Universal Robots ur3 Original Instructions Manual Download Page 91

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Servicemanual_UR3_en_rev3.1.2

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

Replace 48V power supply

During power up (within the first three seconds of

power up) measure that 230V AC is present on

48V_PSU1 connector on current distributor PCB

Power controller OFF/ON

Measure that 12V DC is present in the red

connector/flatcable on the current distributor

Replace current distributor

Check log history for error messages and consult

the section Error Codes for detailed explanation

Replace Safety Control

Board

YES

Summary of Contents for ur3

Page 1: ...Service Manual Revision UR3_en_3 1 2 Original instructions Robot UR3 with CB3 controller Valid from robot s n 2014330001 ...

Page 2: ...versal Robots check 9 3 1 2 Robot arm configuration 10 3 1 3 Brake release 11 3 1 4 General guidance to separate joint from counterpart 12 3 1 5 Torque values 17 3 1 6 Base joint Base mounting bracket 18 3 1 7 Shoulder joint Base joint 20 3 1 8 Upper arm Shoulder joint 21 3 1 9 Elbow joint Upper arm 22 3 1 10 Elbow counterpart Elbow joint 23 3 1 11 Wrist 1 joint Lower arm 25 3 1 12 Wrist 2 joint W...

Page 3: ... 61 4 1 Update software 61 4 2 Update joint firmware 63 4 3 Using Magic files 63 5 Troubleshooting 64 5 1 Error codes 64 5 2 LED indicators and Fuses on Safety Control Board 86 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 a...

Page 4: ...ts 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 progra...

Page 5: ...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 2015 by Universal Robots A S The ...

Page 6: ...tion where it is stretched out horizontally o Monitor that the robot maintains its position when not holding the robot and the Free drive button still pressed Test Back drive mode o If robot is close to collision the BACKDRIVE function can be used to move robot arm to safe position before initializing o Press ON to enable power for the joints Do NOT release the brakes o Press and hold Freedrive st...

Page 7: ...oller If any dirt dust is present Gently use a vacuum cleaner to remove particles Use a soft cloth You can add Water Isopropyl alcohol 10 Ethanol alcohol or 10 Naphtha 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 r...

Page 8: ... 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 damage Inspect flat rings for wear and damage Replace flat rings if worn out or damaged Inspect blue lids on all joints for any cracks or damage Replace blue lids if cracked or damaged Inspect that screws for blue lids are in place and properly tig...

Page 9: ...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 am...

Page 10: ...Wrist 3 joint 3 1 13 Wrist 3 joint Wrist 2 joint 3 1 12 Wrist 2 joint Wrist 1 joint 3 1 11 Wrist 1 joint Lower arm 3 1 10 Elbow counterpart Elbow joint 3 1 9 Elbow joint Upper arm 3 1 8 Upper arm Shoulder joint 3 1 7 Shoulder joint Base joint 3 1 6 Base joint Base mounting bracket Size 0 Size 0 Size 0 Size 1 Size 2 Size 2 ...

Page 11: ...nt to make proper mechanical support prior to releasing the brake Always make sure personnel are in no risk when releasing the brake Do not move the joint more than necessary Not more than about 160 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 brake pin down to release joint can then be ro...

Page 12: ... 3 Check the guide in this manual in details before you continue 2 Move the robot to a comfortable position for disassembly or if necessary dismount entire robot arm from work cell and place on a solid surface 3 Shut down the controller 4 Remove blue lid 5 Now reattach one of the screws for the blue lids to connect an alligator Clip on your ESD wristband as shown below 6 Gently unplug the cable co...

Page 13: ...r disconnecting the wires gently remove black flexible flat ring with a tiny screwdriver and twist it around the joint housing 8 Slide back the black teflon ring Marked with red 6 8 or 10 screws become visible Loosen the screws 9 Pull the two parts gently apart ...

Page 14: ... carefully clean the screws and attach Loctite 648 on the screws before assembly 3 Important note Always replace the black flexible flat ring to maintain the IP classification 4 Orientate the joints according to the marks and gently push the two joints together In the below drawing the marks are indicated with red 5 Gently tighten the 6 8 or 10 screws and then tighten in cross order with the corre...

Page 16: ...duce electrical noise in the system 9 Mount the blue lid on the joint and tighten with 0 4Nm 10 Proceed to 3 1 15 Dual Robot Calibration and Joint calibration for calibrating the Robot Twist the communication cable 1 5 to 2 full rounds before connection Twist the communication cable 1 5 to 2 full rounds before connection Twist the communication cable 1 5 to 2 full rounds before connection ...

Page 17: ...10 J2 Elbow Lower arm 1 3Nm Torx T10 Lower arm J3 Wrist 1 1 3Nm Torx T10 J3 Wrist 1 J4 Wrist 2 1 3Nm Torx T10 J4 Wrist 2 J5 Wrist 3 1 3Nm Torx T10 J5 Wrist 3 Tool mounting bracket 1 3Nm Torx T10 Tool Gripper M6 10Nm Blue lid Base Shoulder and Elbow 0 4Nm Torx T10 Blue lid Wrist 1 Wrist 2 and Wrist 3 0 4Nm Torx T8 Attention Click the torque tools 3 times before use to get the correct calibrated tor...

Page 18: ...o separate joint from counterpart 1 Shut down the controller 2 Remove black flexible flat ring with a tiny screwdriver and twist it around the joint housing 3 Slide back the black teflon ring 10 screws become visible Loosen the screws 4 Pull the Base mounting bracket and Base joint gently apart 5 Disconnect wires from the EMC filter in the Base mounting bracket ...

Page 19: ...acket and reconnect wires to the EMC filter Twist the communication cable 1 5 to 2 full rounds before it is connected To reduce electrical noise in the system 1 x red wire 48V DC 1 x black wire GND White and black bus connector 4 Orientate the joint and Base mounting bracket according to the marks and gently push them together 5 Press gently the base and base mounting bracket together to align the...

Page 20: ...esidues of old Loctite in screw holes with a M4 tap tool for threads before assembling the joint to get the correct torque on the new screws 2 Important note Always use new pre coated screws when it is possible If you have to assemble with old screws carefully clean the screws and attach Loctite 648 on the screws before assembly 3 Orientate the Base joint and Shoulder joint according to the marks ...

Page 21: ...rew holes with a M4 tap tool for threads before assembling the joint to get the correct torque on the new screws 2 Important note Always use new pre coated screws when it is possible If you have to assemble with old screws carefully clean the screws and attach Loctite 648 on the screws before assembly 3 Orientate the Shoulder joint and Upper arm according to the marks and gently push them together...

Page 22: ...crew holes with a M3 tap tool for threads before assembling the joint to get the correct torque on the new screws 2 Important note Always use new pre coated screws when it is possible If you have to assemble with old screws carefully clean the screws and attach Loctite 648 on the screws before assembly 3 Orientate the Elbow joint and Upper arm according to the marks and gently push them together 4...

Page 23: ...hut down the controller 1 Remove black flexible flat ring with a tiny screwdriver and twist it around the joint housing 2 8 screws become visible Loosen the screws 3 Pull the Elbow joint and Elbow counterpart gently apart 4 Disconnect wires Without bending the printed circuit board The power supply connector has a lock that has to be engaged before it is pulled out of the printed circuit board ...

Page 24: ...e to assemble with old screws carefully clean the screws and attach Loctite 648 on the screws before assembly 3 Reconnect connectors Twist the communication cable 1 5 to 2 full rounds before it is connected To reduce electrical noise in the system 1 x red wire 48V DC 1 x black wire GND White and black bus connector 4 Orientate the joint and Elbow counterpart according to the marks and gently push ...

Page 25: ...tband 3 Disconnect wires between Wrist 1 joint and Lower arm Without bending the printed circuit board The power supply connector has a lock that has to be engaged before it is pulled out of the printed circuit board 4 After disconnecting the wires gently remove black flexible flat ring with a tiny screwdriver and twist it around the Lower arm 5 Remove the plastic cover ring 6 screws become visibl...

Page 26: ...y 3 Orientate the Wrist 1 joint and Lower arm according to the marks and gently push them together 4 Gently tighten the 6 screws and then tighten in cross order with 1 3Nm 5 Place the plastic cover ring according to the mark on the flange On the photo the mark is indicated in red 6 Gently put the flat ring back on top of the plastic cover ring 7 Connect ESD wristband 8 Twist the communication cabl...

Page 27: ...3 Disconnect wires between Wrist 1 joint and Wrist2 joint without bending the printed circuit board The power supply connector has a lock that has to be engaged before it is pulled out of the printed circuit board 4 After disconnecting the wires gently remove black flexible flat ring with a tiny screwdriver and twist it around the joint housing 5 Remove the plastic cover ring 6 screws become visib...

Page 28: ...he screws before assembly 3 Orientate the Wrist 2 joint and Wrist 1 joint according to the marks and gently push them together 4 Gently tighten the 6 screws and then tighten in cross order with 1 3Nm 5 Place the plastic cover ring according to the mark on the flange 6 Gently put the flat ring back on top of the teflon ring 7 Connect ESD wristband 8 Twist the communication cable 1 5 to 2 full round...

Page 29: ...ls and photos please see 3 1 4 General guidance to separate joint from counterpart 1 Shut down the controller 2 Remove black flexible flat ring with a tiny screwdriver and twist it around the joint housing 3 Remove the plastic cover ring 6 screws become visible Loosen the screws 4 Connect ESD wristband 5 Pull the Tool flange and Wrist 3 joint gently apart 6 Disconnect wires Without bending the pri...

Page 30: ...rews and attach Loctite 648 on the screws before assembly 4 Reconnect connectors Twist the communication cable 1 5 to 2 full rounds before it is connected To reduce electrical noise in the system 1 x red wire 48V DC 1 x yellow wire GND White and green bus connector 5 Orientate the Tool flange and Wrist 3 joint according to the marks and gently push them together 6 Place the plastic cover ring acco...

Page 31: ...ions Performing a Dual Robot Calibration after replacement of a joint will let the robot continue in the production line without modifying waypoints in the robot program To perform a Dual Robot Calibration you need 2 robots calibration Horse and calibration tool connector Go to http www universal robots com support for downloading CalibrationManual pdf Joint calibration described in this section A...

Page 32: ... you can make a calibration of joints After this you must expect to adjust the most important waypoints Make sure that the base of the robot is horizontal 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 ...

Page 35: ...All rights reserved 35 Servicemanual_UR3_en_rev3 1 2 Select the desired joint by directly clicking the status line for that joint Press Arm current joint to release the brake on the selected joint ...

Page 36: ...6 Servicemanual_UR3_en_rev3 1 2 Use the Up and Down buttons in the Move window to navigate the joint to the correct zero position according to the following illustrations Press STOP when the joint is in the correct position ...

Page 37: ...fset 180 degree from vertical aligned if Base if horizontal the slot for cable in back of robot base Make sure that base of robot is horizontal use spirit level to align joints Wrist 2 Wrist 3 Wrist 2 zero position is aligned similar Wrist 3 zero position is aligned so tool connector to Base joint with tool flange parallel is pointing upward with wrist Mount two bolts in tool holes and use spirit ...

Page 39: ...All rights reserved 39 Servicemanual_UR3_en_rev3 1 2 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 ...

Page 40: ... 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 Press Turn power on and the connected joints turn into BOOTLOADER Press Go to Idle and the connected joints turn into READY Select Joint ID ...

Page 41: ... Servicemanual_UR3_en_rev3 1 2 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 ...

Page 42: ...be setup on the robot Recommended spare joints for UR3 are marked with Robot UR3 Wrist 3 ID 5 Size 0 Alignment mark Wrist 2 ID 4 Size 0 Wrist 1 ID 3 Size 0 Elbow ID 2 Size 1 Shoulder ID 1 Size 2 Base ID 0 Size 2 To use a wrist 3 joint as wrist 1 or wrist 2 it is necessary to modify the joint See 3 1 19 Modify wrist 3 to Wrist 1 or wrist2 ...

Page 43: ... orientation of the output flange has to be changed The joint ID has to be modified Use the ESD guidelines for the modification of the wrist see 3 2 1 Handling ESD sensitive parts The Wrist 3 has the slipring for infinite turning of the tool mounting bracket Cut the wires for the slipring Unscrew the Slipring Remove the Slipring gently ...

Page 44: ...17 Change joint ID The removed slipring with screws Parts for wrist 1 and wrist 2 Attach the plastic protection Put the wires through the joint and attach and assemble the connectors for the communication and power There is no cable tie for this joint NB Pull gently in each wire to be sure the connector is attached correct in the plastic part of the connector ...

Page 45: ...elow in addition to all the usual precautions such as turning off power before removing logic cards 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 Keep the ESD sensitive part in its original shipping container a special ESD bag until the part is ready to be installed ...

Page 46: ...cemanual_UR3_en_rev3 1 2 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 Step 1 Put OLD board into spare ESD bag Step 2 Take NEW board out of ESD bag ...

Page 47: ...f the ESD sensitive part needs to be put down for any reason then first put it into its special ESD 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 ...

Page 48: ... sensitive parts from being accidentally touched by other personnel and do not put unprotected ESD sensitive parts on a table Be extra careful in working with ESD sensitive parts when cold weather and heating is used because low humidity increases static electricity ...

Page 49: ...cement of motherboard 3 1 Take care of ESD handling 3 2 1 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 loosen the 3 Torx screws 2 Remove the aluminum cover plate ...

Page 50: ... with white brown yellow and green wires 12 V Power 2 DVI cable for TP screen 3 Ethernet cable 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 7 Remove the 4 screws from the 2 holding brackets 1 2 3 4 5 6 ...

Page 51: ...R3_en_rev3 1 2 8 Replace Motherboard 9 Insert the 6 cables in correct connectors 10 Re install USB stick for UR system SW 11 Carefully put back the aluminum cover plate make sure to mount it correct and fix it with the 3 screws 1 3 4 6 2 5 ...

Page 52: ...w to replace Safety Control Board in Controller box 1 Check that the software on the robot is as new as the firmware version on the SCB If the software on the robot is too old then you get an error C203A0 Find the SCB firmware ver on the Ethernet connector Find the firmware versions in the About menu Shortcut to About is available from software version 3 2 18642 ...

Page 53: ...d 53 Servicemanual_UR3_en_rev3 1 2 2 Shut down the controller and disconnect the power cable open the controller cabinet Carefully remove all plugs and connectors 3 Loosen the 5 Torx screws and remove the aluminum cover ...

Page 54: ...olding the Safety Control Board 6 Replace Safety Control Board with new one and tighten the 14 screws to hold the board 7 Insert all connectors and plugs in correct positions Eventually see section 5 4 1 Schematic overview 8 Carefully attach the aluminum cover make sure to mount it correct and fix it with the 5 screws ...

Page 55: ...4 cables 1 Red plug with black cable 12 V Power 2 Black DVI cable for the TP screen 3 Black USB cable For the TP USB connector 4 Black cable for RS232 connection for the TP touchscreen 2 Remove the bracket foot of the controller box that holds the cable inlet and pull out the cables and plugs through this hole 3 Replace teach pendant with new insert cable in cable inlet and perform reconnection of...

Page 56: ... to replace 48V power supply in Controller box Note use the same procedure for power down and removing the aluminum covers as in Chapter 3 2 2 Replacement of motherboard 3 1 and 3 2 3 Replacement of Safety Control Board SCB 1 Remove the handle on Controller box by loosen the 2 screws holding it 2 Removes the black and orange wires for the energy eater fan ...

Page 57: ...out the controller module from the Controller box 5 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 have one and the UR10 have two 48V power supplies Before dismounting the 48V power supply mark and disconnect the cables from that supply ...

Page 58: ...e 48V power supply with new one 8 Reconnect the wires for the 48V power supply 9 Re install Controller module in reverse order and connect the 2 wires for the fan and cables for the teach pendant 10 Carefully put back the aluminum cover make sure to mount it correct and fix it with the screws 11 Connect power and verify that teach pendant works properly ...

Page 59: ...r supply follow exactly the same steps as for the procedure in chapter 3 2 5 Replacement of 48V power supply 1 The 12V power supply is placed in top of rack The screws holding it in the frame are placed on the sides 2 Replace 12V power supply with new one 3 Reconnect the wires for the 12V power supply 4 Re install Controller module in reverse order and connect the 2 wires for the fan and cables fo...

Page 60: ...ment of teach pendant 1 Current distributor is placed on top of rack 2 Before dismounting the current distributor mark and disconnect the cables from the circuit 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 the teach pendant 6 Carefully put back t...

Page 61: ...te in order to avoid surprises caused by changed or added functionality In case of concerns related to your actual or planned applications please contact your supplier for advice and assistance Follow the instructions in the guide in the download section of the support web site Find it under universal robots com support Instructions to update software 1 Download software update Carefully read requ...

Page 62: ...bot 7 Press button Search for searching after software update on USB stick 8 Select the found software update and press UPDATE 9 Press YES to update the software 10 Wait for update to complete after successful update controller will automatically power off 11 Remove USB stick and boot robot ...

Page 63: ...tick is inserted Go to http www universal robots com support to download Magic files Instruction for using Magic files 1 Download Magic file 2 Save it in the root folder on a USB stick 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 until after the last file has been run Multiple folders will be create...

Page 64: ...sor A or processer B is communicating the Safety Control Board or cable between the Motherboard and Safety Control Board is defect a Check TCP IP connection between Motherboard and Safety Control Board b Exchange Safety Control Board CODE_4A3 Communication with Safety Control Board B uP lost If either processor A or processer B is communicating the Safety Control Board or cable between the Motherb...

Page 65: ...ed Incorrect safety configuration Update the miscellaneous settings in the Safety Configuration CODE_4A12 Communication with joint 0 lost More than 1 package lost CODE_4A13 Communication with joint 1 lost More than 1 package lost CODE_4A14 Communication with joint 2 lost More than 1 package lost CODE_4A15 Communication with joint 3 lost More than 1 package lost CODE_4A16 Communication with joint 4...

Page 66: ...l Board B CODE_4A86 Packet counter disagreement in packet from joint 0 CODE_4A87 Packet counter disagreement in packet from joint 1 CODE_4A88 Packet counter disagreement in packet from joint 2 CODE_4A89 Packet counter disagreement in packet from joint 3 CODE_4A90 Packet counter disagreement in packet from joint 4 CODE_4A91 Packet counter disagreement in packet from joint 5 CODE_4A92 Packet counter...

Page 67: ...PC Communication error between Safety Control Board and Motherboard Check ethernet connection between circuit boards Eventually update the software CODE_26 Motor Encoder index drift detected Joint mechanical problem Replace joint CODE_27 Calibration data is invalid or does not exist selftest is needed CODE_29 Online Calibration data checksum failed Calibration data is not in the joint a Power OFF ...

Page 68: ...r voltage too high Replace joint CODE_39A100 Watchpoint fault ADC task timeout CODE_39A101 Watchpoint fault Motor Control task timeout CODE_39A102 Watchpoint fault Motor encoder task timeout CODE_39A103 Watchpoint fault Joint encoder task timeout CODE_39A104 Watchpoint fault Communication task timeout CODE_39A105 Watchpoint fault RAM test task timeout CODE_39A106 Watchpoint fault CalVal test task ...

Page 69: ...der mounting Replace joint CODE_47 AD Converter hit low limit EMC issue external or electronics internal a Check grounding and shielding for EMC problems b Replace Item CODE_48 Powerbus voltage drop detected Error on 48V powerbus to robot arm Check 48V output from PSU Check current distributor PCB Replacement of 48V PSU or current distributor is necessary CODE_49 RS485 receive warning CODE_49A200 ...

Page 70: ... This error can have several root causes and you have to measure the voltage some places There are 3 different components that could be the root cause and you have to measure the voltage to determine which one of them that is the faulty one 48 V power supply Current distributor Safety Control Board Find the schematic drawing in the this service manual CODE_50A25 Robot voltage present at 48V PSU po...

Page 71: ...pe Look for short circuit In cable and in robot arm CODE_50A102 Voltage rising too slowly Robot Problem 48V CODE_50A103 Voltage failed to reach acceptable level Robot Problem 48V CODE_51 CRC check failure on secondary bus CODE_51A0 Processor B CODE_51A1 Primary screen processor CODE_51A2 Secondary screen processor CODE_51A3 Primary E67 CODE_51A4 Secondary E67 CODE_53 IO overcurrent detected Safety...

Page 72: ...t disappear from robot SCB hardware fault Replace Safety Control Board SCB CODE_55A52 5V 3V3 or ADC error 5V too low SCB hardware fault Replace Safety Control Board SCB CODE_55A53 5V 3V3 or ADC error 5V too high SCB hardware fault Replace Safety Control Board SCB CODE_55A90 Bootloader error robot voltage too low or current too high CODE_55A91 Bootloader error robot voltage too high CODE_55A100 Saf...

Page 73: ...ear related to encoder mounting Reduce acceleration in user program Replace joint if necessary CODE_71 Startup check error Fault Firmware in joint CODE_71A1 Hardware is size1 software is not Fault Firmware in joint CODE_71A2 Hardware is size2 software is not Fault Firmware in joint CODE_71A3 Hardware is size3 software is not Fault Firmware in joint CODE_71A4 Hardware is size4 software is not Fault...

Page 74: ...4A2 Speed reading is not valid Warning The argument is the sum of C74 errors CODE_74A4 System error malfunction or inconsistent calibration detected Warning The argument is the sum of C74 errors CODE_74A8 Supply voltage is out of range Warning The argument is the sum of C74 errors CODE_74A16 Temperature is out of range Warning The argument is the sum of C74 errors CODE_74A64 Signal low Too far fro...

Page 75: ...ise CODE_77 Sudden position change detected on the joint encoder The position reading from the encoder was different than expected CODE_78 Large sudden position change detected on the joint encoder The position reading from the encoder was severely different than expected the latest measurement was discarded Contact your local service provider for assistance CODE_78A255 Large sudden position chang...

Page 76: ... cannot move linear in a singularity Use jointspace movement or change the motion CODE_155 Protective Stop Robot cannot maintain its position check if payload is correct CODE_156 Protective Stop Wrong payload or mounting detected or something is pushing the robot when entering Freedrive mode The robot may move unexpected due to wrong settings Verify that the TCP configuration and mounting in the u...

Page 77: ...blend radius is too large compared to the distance between the waypoints Decrease the blend radius or choose waypoints that are further apart CODE_171A4 Overlapping Blends in a MoveJ a waypoint was skipped Decrease the blend radius or choose waypoints that are further apart CODE_171A5 Overlapping Blends in a MoveJ a waypoint was skipped Decrease the blend radius or choose waypoints that are furthe...

Page 78: ...joint CODE_191A4 TCP position limit violated CODE_191A5 TCP orientation limit violated CODE_191A6 Power limit violated Reduce acceleration or speed for joint CODE_191A7 Joint torque window violated CODE_191A8 Joint torque window too large CODE_191A9 Reduced mode output violation CODE_191A10 Safeguard stop output violation CODE_191A11 Emergency stop output violation CODE_191A12 Momentum limit viola...

Page 79: ...high payload CODE_191A31 Operation mode switch is present while the three position switch is missing CODE_192 Safety system fault CODE_192A1 Robot still powered in emergency stop When emergency stop is active the robot arm powers off The controller is responsible for sending the power off command This error is generated if the safety system detects that the robot arm still has power CODE_192A2 Rob...

Page 80: ...ly CODE_192A21 Momentum disagreement CODE_192A22 Robot moving output disagreement Safety I O uP A and uP B disagreement Check Cables and Software error on motherboard CODE_192A23 Wrong processor ID CODE_192A24 Wrong processor revision CODE_192A25 Potential brownout detected Voltage drop on Safety Control Board SCB or defect SCB CODE_192A26 Emergency stop output disagreement Safety I O uP A and uP ...

Page 81: ...CODE_193A4 Joint 4 is in fault mode SCB has detected an error See previous error or update the firmware on the joint or reboot system CODE_193A5 Joint 5 is in fault mode SCB has detected an error See previous error or update the firmware on the joint or reboot system CODE_193A6 Tool is in fault mode SCB has detected an error See previous error or reboot system CODE_193A7 Screen 1 is in fault mode ...

Page 82: ...hen the brake release is requested 1 Check for loose communication cable 2 replace Wrist 1 CODE_194A132 Joint 4 not ready while brake release requested Must be at least in IDLE mode when the brake release is requested 1 Check for loose communication cable 2 replace Wrist 2 CODE_194A133 Joint 5 not ready while brake release requested Must be at least in IDLE mode when the brake release is requested...

Page 83: ...cted an error Replace Safety Control Board SCB CODE_200A12 3V3 voltage too low SCB uP A has detected an error Replace Safety Control Board SCB CODE_200A13 3v3 voltage too high SCB uP A has detected an error Replace Safety Control Board SCB CODE_200A14 48V input is too low Check 48 V power supply current distributer energy eater or replace SCB CODE_200A15 48V input is too high Check 48 V power supp...

Page 84: ...tware version is the same or newer than the firmware on the safety control board Reload the installation and re boot the robot CODE_204A0 Protective Stop Invalid setpoint CODE_204A1 Sudden change in target position CODE_204A2 Inconsistency between target position and speed CODE_204A3 Sudden stop The program contains motions that are not ramped correctly down To abort a motion use stopj or stopl sc...

Page 85: ...et joint position Joint 2 Elbow CODE_206A3 Target joint speed does not match target joint position Joint 3 Wrist 1 CODE_206A4 Target joint speed does not match target joint position Joint 4 Wrist 2 CODE_206A5 Target joint speed does not match target joint position Joint 5 Wrist 3 CODE_207 Fieldbus input disconnected Check fieldbus connections or disable the fieldbus in the installation ...

Page 86: ...f the 24 V is from the controller or external power supply LED indicators 12V PSU On when the power plug is connected 12V System On when the power on has been activated 5V On when 12 V System is on and indicate that 5 V is ok 4V On when 12 V System is on and indicate that 4 V to analog I O is ok 3V3A On when 5V is on and indicate 3 3 V for logic Safety circuit A 3V3B On when 5V is on and indicate ...

Page 87: ...ence you should measure the voltage See the E Plan diagram 5 4 1 Schematic overview 3 1 Measure the 48V on the Safety Control Board SCB where the 48V comes from the Current distributor And check this 1 second pulse 3 1 1 The voltage is measured on the Safety Control Board That means the Safety Control Board is defect 3 1 2 No voltage is measured on the Safety Control Board Then measure the 230 V o...

Page 88: ... CONTROLLER displayed at INITIALIZING screen Defective Safety Control Board Replace Safety Control Board and verify problem is solved Replace Ethernet cable between motherboard and Safety Control Board and verify problem is solved Replace motherboard and verify problem is solved Defective motherboard YES YES NO NO Defective Ethernet cable YES ...

Page 89: ...n the right side of the Safety Control Board See LED indicators and Fuses on Safety Control Board Measure that 230V AC is present on power input connector on 12V power supply During power up within first few seconds check that the 48 V LED and R LED are lid before they turns off again The no 3 and no 5 LED from the bottom on the Safety Control Board Replace Safety Control Board Replace motherboard...

Page 90: ...obot can not operate Adjust waypoints away from this area or reduce speed acceleration YES NO Adjust payload and tcp settings YES Adjust center of mass using script code set_payload YES NO Is robot moving with excessive speed or accelerating very hard Reduce speed or acceleration YES NO Press free drive button on back of TP and check the free drive function of all joints observe any abnormal frict...

Page 91: ...ilure with a joint or the tool Control box failure Replace 48V power supply During power up within the first three seconds of power up measure that 230V AC is present on 48V_PSU1 connector on current distributor PCB Power controller OFF ON Measure that 12V DC is present in the red connector flatcable on the current distributor Replace current distributor Check log history for error messages and co...

Page 92: ...te of tool switch from OFF to ON Go to LOW LEVEL CONTROL in EXPERT MODE consult chapter 4 2 for how to access EXPERT MODE Does state of tool switch to READY Replace tool Check log history for error messages and consult the section Error Codes for detailed explanation NO YES Unmount tool and check black comm connector is fully inserted in printed circuit board YES NO Continue to next page ...

Page 93: ...N POWER ON and Go to Idle and Arm robot Does state of all joints J0 J5 switch from Power OFF to READY Does state of joint switch to READY Replace joint NO YES YES Remove blue lid of joint and check black comm connector is fully inserted Continued NO Communication ok to joints and tool ...

Page 94: ...ss free drive button on back of TP and check the free drive function of all joints any abnormal friction or behavior observed Inspect joint with abnormal behavior Check log history for error messages and consult the section Error Codes for detailed explanation YES YES NO NO Press free drive button on back of TP and check the free drive function of all joints any excessive noise observed YES NO Ins...

Page 95: ... rights reserved 95 Servicemanual_UR3_en_rev3 1 2 5 4 Electrical drawing 5 4 1 Schematic overview Diagrams in pdf or in E plan format can be found on the support site http www universal robots com support ...

Page 100: ...All rights reserved 100 Servicemanual_UR3_en_rev3 1 2 5 4 2 E Plan diagrams Diagrams in pdf or in E plan format can be found on the support site http www universal robots com support ...

Page 113: ...B 122745 Energy eater incl fan 164228 Connector Epic w cable UR3 Controller output connector to robot arm 171031 RAM module DDR3L 177503 Filter kit for controller 106800 Euromap E67 kit CB3 122671 Euromap E67 Bypass Plug 122673 Euromap E67 module CB3 123670 Euromap E67 cable 6 m Robot arm 122030 Base Mounting Bracket incl Cable 6 m UR3 124122 Joint Size 2 Base UR3 124222 Joint Size 2 Shoulder UR3 ...

Page 114: ...on 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...

Page 115: ...obot 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 3 1 3 Brake release Power down disconnect power and disconnect robot arm f...

Page 116: ...ngelog 8 1 Changelog Date Revision Action Changes 20 Marts 2015 UR3_en_3 1 1 Added Revision 3 1 1 released December 2015 UR3_en_3 1 2 Added More details for replacements of parts additional error codes Updated Electrical drawings Torque value for elbow changed ...

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Universal Robots ur3, Original Instructions Manual

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