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Universal Robots 2014350001 Service Manual Download Page 149

C220A1

Kinematic
Calibration

Actual version on the robot
arm is not supported

Update Software

C220A2

Kinematic
Calibration

Kinematic Calibration file
was replaced with file from
the arm

Update Software

C220A3

Kinematic
Calibration

Kinematic Calibration
uploaded to the arm

Update Software

C220A4

Kinematic
Calibration

Kinematic Calibration
reuploaded to the arm

Update Software

C257A

Unknown message

C258A

Invalid Payload

Please insert a valid payload

C259A

Filesystem related
issue

C259A0
to
C259A81

Critical error

A critical error occurred in
the filesystem

a) Do a Complete rebooting
sequence
b) Update robot Software
c) Reimage SD card
d) Contact your local
Universal Robots service
provider for assistance.

C260A

Brake Release

Brake release not
responding properly

a) Check the brake release
system
b) Do a Complete rebooting
sequence 
c) Contact your local
Universal Robots service
provider for assistance.

C260A0

Critical error

A critical error occurred
during Brake Release

a) Do a Complete rebooting
sequence
b) Ensure the mounted
payload, TCP and CoG
matches your configuration.
c) Update robot software
d) For further assistance,
contact your local Universal
Robots service provider.

C260A1
to
C260A21

Brake Release

Motor moved only

C261A

Temperature Sensor

Service Manual

143

UR5

7. Troubleshooting

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Summary of Contents for 2014350001

Page 1: ...Revision UR5_en_3 2 7 Robot UR5 with CB3 0 3 1 3 2 controller CB3 0 valid from robot s n 2014350001 to 2016351863 CB3 1 valid from robot s n 2016351864 to 2019351625 CB3 2 valid from robot s n 201935...

Page 2: ...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...

Page 3: ...1 5 Service and Replacement of parts 13 5 1 Handling ESD Sensitive Parts 13 5 1 1 Recommended Tools 16 5 2 Robot Arm 17 5 2 1 Before returning any part to Universal Robots 17 5 2 2 Robot Arm Configura...

Page 4: ...are 80 6 1 Update software 80 6 2 Update joint firmware 82 6 3 Using Magic files 84 6 4 Backup of data 85 6 4 1 Hardware Requirements 85 6 4 2 Software Requirements 86 6 4 3 How to Access Linux Partit...

Page 5: ...matic Overview 213 7 4 2 E Plan Diagrams 217 8 Spare Parts 224 8 1 Robot arm 224 8 2 Controller 226 8 3 Tools 227 9 Packing of Robot 229 10 Change Log 231 Service Manual UR5 Copyright 2009 2021 by Uni...

Page 6: ...UR5 Service Manual Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 7: ...personnel Before performing service related operations always make sure to stop the robot program and disconnect the main power to any potential dangerous tool on the robot or in the work cell In the...

Page 8: ...ARNING These warnings mean a hazardous situation which if not avoided could result in death or serious injury CAUTION These warnings mean a hazardous situation which if not avoided could result in min...

Page 9: ...cases very small amounts of grease can seep from the joint This does not affect the specified function or lifetime of the joint NOTICE Never use compressed air to clean the controller or robot arm as...

Page 10: ...he Teach Pendant functions Press the Emergency Stop button on the Teach Pendant Observe that the robot stops and turns off the power to the joints Power on robot again Test Freedrive mode Unmount atta...

Page 11: ...active and test that they can be triggered 4 1 3 Visual Inspection Disconnect power cable from controller Check that the terminals on the Safety Control Board are properly inserted and do not have lo...

Page 12: ...em thoroughly using low pressure air Replace filters if necessary Gently remove the outer plastic frame and maintain the filter UR5 6 Service Manual 4 Recommended Inspection Activities Copyright 2009...

Page 13: ...ge Control Box Controller box has two filters one mounted on each side of the box Service Manual 7 UR5 4 Recommended Inspection Activities Copyright 2009 2021 by Universal Robots A S All rights reserv...

Page 14: ...em thoroughly using low pressure air Replace filters if necessary Gently remove the outer plastic frame and maintain the filter UR5 8 Service Manual 4 Recommended Inspection Activities Copyright 2009...

Page 15: ...l or 10 Naphtha In rare cases very small amounts of grease can be visible from the joint This does not affect the function use or lifetime of the joint Due to the added focus on cleaning your robot Un...

Page 16: ...s recommends be performed according to the marked time interval If upon inspection the referenced parts are not in an acceptable state please rectify immediately Use the following sections as guide 2...

Page 17: ...pose of the functional inspection is to ensure that screws bolts tools and robot arm are not loose The screws bolts mentioned in the inspection plan should be checked with a torque wrench with the cor...

Page 18: ...ten properly if necessary Correct torque value for screws on blue lids are 0 4Nm If any damage is observed on a robot within the warranty period contact the distributor from which the robot has been p...

Page 19: ...removing circuit boards Keep the ESD sensitive part in its original shipping container a special ESD bag until the part is ready to be installed Put the ESD wrist strap on your wrist Connect the wris...

Page 20: ...e ESD bag Step 2 Take NEW board out of ESD bag Hold the ESD sensitive part by its edges Do not touch its pins UR5 14 Service Manual 5 Service and Replacement of parts Copyright 2009 2021 by Universal...

Page 21: ...aterial 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 ESD bag Service Manual 15 UR5 5 Service and Replacement of parts Copyright...

Page 22: ...cold weather and heating is used because low humidity increases static electricity 5 1 1 Recommended Tools Robot arm Service kit part no 109010 Control box Below tool should be ESD safe tools Slotted...

Page 23: ...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 Shee...

Page 24: ...portant to dismount any dangerous parts to avoid 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...

Page 25: ...before starting the repair 1 Service kit with torque tools ESD Wristband etc 2 Thoroughly read and understand this guide 2 Move the robot to a comfortable position for disassembly or if necessary dism...

Page 26: ...er or similar tool and pull it back over joint housing away from its original position 10 Slide the grey Teflon ring back 10 screws become visible 5 on each side of joint Loosen the screws with an ope...

Page 27: ...aded holes in the joint housing the joint will most likely have these already inserted CAUTION It s important that the correct screws are placed in the correct hole The blue marked screws are shorter...

Page 28: ...twisting the parts clockwise roughly 5 degrees until a mechanical stop is met 3 Gently tighten the screws until they are almost in the correct position then tighten in cross order as shown in the numb...

Page 29: ...CTION TORQUE HEAD SIZE Base mounting bracket J0 Base 2 6Nm 7 mm J0 Base J1 Shoulder 2 6Nm 7 mm J1 Shoulder Upper arm 2 6Nm Hex key 3 Upper arm J2 Elbow 2 6Nm Hex key 3 J2 Elbow Lower arm 2 6Nm 7 mm Lo...

Page 30: ...g Bracket Disassemble For details and photos please see General Guidance to Separate Joint from Counterpart UR5 24 Service Manual 5 Service and Replacement of parts Copyright 2009 2021 by Universal Ro...

Page 31: ...ds before it is connected to reduce electrical noise in the system 3 Gently insert base plate with screws and washers into the Base joint 4 Make sure the washers are fully inserted and flush against t...

Page 32: ...in opposite directions around 10 mm until a mechanical stop is met holes are keyhole type 9 Pull away the Base joint from Shoulder joint Assemble For details and photos please see General Guidance to...

Page 33: ...Shoulder joint Disassemble For details and photos please see General Guidance to Separate Joint from Counterpart 1 Shut down the controller 2 Remove blue lid on Shoulder joint 3 Connect ESD wristband...

Page 34: ...r arm end mount screws into shoulder joint 2 Tighten the 10 screws lightly and then tighten in cross order with 2 6Nm 3 Mount the alignment screw and tighten with 0 4Nm 4 Connect ESD wristband 5 Recon...

Page 35: ...and Elbow counterpart with a tiny screwdriver or similar tool and twist it around the joint housing 4 Slide the grey Teflon ring back 10 screws become visible 5 on each side of joint Loosen the screw...

Page 36: ...ently twisting the parts in opposite directions until a mechanical stop is met 5 Tighten the 10 screws lightly and then tighten in cross order with 2 6Nm 6 Slide the grey Teflon ring in place and gent...

Page 37: ...holes are keyhole type 9 Pull away the lower arm from Wrist 1 joint Assemble For details and photos please see General guidance to separate joint from counterpart 1 Gently insert Wrist 1 joint with s...

Page 38: ...ck flexible flat ring between Wrist 1 and Wrist 2 with a tiny screwdriver or similar tool and twist it around the joint housing 7 Slide the grey Teflon ring back 8 screws become visible 4 on each side...

Page 39: ...ctors as illustrated into Wrist 2 Twist the communication cable 1 5 to 2 full rounds before it is connected to reduce electrical noise in the system 8 Mount blue lid on Wrist 1 joint and tighten with...

Page 40: ...ns approximately 3 mm for each screw 5 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 t...

Page 41: ...on top of the Teflon ring 8 Mount the alignment screw and tighten with 0 4Nm 9 Proceed to chapter Dual Robot Calibration for calibrating the robot 5 2 15 Instructions for calibrating a joint After re...

Page 42: ...tion of all joints 2 Swipe from left to right across the UNIVERSAL ROBOTS logo on main screen of PolyScope 3 Enter password lightbot and press OK UR5 36 Service Manual 5 Service and Replacement of par...

Page 43: ...Polyscope Installation tab are active The protective stop is NOT active Set all safety settings to their lowest settings before moving the robot 5 Press Turn power on to enable power to joints Service...

Page 44: ...ctly clicking the status line for that joint Currently selected joint is highlighted in blue 8 Press Arm current joint to release the brake on the selected joint UR5 38 Service Manual 5 Service and Re...

Page 45: ...ro position according to the following illustrations Press STOP when the joint is in the correct position 9 Zero position illustrations Base Shoulder Elbow Wrist 1 Service Manual 39 UR5 5 Service and...

Page 46: ...lign joints Wrist 2 Wrist 3 Wrist 2 zero position is aligned similar to Base joint with tool flange parallel with wrist 1 output flange Wrist 3 zero position is aligned so tool connector is pointing u...

Page 47: ...to Normal 13 Verify zero position by moving the robot to HOME If not satisfied with the zero position perform the procedure once again Service Manual 41 UR5 5 Service and Replacement of parts Copyrigh...

Page 48: ...universal robots com support to download the Calibration Manual in PDF format Simple Joint calibration as described in 3 1 15 Instructions of calibrating a joint After replacing a joint the zero posit...

Page 49: ...TLOADER mod 4 Press Go to Idle and the connected joints enter READY mode 5 Select Joint ID tab 6 Select J5 The one to be changed 7 Uncheck Exchange IDs box 8 In dropdown box select ID no 3 9 Press Set...

Page 50: ...Adaptation The UR5 and UR10 consist of four different joint sizes some of which are interchangeable between different positions robots Recommended spare joints for UR5 and UR10 are marked UR5 44 Serv...

Page 51: ...alibrating a joint 5 2 19 Wire Bundle Installation Guide General As well as the Wire bundle kit for the correct joint size the Following ESD approved tools are recommended for this replacement Tool fo...

Page 52: ...ount the grommet into the flex plate with the tweezers or the small flat nose screwdriver Hold the heat shrink with tweezers while sliding down the grommet UR5 46 Service Manual 5 Service and Replacem...

Page 53: ...ug hole marked with a line also shown with red arrow Remember to orientate the barbs as described above Insert the red into the other plug hole When done check that the connector pins are firmly hooke...

Page 54: ...te pin in the other plug hole When done check that the connector pins are firmly hooked inside the plug by pulling gently in the wires If not check that the orientation of the barbs is correct If inse...

Page 55: ...flange Mount the grommet into the flex plate with the tweezers or the small flat nose screwdriver Hold the heat shrink with tweezers while sliding down the grommet into position Service Manual 49 UR5...

Page 56: ...two thicker red and black wires needs to be stripped approx 5mm Mount the cable shoes Use the clamping tool as described by the manufacture Check that the wire is secure in the cable shoes UR5 50 Serv...

Page 57: ...ne check that the connector pins are firmly hooked inside the plug by pulling gently in the wires If not check that the orientation of the barbs is correct If inserted correctly use a tool to press on...

Page 58: ...rm wire bundle kit contains wire bundle for multiple robot types Please be sure use the correct length Both ends of this wire bundle are identical so inserting in either direction is acceptable UR5 52...

Page 59: ...teps in section Complete rebooting sequence When completing the following replacement please follow the guidelines laid out in section Handling ESD sensitive parts NOTICE Motherboard 3 0 uses compact...

Page 60: ...ect cable connections from motherboard 1 White plug with white brown yellow and green wires 12 V Power 2 Black USB cable for Teach Pendant USB connector 3 Ethernet cable to external connector 4 Ethern...

Page 61: ...rect positions Special attention on the Ethernet cable to the Safety Control Board It must be connected to the right connector on the mother board 8 Re install flash card and RAM block 9 Carefully put...

Page 62: ...please follow the guidelines laid out in section Handling ESD sensitive parts How to replace motherboard 3 1 1 Shut down the controller and disconnect the power cable open the controller cabinet and...

Page 63: ...e to Safety Control Board SCB 4 Ethernet cable to external connector 5 Black USB cable for TP USB connector 6 Grey flat cable for RS232 connection for TP touch 4 Remove the 4 screws from the 2 holding...

Page 64: ...on provides guidelines for exchanging an existing CB3 motherboard with a new CB3 1 motherboard It is solely intended for advanced integrators of UR robots Parts and check list 122430 CB3 0 to CB3 1 Up...

Page 65: ...and to the system ground point This discharges any static electricity in your body to ground Remove shields by removing the 7 x T20 torx screws Remove all cables attached to the motherboard and the co...

Page 66: ...ews were before Place the black cable from the Teach Pendant and the Ethernet cable on the left side of the Standoff as shown on the photo Note If your Ethernet cable has a black plug Figure 1 at one...

Page 67: ...larger standoffs Mount the motherboard onto the standoffs Please note that the two screws toward the outside of the controller may be more difficult to get into position Service Manual 61 UR5 5 Servic...

Page 68: ...ble under the motherboard and to the connector as shown in the photo below Plug the new power cable from the SCB to the CB 3 1 motherboard as shown UR5 62 Service Manual 5 Service and Replacement of p...

Page 69: ...ion Mount the new cover for the Safety Control Board Mount all the connectors again according to the sticker on the cover and photo below The USB stick should be plugged into the blue USB port Softwar...

Page 70: ...programs all of the following files urp txt script installation variable old Detailed description on backup of data can be found in backup of data If the old CB 3 0 motherboard is defective use a flas...

Page 71: ...This can also be found in the About menu Shortcut to About by clicking on the UR logo in the top right corner of the screen is available from software version 3 2 18642 2 Shut down the controller and...

Page 72: ...Remove the 14 screws holding the board in place 6 Replace Safety Control Board with new one and tighten the 14 screws to fasten the board in place 7 Insert all connectors and plugs back into their co...

Page 73: ...the guidelines laid out in section Handling ESD sensitive parts NOTE Use the same procedure for power down and removing the aluminum cover plates as in chapter Replacement of Motherboard 3 0 Replaceme...

Page 74: ...complete shutdown Follow the first 3 steps in section 5 3 7 Complete rebooting sequence When completing the following replacement please follow the guidelines laid out in section Handling ESD sensiti...

Page 75: ...bracket by removing the 8 torx screws and that hold it in place 3 Pull the two plates apart Service Manual 69 UR5 5 Service and Replacement of parts Copyright 2009 2021 by Universal Robots A S All rig...

Page 76: ...ginal Control Box WARNING Before replacing ANY components inside the control box it is IMPORTANT to do a complete shutdown Follow the first 3 steps in section Complete rebooting sequence When completi...

Page 77: ...Detach the controller box handle by removing the 2 screws holding it in place 3 Disconnect the 2 wires for the energy eater and fan 4 Remove the 2 nuts M6 in the bottom of controller module 5 Gently t...

Page 78: ...tor The module is not loose from the controller 10 Power supplies are located in the rack under the controller module the two 48V power supplies are the lower ones in the rack UR3 and UR5 has one and...

Page 79: ...te making sure to mount it correctly and fix into place with the screws 16 Connect power and verify that teach pendant works properly Merge Control Box WARNING Before replacing ANY components inside t...

Page 80: ...in chapter Replacement of Motherboard 3 0 Replacement of Motherboard 3 1 or Replacement of Safety Control Board 1 Remove teach pendent cable see previous section 2 Disconnect all the marked wires fro...

Page 81: ...erclockwise and place it on the controller edge 6 Cut the cable tie that ties the robot cable unplug the connectors from the Safety Control Board and remove the cable 7 Turn the module 180 clockwise a...

Page 82: ...rack UR3 and UR5 has one and UR10 has two 48V power supplies Before removing the 48V power supply label the wires then disconnect them from that supply 10 Remove the screws keeping the defective 48V p...

Page 83: ...do a complete shutdown Follow the first 3 steps in section Complete rebooting sequence When completing the following replacement please follow the guidelines laid out in section Handling ESD sensitiv...

Page 84: ...ount it correctly and fix it in place with the 5 screws 6 Connect power and verify that teach pendant functions correctly 5 3 8 Replacement of Current distributor WARNING Before replacing ANY componen...

Page 85: ...t board 3 Replace current distributor with new one 4 Reconnect the wires for the current distributor 5 Re install controller module in reverse order and connect the 2 wires for the fan and cables for...

Page 86: ...on the robot was produced with 2 We advise you only to update if you can benefit from the new features or the fixed issues 3 We advise you to thoroughly read the release notes before performing an upd...

Page 87: ...left side menu select Update Robot 7 Press button Search to search for software update files on USB stick 8 Select the desired software update and press UPDATE Service Manual 81 UR5 6 Software Copyri...

Page 88: ...pdate caused by improper operation Software version 3 1 16828 and newer When the software is updated on a robot the firmware is automatically updated After replacement of a joint on a robot the firmwa...

Page 89: ...UNIVERSAL ROBOTS logo on main screen of PolyScope 2 Enter password lightbot and press OK 3 You are now in Expert Mode press Low Level Control Service Manual 83 UR5 6 Software Copyright 2009 2021 by Un...

Page 90: ...lly Controller MUST NOT be powered off during this update 7 After successful update press Back 8 Back in Expert Mode press Return to Normal 9 Firmware has now been updated 6 3 Using Magic files For ea...

Page 91: ...x_1etc 3 Insert USB stick into USB connector on right hand side of teach pendant 4 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...

Page 92: ...tition driver Ext2Fsd but other windows Linux reader can be used as well these are however not tested by Universal Robots 6 4 3 How to Access Linux Partition from Windows Download and install Ext2Fsd...

Page 93: ...n card reader and the UR USB in one of the computers USB ports 2 CB3 Open windows explorer navigate to the CF card open the folder programs select all the files in the folder right click and select Co...

Page 94: ...3 Navigate to the UR USB right click on the folder programs and select Paste UR5 88 Service Manual 6 Software Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 95: ...4 Navigate to the root folder on the CF Card Service Manual 89 UR5 6 Software Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 96: ...UR5 90 Service Manual 6 Software Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 97: ...ghlighted in yellow then right click and select Copy If the urpass file or ursafetypass file is not visible on the CF card then the files don t need to be saved Service Manual 91 UR5 6 Software Copyri...

Page 98: ...click on the folder root and select paste 7 A prompt will popup when the files are being copied in the prompt choose Copy and replace UR5 92 Service Manual 6 Software Copyright 2009 2021 by Universal...

Page 99: ...e checkbox marked yellow 9 All required files are copied UR USB can now be inserted in new motherboard and booted Service Manual 93 UR5 6 Software Copyright 2009 2021 by Universal Robots A S All right...

Page 100: ...On the Safety Control Board Processor A A uP SafetySys1 On the Safety Control Board Processor B B uP SafetySys2 PSU Power Supply PC Controller LVD Low Voltage Detected Error code Description Explanati...

Page 101: ...ence c Replace Safety Control Board C4A3 Communication with Safety Control Board B uP lost Same as C4A2 C4A4 Communication with primary Teach Pendant uP lost a Check RS485 12V connection between Mothe...

Page 102: ...that the communication cables are connected properly b Do a Complete rebooting sequence C4A13 Communication with joint 1 lost More than 1 package lost Same as C4A12 C4A14 Communication with joint 2 lo...

Page 103: ...s C4A12 C4A74 Lost package from joint 4 Serial communication problem with one or more joints Same as C4A12 C4A75 Lost package from joint 5 Serial communication problem with one or more joints Same as...

Page 104: ...counter disagreement in packet from joint 1 More than 1 package lost Same as C4A12 C4A88 Packet counter disagreement in packet from joint 2 More than 1 package lost Same as C4A12 C4A89 Packet counter...

Page 105: ...ipment C10A Controller communication issue C10A1 Lost packet from Controller C10A101 Controller packet received too early C10A102 Packet counter does not match C10A103 Controller is sending packets to...

Page 106: ...han two times in a row replace joint C29A Online Calibration data checksum failed a Do a Complete rebooting sequence b If this happens more than two times in a row replace joint C30A Master received d...

Page 107: ...ing Fault C39A1 Max current deviation failure a Do a Complete rebooting sequence b If this happens more than two times in a row replace joint C39A2 Max joint encoder speed exceeded Same as C39A1 C39A3...

Page 108: ...imit joint EMC issue external or electronics internal Check grounding and shielding for EMC problems C41A RC Oscillator Trim register hit high limit C42A RC Oscillator Trim register hit low limit C43A...

Page 109: ...ning C49A200 Secondary RS485 bus is down Bus for Teach Pendant Processor A and Processor B on Control Board Check TCP IP 12V cable to Teach Pendant C50A Robot powerup issue Electrical error control bo...

Page 110: ...oard C50A19 Warning Waiting for a valid euromap67 activated status bit from secondary Safety Control Board C50A20 5V 3V3 or ADC error 5V too high C50A21 5V 3V3 or ADC error 5V too low C50A22 Robot cur...

Page 111: ...above threshold C50A53 58V generator deviation error C50A54 5V regulator too low C50A55 5V regulator too high C50A56 4V generator too low C50A57 4V generator too high C50A80 Last CPU reset caused by L...

Page 112: ...acceptable level C50A104 The IMMI module does not respond C51A CRC check failure on secondary bus C51A0 Processor B C51A1 Primary screen processor CRC check failure on safety processor 1 in Teach Pend...

Page 113: ...butor or 48V Power supply and Current distributor for issues b Do a Complete rebooting sequence C55A33 Safety relay error a relay is stuck Current distributor error a Check cable from Control Board to...

Page 114: ...ebooting sequence b If this happens more than two times in a row replace Control Board C55A90 Bootloader error robot voltage too low or current too high C55A91 Bootloader error robot voltage too high...

Page 115: ...coder not calibrated C59A Overcurrent shutdown Overcurrent in joint Argument Current in Amps a Check for short circuit b Do a Complete rebooting sequence c If this happens more than two times in a row...

Page 116: ...r on joint communication error a Check for short circuit b Do a Complete rebooting sequence c If this happens more than several times in a row replace joint C70A Close to gearbox shear limit Accelerat...

Page 117: ...rminals or defect PCB a Check joint for damaged or loose connections b Replace the joint C71A10 Phase 1 is unconnected or not working The motor wires are damaged bad connection in screw terminals or d...

Page 118: ...48V or UR10 flash card in UR5 robot Check power connection between power supply and Control Board and check that the flash card and robot match C72A3 2 PSUs active but we expect 1 UR5 UR5 flash card i...

Page 119: ...row replace joint C75A2 Speed reading is not valid a Do a Complete rebooting sequence b If this happens more than two times in a row replace joint C75A4 System error malfunction or inconsistent calib...

Page 120: ...r very heavy electrical noise C77A Sudden position change detected on the joint encoder The position reading from the encoder was different than expected C78A Large sudden position change detected on...

Page 121: ...oad and mounting settings C115A Unknown robot type The robot type specified in the configuration is unknown C116A Realtime part warning Possible CPU overload due to structure of user program Restructu...

Page 122: ...ity and acceleration settings Log screen may contain additional information Check payload center of gravity and acceleration settings C153A3 wrist 1 Check payload center of gravity and acceleration se...

Page 123: ...Freedrive mode The robot may move unexpected due to wrong settings Verify that the TCP configuration and mounting in the used installation is correct C157A Protective Stop Collision detected by joint...

Page 124: ...Make sure no objects are in the path of the robot and resume the program C157A5 wrist 3 Check payload center of gravity and acceleration settings Log screen may contain additional information Make sur...

Page 125: ...are correctly specified C158A5 wrist 3 The user specified payload is 0kg please make sure this is correct Specifying an incorrect payload mass and or center of gravity may cause poor robot performance...

Page 126: ...is correct Specifying an incorrect payload mass and or center of gravity may cause poor robot performance and or protective stops Make sure the specified payload mass and center of gravity are correct...

Page 127: ...rformance and or protective stops Make sure the specified payload mass and center of gravity are correct C171A Issue with blends C171A0 A MoveC waypoint were skipped due to a blend The value for the b...

Page 128: ...hoose waypoints that are further apart C171A12 Overlapping Blends in a MoveL a waypoint was skipped Decrease the blend radius or choose waypoints that are further apart C171A13 Overlapping Blends in a...

Page 129: ...tion causes too high joint torques on Shoulder Problem identified in program Same as C173A0 C173A8 Robot motion causes too high joint torques on Elbow Problem identified in program Same as C173A0 C173...

Page 130: ...ump in joint torques on Wrist 2 C174A5 Robot motion causes too high jump in joint torques on Wrist 3 C174A6 Base Problem identified when executing program on a specified line C174A7 Shoulder Problem i...

Page 131: ...warm up Same as C187A1 C191A Safety system violation C191A1 Joint position limit violated The maximum range has been exceeded C191A2 Joint speed limit violated The maximum speed has been exceeded C191...

Page 132: ...bot moves while in this mode a Check if the robot is physically pushed while safeguard stopped b Check TCP configuration payload and mounting settings C191A16 Robot did not stop in time C191A17 Receiv...

Page 133: ...mum stop time a Check that max payload of the robot has not been exceeded b Check TCP configuration payload and mounting settings C191A29 System Emergency Stop exceeded maximum stop time a Check that...

Page 134: ...s connections to these devices C192A3 System emergency stop disagreement System E stop circuit problem Check safety devices and cables connections to these devices C192A4 Safeguard stop disagreement S...

Page 135: ...disagreement Safety I O uP A and uP B disagreement Check safety devices and cables connections to these devices C192A15 Reduced mode output disagreement Safety I O uP A and uP B disagreement Check sa...

Page 136: ...devices C192A27 Safeguard stop output disagreement Check safety devices and cables connections to these devices C192A28 Robot not stopping output disagreement Check safety devices and cables connecti...

Page 137: ...40 Operation mode switch input disagreement C193A One of the nodes is in fault mode C193A0 Base Joint a See previous error b Update the firmware on the joint c Do a Complete rebooting sequence C193A1...

Page 138: ...ocessor 1 in Teach pendant a See previous error b Do a Complete rebooting sequence C193A8 Screen 2 Control Board has detected an error on Safety processor 2 in Teach pendant a See previous error b Do...

Page 139: ...r loose communication cable C194A132 Wrist 2 not ready while brake release requested Must be at least in IDLE mode when the brake release is requested Check for loose communication cable C194A133 Wris...

Page 140: ...ected an error a Do a Complete rebooting sequence b If this happens more than two times in a row replace Safety Control Board C200A5 Register test failed Safety Control Board uP A has detected an erro...

Page 141: ...ete rebooting sequence b If this happens more than two times in a row replace Safety Control Board C200A13 3v3 voltage too high Safety Control Board uP A has detected an error a Do a Complete rebootin...

Page 142: ...ply current distributer energy eater and Control Board for issues C200A20 24V IO voltage is too low a Do a Complete rebooting sequence b Disconnect I O check external power supply if connected and che...

Page 143: ...en received a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C201A1 SCB uA is not responding No data or invalid data was recei...

Page 144: ...obot b Check TCP configuration payload and mounting settings C204A3 Sudden stop The program contains motions that are not ramped correctly down To abort a motion use stopj or stopl script commands to...

Page 145: ...206A5 Target joint speed does not match target joint position change Wrist 3 C207A Fieldbus input disconnected Check fieldbus connections RTDE ModBus EtherNet IP and Profinet or disable the fieldbus i...

Page 146: ...s The calibration checksum stored in the calibration conf does not match the values from the joint s If moving a program from a different robot to this one re kinematic calibrate the second robot to i...

Page 147: ...e the second robot to improve kinematics otherwise ignore this message C214A6 The Kinematic Calibration checksum does not match for Wrist 3 checksum The calibration checksum stored in the calibration...

Page 148: ...ove them C218A A thread used a lot of time There may be an infinite loop or other command that does not move the robot this can cause program overload Add a Wait command or sync script to split long p...

Page 149: ...booting sequence b Update robot Software c Reimage SD card d Contact your local Universal Robots service provider for assistance C260A Brake Release Brake release not responding properly a Check the b...

Page 150: ...Robots service provider for assistance C263A Motor Encoder C263A0 to C263A31 Critical error on Motor Encoder A critical error occurred in the Motor Encoder a Do a Complete rebooting sequence b Update...

Page 151: ...ss running behind a Check that the program and client interface is not taking unnecessary resources C271A1 to C271A5 Runtime is too much behind One of the threads might be using too much time Consider...

Page 152: ...r local Universal Robots service provider for assistance C273A5 Disagreement on Safety Control Board State A critical disagreement occurred within the safety system a Do a Complete rebooting sequence...

Page 153: ...fety system a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C273A12 Disagreement on Teach Pendant State A critical disagreeme...

Page 154: ...isagreement occurred within the safety system a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C273A19 Torque Window disagreem...

Page 155: ...red within the safety system a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C273A26 Maximum stopping time disagreement A cri...

Page 156: ...disagreement occurred within the safety system a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C273A33 Momentum disagreement...

Page 157: ...ment occurred within the safety system a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C273A40 Disagreement on motor paramete...

Page 158: ...nfiguration version minor a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C273A47 Disagreement on state A critical disagreeme...

Page 159: ...eement A critical disagreement occurred within the safety system a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C273A54 Cros...

Page 160: ...rror occurred in the servo module a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C279A Flash in joint C279A0 to C279A20 Crit...

Page 161: ...the Fault State a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C281A4 Joint entered the Violation State a Do a Complete reb...

Page 162: ...payload TCP and CoG matches your configuration c Update software d Contact your local Universal Robots service provider for assistance C281A10 Robot State Machine Failed to power on the Robot arm a D...

Page 163: ...Update software c Contact your local Universal Robots service provider for assistance C281A15 IMMI entered the Violation State a Do a Complete rebooting sequence b Update software c Contact your loca...

Page 164: ...6 Systick Systick Sync unexpected SysTick timer LOAD value cpu clock cycles a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C...

Page 165: ...Systick The internal SoC count value has been resynchronized with the FPGA SoC count a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for as...

Page 166: ...er for assistance C283A10 Robot Emergency Stop Input disagreement within the safety system The input signals are not switching simultaneously or are incorrectly connected a Ensure both inputs are prop...

Page 167: ...A16 Safety system Operation Mode Switch is defined and no Three Positional Device is defined a Ensure both inputs are properly connected b Contact your local Universal Robots service provider for assi...

Page 168: ...y system Lost several safety packages in a row from other safety processor a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C2...

Page 169: ...C283A30 Safety system Trying to reapply a part of the Robot Configuraton a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C28...

Page 170: ...b Update software c Contact your local Universal Robots service provider for assistance C283A38 Robot Not Stopping Output disagreement within the safety system a Do a Complete rebooting sequence b Upd...

Page 171: ...e the mounted payload TCP and CoG matches your configuration b Slow down movements c Check safety setting d Contact your local Universal Robots service provider for assistance C283A44 The tool moved t...

Page 172: ...ed payload TCP and CoG matches your configuration b Slow down movements c Check safety setting d Contact your local Universal Robots service provider for assistance C283A49 Tool orientation limit exce...

Page 173: ...duced Mode limit is less than or equal to the Normal Mode Limit C283A55 Maximum Joint Speed of a specified joint in Reduced Mode is invalid Ensure the Reduced Mode Limit is less than or equal to the N...

Page 174: ...he Robot Moving Output The output is active when voltage is low Make sure output is not short circuited to a power supply C283A64 Tool Direction Vector Length for Normal Mode is not 1 0 Reconfigure To...

Page 175: ...ser config versions is higher than supported C283A78 Safety system The user config versions is lower than supported C283A79 Safety system Safe home position out of range C283A80 Safety system Force li...

Page 176: ...sistance C283A86 Automatic Safeguard Reset Input disagreement within the safety system The input signals are not switching simultaneously or are incorrectly connected a Ensure both inputs are properly...

Page 177: ...your local Universal Robots service provider for assistance C283A91 The Injection Molding Machine Interface System Emergency Stop Output is not active Failed to activate the System Emergency Stop Out...

Page 178: ...interference with the joints d Contact your local Universal Robots service provider for assistance C285A Joint Keep Alive System C285A0 to C285A15 Critical error A critical error occurred in the Join...

Page 179: ...t therefore the robot powered down Check connections to make sure the Tool Digital Output currents are within specified limits C289A6 Current on the POWER pin is outside of the allowed range Too high...

Page 180: ...EEPROM failed C291A4 EEPROM Read from EEPROM failed C291A5 EEPROM Verification of written data failed C291A6 EEPROM Difference in data when comparing the source and the data written C291A7 EEPROM Writ...

Page 181: ...wrong C296A Start up check C296A0 Critical error A critical error occurred during startup a Check 10A fuse b Do a Complete rebooting sequence c Update software d Contact your local Universal Robots se...

Page 182: ...up check Check the expected interval ticks C296A17 Start up check Check the measured interval ticks C296A18 Start up check Motor Kt value is outside manufacturer specifications C296A19 Start up check...

Page 183: ...disagree on Joint Size C297A4 Joint validation Joints disagree with configuration on Joint Size C297A5 Joint validation Found Joint disabled in configuration C297A6 Joint validation Joint processors d...

Page 184: ...xpectedly C299A3 RX framing error Framing error detected on received data a Check external equipment connection b Verify the communication configuration matches the hardware c Do a Complete rebooting...

Page 185: ...essage monitor Position data mismatch Same as C301A0 C301A4 Safety message monitor Revolution data mismatch Same as C301A0 C301A5 Safety message monitor Temperature data mismatch Same as C301A0 C301A6...

Page 186: ...abled Same as C301A0 C301A26 Safety message monitor Motor parameter R_pp data mismatch Same as C301A0 C301A27 Safety message monitor Motor parameter L_pp data mismatch Same as C301A0 C301A28 Safety me...

Page 187: ...nce b Update software c Contact your local Universal Robots service provider for assistance C303A System status a Do a Complete rebooting sequence b Update software c Contact your local Universal Robo...

Page 188: ...Reset caused by core LOCKUP event Same as C303A C303A18 System status Reset caused by JTAG Same as C303A C303A19 System status Unexpected core frequency configured Same as C303A C304A Self monitoring...

Page 189: ...lead has become disconnected or loose a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for assistance C305A Robot Power Control C305A0 Critic...

Page 190: ...ble between Control Box and Robot Arm is correctly connected and it has no damage c Check for loose connections d Do a Complete rebooting sequence e Update software f Contact your local Universal Robo...

Page 191: ...for assistance C305A9 The Power State was not OFF when trying to power on the Robot a Do a Complete rebooting sequence b Update software c Contact your local Universal Robots service provider for ass...

Page 192: ...instances of mismatched control package sequence numbers within last second C306A8 Joint Sanity check of control package sequence numbers recovered after detecting bad sequence numbers C306A9 Joint m...

Page 193: ...t command received a Keep Alive System message from SCB uPA C309A4 Keep Alive System A Keep Alive System message with wrong sequence received from SCB uPB C309A5 Keep Alive System Timeout reached whil...

Page 194: ...om SCB uPA C309A13 Keep Alive System Go to Violation command received in Keep Alive System message from SCB uPB C309A14 Keep Alive System Invalid command received in Keep Alive System message from SCB...

Page 195: ...not detected on the Configurable Output CO The generated OSSD pulses on the safety output were not seen during readback a Verify if safety output is not connected to any power supply or another safety...

Page 196: ...service provider for assistance C317A0 Failure injection Injecting type unexpected C317A1 Failure injection Missing handler for specified type C317A2 Failure injection Invalid data provided to specif...

Page 197: ...dpoint Data inbound timeout from specified port C323A4 SCB Endpoint Endpoint Priority data outbound timeout to specified port C323A5 SCB Endpoint Endpoint Data outbound timeout to specified port C324A...

Page 198: ...erface Moulding Area Free output readback does not match the produced value First byte produced value second byte read value Check output C330A3 Injection Molding Machine Interface 24V IO voltage outs...

Page 199: ...uration file could not be updated C332A3 Servo configuration Failed to create configuration file due to unknown PCB_type C332A4 Servo configuration Failed to acquire the motor datasheet due to unsuppo...

Page 200: ...have exceeded the safety settings watch out for high values not allowed in the robot a Check speeds and accelerations in the program b Check usage of TCP payload and CoG correctly c Check external eq...

Page 201: ...ensor is expected but no signals from the sensor can be detected a Do a Complete rebooting sequence b Check for loose connections c Check for damages to the Tool sensor d Update software e Contact you...

Page 202: ...c Contact your local Universal Robots service provider for assistance C710A0 Critical error A critical error occurred during ROM validation Same as C710A C710A1 ROM corrupted A critical error occurre...

Page 203: ...ame as C740A C740A1 1V2 voltage is outside of the allowed range Same as C740A C740A2 1V8 voltage is outside of the allowed range Same as C740A C740A3 2V5 voltage is outside of the allowed range Same a...

Page 204: ...range Same as C740A C740A20 24V SPI IO voltage 24V voltage IO is outside its limits Below 23 0V above 25 7V a Do a Complete rebooting sequence b Check for loose connections c Check for damages to the...

Page 205: ...Enabling button Check for connections problem Check 3PE functionality Same as C740A24 C900A Debug message data 7 2 LED indicators and Fuses on Safety Control Board Safety Control Board SCB 1 Fuse 48...

Page 206: ...t arm A Indicates Status for Logic A a blink sequence B Indicates status for Logic B a blink sequence 7 2 1 Normal Startup Sequence for a CB3 x UR5 1 The 12V Power supply LED is on when the power plug...

Page 207: ...s defect 2 No voltage is measured on the Safety Control Board Then measure the 230 V on the input side of the 48V power supply If the voltage pulse of 1 second is present the Power supply is defect 3...

Page 208: ...ed During Power Up 7 3 3 Protective Stop Read also article 18939 on the support site www universal robots com support UR5 202 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A...

Page 209: ...Personnel simply resetting a fault without review of why the fault has happened WARNING Ignoring protective stops masks fault detection Pay careful attention to protective stops Learn why they happen...

Page 210: ...e stops are indications of issues including program or production issues not only safety issues An application which results in daily protective stops is not designed correctly and needs to be modifie...

Page 211: ...Service Manual 205 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 212: ...7 3 5 Checklist After a Collision UR5 206 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 213: ...o Joints and Tool 7 3 7 Complete Rebooting Sequence To do a complete reboot of the robot system follow these 5 steps Service Manual 207 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A...

Page 214: ...Drawing Diagrams in pdf or in E plan format can be found on the support site www universal robots com support UR5 208 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All r...

Page 215: ...Service Manual 209 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 216: ...UR5 210 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 217: ...Service Manual 211 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 218: ...UR5 212 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 219: ...Overview Diagrams in pdf or in E plan format can be found on the support site www universal robots com support Service Manual 213 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All...

Page 220: ...UR5 214 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 221: ...Service Manual 215 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 222: ...UR5 216 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 223: ...rams Diagrams in pdf or in E plan format can be found on the support site https www universal robots com support Service Manual 217 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S Al...

Page 224: ...UR5 218 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 225: ...Service Manual 219 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 226: ...UR5 220 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 227: ...Service Manual 221 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 228: ...UR5 222 Service Manual 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 229: ...Service Manual 223 UR5 7 Troubleshooting Copyright 2009 2021 by Universal Robots A S All rights reserved...

Page 230: ...4321 Joint Size 1 Elbow UR3 124122 Joint Size 2 Base UR3 124222 Joint Size 2 Shoulder UR3 104003 Elbow counterpart and lower arm kit UR3 103305 103305 Flat ring sealing set UR5 external 103405 103405...

Page 231: ...ze 2 Wrist 2 UR10 CB3 122022 Joint Size 2 Wrist 2 UR10 CB2 122322 Joint Size 2 Wrist 3 UR10 CB3 122023 Joint Size 2 Wrist 3 UR10 CB2 122324 Joint Size 3 Elbow UR10 CB3 122034 Joint Size 3 Elbow UR10 C...

Page 232: ...cl Bypass plug and cable 123670 123670 Euromap E67 cable 6m 122671 122671 Euromap E67 Bypass Plug 122650 Motherboard kit CB2 1 and CB3 1 incl RAM 122700 Masterboard kit CB2 122420 CB2 0 to CB2 1 Mothe...

Page 233: ...crewdriver torx T10 109104 109104 Torque screwdriver torx T8 T10 109111 Torque screwdriver torx T10 109112 Torque screwdriver torx T20 109105 109105 Torque wrench hex 5 5mm Size 1 and Size 2 109106 10...

Page 234: ...173100 Cable for tool external with angle connector 173101 Cable for tool external w 90 degree connector UR5 228 Service Manual 8 Spare Parts Copyright 2009 2021 by Universal Robots A S All rights re...

Page 235: ...Universal Robots products in original Universal Robots packaging Download correct put_in_box program regarding robot type and packing material from www universal robots com support Upload the program...

Page 236: ...arm and controller box in designated boxes Make sure the robot arm is correctly orientated within the box UR5 230 Service Manual 9 Packing of Robot Copyright 2009 2021 by Universal Robots A S All righ...

Page 237: ...0 Added 3 1 19 Wire bundle installation guide December 2016 Added 3 1 4 Bolt length for joints Added Error code C71A12 Added 3 1 5 Added tolerance to Size 3 torque Corrected 5 2 LED startup sequence...

Page 238: ...n 3 1 4 August 2019 UR5_ en_3 2 4 Added Merge control box details Sep 2019 UR5_ en_3 2 5 Added More info in section 5 3 3 Protective stop Oct 2019 UR5_ en_3 2 6 Changed Title and wording in section 2...

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