5.3.1 ControlBox: NO CONTROLLER displayed in Initializing

ControlBox = NO
CONTROLLER displayed at
INITIALIZING screen

Replace ethernet cable between motherboard YES Defective ethernet cable


and Masterboard and verify problem is solved

NO

Replace Masterboard and verify problem is solved YES Defective Masterboard

NO

Replace motherboard and verify problem is solved YES Defective motherboard

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5.3.2 NO CABLE displayed during power up

NO CABLE displayed during


power up > controller shuts
off after few seconds

Measure that 230V AC is present on power input NO Replace current distributor


connector on 12V power supply

YES

Measure that 12V DC is present on 12V_IN


NO Replace 12V power supply
connector on Masterboard and diode marked 12V
in top right corner of Masterboard is lit

YES

During power up (within first few seconds) check


NO Replace Masterboard
that the top four diodes in top right corner of
Masterboard are lit before they turns off again

YES

Replace motherboard

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5.3.3 Force limit protective stop

Force Limit Protective Stop

Payload and tcp settings in Installation\Mounting Adjust payload and tcp


YES
must correspond with actual tool. settings
Are settings incorrect?

NO

Adjust center of mass using


Is center of mass very different from tcp point? YES
script code set_payload()
(software v1.7 or newer)

NO

Are waypoints positioned very close to cylindrical Adjust waypoints away


YES
area around base of robot where robot can not from this area or reduce
operate? speed/acceleration

NO

Are robot moving with excessive speed or Reduce speed or


YES
accelerating very hard? acceleration

NO

Press teach button on back of TP and check the Inspect joint with abnormal
YES
teach function of all joints > any abnormal friction behavior, joint might have
or behavior observed? mechanical failure

NO

Contact distributor from where robot has been


purchased

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5.3.4 Power on failure in Initializing

If power turns off a few seconds after Robot Power is turned On in the Initializing window, there are many
possible causes for this phenomenon.

Most likely it is a control box failure or a communication failure with a joint or the tool.

Control box failure

Check log history for error messages and consult


the section Error Codes for detailed explanation

Power controller OFF/ON

During power up (within the first three seconds of


YES Replace 48V power supply
power up) measure that 230V AC is present on
48V_PSU1 connector on current distributor PCB

NO

Measure that 12V DC is present in the red YES Replace current distributor
connector/flatcable on the current distributor

NO

Replace Masterboard

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Communication failure with
a joint or the tool connector

Check log history for error messages and consult


the section Error Codes for detailed explanation

Go to LOW LEVEL CONTROL in EXPERT MODE


(consult chapter 4.2 for how to access EXPERT
MODE)

Go to tab POWER ON/OFF and press TURN Unmount tool and check
NO
POWER ON. Does state of tool switch from green comm. connector is
BROKEN COMM. ERROR to READY? fully inserted in pcb

YES

YES Does state of tool switch to


READY?

NO

Continue to
next page Replace tool

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Continued

Go to tab POWER ON/OFF and press TURN Remove blue lid of joint and
NO
POWER ON. Does state of all joints J0-J5 switch check green comm.
from BROKEN COMM. ERROR to READY? connector is fully inserted

YES

YES Does state of joint switch to


READY?

NO

Communication ok to joints and tool Replace joint

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5.3.5 Checklist after a collision

Checklist after a collision

Check log history for error messages and consult


the section Error Codes for detailed explanation

Stop robot program and eventually press the


Emergency button prior to entering the work cell

Visually inspect robot arm. Remove lid and inspect


YES
Are any parts visually damaged, like damages on parts inside of joint
one of the blue lids?

NO

Press teach button on back of TP and check the Inspect joint with abnormal
YES
teach function of all joints > any abnormal friction behavior
or behavior observed?

NO

Press teach button on back of TP and check the Inspect joint with abnormal
YES
teach function of all joints > any excessive noise noise. If click noises appear,
observed? check brake pin

NO

Start the robot program in NOreduced speed and


verify robot is running as intended

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5.4 Schematic drawing

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5.4.1 Tool connector

Tool connector

Pin 1 AI[2]
Pin 2 AI[3]
Pin 3 DI[0]
Pin 4 DI[1]
Pin 5 12V/24V DC
Pin 6 DO[0]
Pin 7 DO[1]
Pin 8 GND

Note: Supply current in both modes 12V and 24V is maximum 600 mA

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6. Spare parts
6.1 Spare part list

Item no. Item designation


Controller:
122550 Controller excl. Teach Pendant UR10
122810 Controller incl. Teach Pendant UR10
122092 Teach Pendant incl. Touchscreen and power cables UR5 and UR10
171022 Flash card
106700 Euromap E67 kit (includes E67 module + bypass plug + cable)
123670 Euromap E67 cable 6m
122600 Motherboard kit
122700 Masterboard kit
177002 Power Supply Unit 12V
177003 Power Supply Unit 48V
172080 Current distributor PCB
122740 Energy Eater incl. Fan
164219 Wire bundle controller output UR5
171030 RAM module
177503 Filter kit for controller
132455 Plate Cover f. electronic parts

Robot arm:
122059 Base Mounting Bracket UR10
122031 Joint Size 4 Base UR10
122043 Joint Size 4 Shoulder UR10
122034 Joint Size 3 Elbow UR10
122021 Joint Size 2 Wrist 1 UR10
122022 Joint Size 2 Wrist 2 UR10
122023 Joint Size 2 Wrist 3 UR10
122060 Tool Mounting Bracket UR10
103310 Sealing set UR10, external
103410 Lid set complete UR10 incl. Seal

Accessories:
173101 Cable for tool, angle: external
131095 Lid Tool protective cap Alu. For tool connector
139033 Bracket f. mounting Teach Pendant
132407 Bracket f. mounting Controller
131510 Bracket f. mounting robotarm UR10 (Item & Bosch profile)

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6.2 Tool part list

Item no. Item designation


109010 Service kit UR3/UR5/UR10 (kit includes all of the below part no.s)
109101 Spanner Hex 5.5mm UR5 & UR10
109102 Spanner Hex 7.0mm UR5 & UR10
109110 Spanner Hex 10.0mm UR10 only
Screwdriver Flat 2.5 UR3 & UR5 & UR10
109103 Screwdriver torx T10 UR5 & UR10
109105 Torque wrench Hex 5.5mm Size 1 and Size 2 (1.3 Nm) UR5 & UR10
109106 Torque wrench Hex 7.0mm Size 3 (3.0 Nm) UR5 & UR10
109107 Torque wrench Hex 10.0mm Size 4 (8.0 Nm) UR10 only
109104 Torque screwdriver torx T8 + T10 (0.4 Nm) UR3 & UR5 & UR10
109111 Torque screwdriver torx T10 (1.3 Nm) UR3
109112 Torque screwdriver torx T20 (3.0 Nm) UR3
164084 Bypass cable (for setting joint-ID) UR3 & UR5 & UR10
109180 ESD wrist strap UR3 & UR5 & UR10
Service kit box UR3 & UR5 & UR10

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7. Packing of robot

Packing of robot and controller box for shipment

Remove any external tooling and external electrical connections.

Load program Put_into_box_ur10.urp and follow instructions while removing mounting bolts.

While robot folds together, hold a piece of bubble wrap between Shoulder joint and wrists.

Note: If robot cannot run or power is not available, it is possible to manually release the brakes for
each joint individually and pack the robot accordingly. For brake release, see chapter 3.1.2.

Power down, disconnect power and disconnect robot arm from controller.

Pack robot arm and Controller box in designated boxes.

All rights reserved 99 Servicemanual_UR10_en_2.0.5


8. Changelog

8.1 Changelog

Date Revision Action Changes


3. jan 2013 UR10_en_1.0 Added First revision 1.0 released
24 may 2013 UR10_en_1.0.1 Added Company details added
Added Description of new Magic Files added
Corrected Spare part list corrected
3. sep 2013 UR10_en_1.0.2 Corrected Error code descriptions corrected
Added Illustration for base mounting bracket connections added
22. feb 2014 UR10_en_2.0.1 Added Changelog added
Corrected Error code C115: Cause and remedy corrected
Corrected Spare part list: new part numbers implemented
Added Spare part list: additional part numbers added
Corrected New company address added
31. mar 2014 UR10_en_2.0.2 Added Additional instructions on replacement of tool flange are
added, as additional parts have been added to tool flange
29. July 2014 UR10_en_2.0.3 Added ESD handling and Spare parts updated
12. Jan 2016 UR10_en_2.0.4 Changed Joint part and TP no. is corrected to CB3 special
Added CB3 to CB2 section 3.1.3
Added More error codes
Corrected General information
Jan 2017 UR10_en_2.0.5 Corrected CB3 to CB2 section 3.1.3 Revision joint section removed

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