User Manual - Universal Robots Support
Contents
1. If the available current from the internal power supply is not enough simply use an external power supply as shown above 2 4 2 Digital Inputs Parameter Min Typ Max Unit Input voltage 30 30 V Input guaranteed OFF if 30 7 V Input guaranteed ON if 10 30 V Guaranteed OFF if 0 5 mA ON Current 10 30V 6 10 mA The digital inputs are implemented as pnp which means that they are ac tive when voltage is applied to them The inputs can be used to read buttons sensors or for communication with other PLC systems The inputs are compliant with all three types of digital inputs defined in IEC 61131 2 and EN 61131 2 which means that they will work together with all types of digital outputs defined in the same standards Technical specifications of the digital inputs are shown below Digital Input Simple Button 24V gav d 24V sie 24V DIO D11 Di2 d DIS sl oe en Button The above example shows how to connect a simple button or switch Digital Input Simple Button External Power por e The above illustration shows how to connect a button using an external power source All Rights Reserved 23 URS U2. Connecting an External Emergency Stop Button TA B A TB E01 02 03 E04 EA EB EEA EEB In almost every robot application it is required to connect one or more exter nal emergency stop buttons Doing so is simple and easy An example of how to connect one extra button is shown above Connecting Emergency Stop to Other Machinery When the robot is used together with other electro mechanical machinery it is often required to set up a common emergency stop circuit This ensures that if a dangerous situation arises the operator does not need to think about which buttons to use It is also often preferable for every part of a sub function in a product line to be synchronized since a stop in only one part of the product line can lead to a dangerous situation An example with two UR robots emergency stopping each other is shown below TA TB TAS TBS EOY EO2 Eo3ffE04 TA TB XIA B 01 E02 03 E04 An example where multiple UR robots share their emergency stop function is shown below Connect more robots as robot number 2 is connected This example uses 24V which works with many other machines Make sure to comply with all electrical specifications when
3. Rotate joints individually if necessary f 90n Robot Power Robot Auto OK D B Aut POWER OFF ase m m d r po Should Aut POWER OFF oulder 2 gt uto 5 Elb Aut POWER OFF ow e jL o l Wrist 1 Aut POWER OFF gt Les E m i Wrist 2 Aut POWER OFF ris m hauto Wrist 3 Auto POWER OFF eje E Tool POWER OFF o ControlBox CONNECTING D 2 OK Figure 1 1 The initialization screen 1 2 4 Shutting Down the Robot The power to the robot can be turned off by touching the OFF button at the initialization screen Most users do not need to use this feature since the robot is automatically turned off when the controller box is shutting down 1 2 5 Shutting Down the Controller Box Shut down the system by pressing the green power button on the screen or by using the Shut Down button on the welcome screen Shutting down by pulling the power cord out of the wall socket may cause corruption of the robot s file system which may result in robot malfunction 1 3 Quick start Step by Step To quickly set up the robot perform the following steps l 2 3 4 Cc Unpack the robot and the controller box Mount the robot on a sturdy surface Place the controller box on its foot Plug the robot cable into the connector at the bottom of the controller box Plug in the mains plug of the controller box Press the Emergency Stop button on the front side of the teach pendant
4. 2 Disclaimer All Rights Reserved 36 URS Chapter 5 Declaration of Incorporation 5 1 Introduction According to the machinery directive 2006 42 EC the robot is considered a partly completed machine The following subsections Corresponds to and are in accordance with annex Il of this directive 5 2 Product manufacturer Name Universal Robots A S Address Sivlandvaenget 1 5260 Odense S Denmark Phone number 45 8993 8989 E mail address 5 3 Person Authorised to Compile the Technical Documen tation Name Lasse Kieffer Address Sivlandvaenget 1 5260 Odense S Denmark Phone number 45 8993 897 E mail address kieffer universal robots com 5 4 Description and Identification of Product The robot is intended for simple and safe handling tasks such as pick and place machine loading unloading assembly and palletizing 37 sales universal robots com International VAT number DK29138060 UNIVERSAL ROBOTS 5 5 Essential Requirements Generic denomination URS Function General purpose industrial robot Model URS Serial number of robot arm Serial number of control box Commercial name UR5 5 5 Essential Requirements The individual robot installations have different safety requirements and the in tegrator is therefore responsible for all hazards which are not covered by the general design of the robot However the general
5. 5 Important Notice a 40 EE EEEE E E E eee ee E 40 5 9 Identity and Signature of the Empowered Person Al 43 All Rights Reserved 4 URS Chapter 1 Getting started 1 1 Introduction Congratulations on the purchase of your new Universal Robot URS The robot is a machine that can be programmed to move a tool and com municate with other machines using electrical signals Using our patented pro gramming interface PolyScope it is easy to program the robot to move the tool along a desired trajectory PolyScope is described in the PolyScope Manual The reader of this manual is expected to be technically minded to be fa miliar with the basic general concepts of programming be able to connect a wire to a screw terminal and be able to drill holes in a metal plate No special knowledge about robots in general or Universal Robots in particular is required The rest of this chapter is an appetizer for getting started with the robot 5 UNIVERSAL ROBOTS 1 1 Introduction Ge 1 1 1 The Robot The robot itself is an arm composed of extruded aluminum tubes and joints The joints are named A Base B Shoulder C Elbow and D E F Wrist 1 2 3 The Base is where the robot is mounted and at the other end Wrist 3 the tool of the robot is attached By coordinating the motion of each of the joints the robot can move its tool around freely with the exception of the area directly above and directly below the robot
6. UR robots share emergency stop with other machinery All Rights Reserved 17 URS UNIVERSAL ROBOTS 2 3 The Safety Interface LN p re wm re Mo EAs eoa nipginmssid E e ee olpip mes ma re wm re Ko egos eo Kos soy olola olloh gane ui dopa olopolo _ olog ie fa TTE re T T Electric Specifications A simplified internal schematic of circuitry is shown below It is important to no tice that any short circuit or lost connection will lead to a safe stop as long as only one error appears at a time Failure and abnormal behavior of relays and power supplies results in an error message in the robot log and prevents the robot from powering up TB TA TB 12V 12V Below Specifications of the Emergency Stop Interface Parameter Min Typ Max Unit TA TB Voltage 10 5 12 125 V TA TB Current Each output 120 mA TA TB Current protection 400 mA EA EB EEA EEB Input voltage 30 30 V EA EB EEA EEB Guaranteed OFF if 30 7 V EA EB EEA EEB Guaranteed ON if 10 30 V EA EB EEA EEB Guaranteed OFF if 0 3 mA EA EB EEA EEB ON Current 10 30V 7 14 mA EO1 EO2 EO3 EO4 Contact Current AC DC 0 01 6 A EO1 EO2 EO3 EO4 Cont
7. design of the robot includ ing its interfaces meets all essential requirements listed in annex of 2006 42 EC The technical documentation of the robot is in accordance with annex VII part B of 2006 42 EC All Rights Reserved 38 URS 5 5 Essential Requirements UNIVERSAL ROBOTS Applied directives 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2002 95 EC ROHS Directive 2002 96 EC WEEE Directive Applied harmonized standards ISO 13849 1 2006 Under applied directives ISO 13849 2 2003 ISO 10218 1 2006 Partly ISO 10218 1 2011 Partly ISO 10218 2 2011 Partly ISO 13850 2006 ISO 12100 2010 ISO 3745 2003 IEC 61000 6 2 ED 2 0 2005 IEC 61000 6 4 AMD ED 2 0 2010 IEC 61131 2 ED 3 0 2007 Partly EN ISO 13849 1 2008 EN ISO 13849 1 AC 2009 EN ISO 13849 2 2008 EN ISO 10218 1 2008 Partly EN ISO 10218 1 2011 Partly EN ISO 10218 2 2011 Partly EN ISO 13850 2008 EN ISO 12100 2010 EN ISO 3745 2009 EN 61000 6 2 2005 EN 61000 6 4 A1 2011 EN 61131 2 2007 Partly EN 1037 2010 Applied general standards ISO 9409 1 2004 Partly Not all standards are listed ISO 9283 1999 Partly ISO 9787 2000 Partly ISO 9946 2000 Partly ISO 8373 1996 Partly ISO TR 14121 2 2007 ISO 1101 2004 ISO 286 1 2010 ISO 286 2 2010 IEC 60664 1 ED 2 0 2007 IEC 60947 5 5 1997 IEC 60529 1989 A 1 1999 IEC 60320 1 Ed 2 0 2001 IEC 60204 1 Ed 5 0 2005 Partly EN ISO 9409 1 2004 Partly EN ISO 9283 1999 Partly E
8. in current mode To make it clear how easy it is to use digital inputs some simple examples are shown Using Analog Inputs Non differential POWER GRAY AI8 WHITE SENSOR e e e The simplest way to use analog inputs The output of the sensor can be either current or voltage as long as the input mode of that analog input is set to the same on the I O tab Remember to check that a sensor with voltage output can drive the internal resistance of the tool or the measurement might be invalid GND RED Using Analog Inputs Differential POWER GRAY SENSOR Using sensors with differential outputs is also straightforward Simply connect the negative output part to GND OV with a terminal strip and it will work in the same way as a non differential sensor All Rights Reserved 29 URS UNIVERSAL ROBOTS 2 5 Tool I O All Rights Reserved 30 URS Chapter 3 Safety 3 1 Introduction This chapter gives a short introduction to the statutory documentation and im portant information about the risk assessment followed by a section concerning emergency situations Regarding safety in general all assembly instructions from 1 4 and 2 1 shall be followed Technical specifications of the electrical safety interface including performance level and safety categories are found in sec tion 2 3l 3 2 Statutory documentation A robot installation within the EU shall comply with the m
9. states that a maximum force of 150N combined with a supporting risk assesment is required for collaborative operation the newer standards does not specify a specific maximum force but leaves this to the spe cific risk assesment In general this means that regardless of the standard used a risk assesment shall confirm that the collaborative robot installation is sufficiently safe and for most cases the combination of a well constructed robot installation and the maximum force of 150N is sufficient 3 4 Emergency situations In the unlikely event of an emergency situation where one or more robot joints needs to be moved and robot power is either not possible or unwanted there are three different ways to force movements of the robot joints without powering the motors of the joints Active backdriving If possible power on the robot by pushing the ON button on the initializing screen Instead of pushing the break release button to power up the joint motors push the teach button on the back side of the teach pendant A special backdrive mode is entered and the robot will loosen its breacks automatically while the robot is hand guided Releasing the teach button re locks the breaks 2 Manual break release Remove the joint cover by removing the few M3 screws that fix it Release the break by pushing the plunger on the small electro magnet as shown in the picture below 3 Forced backdriving Force a joint to move by pulling hard in the
10. then enable automatic reset functionality as described in section 2 3 3 Connecting a door switch Connecting a door switch or something comparable is done as shown above Remember to use a reset button configuration if the robot should not start au tomatically when the door is closed again Connecting a light guard How to connect a light guard is shown above It is also possible to use a category 1 ISO 13849 1 and EN 954 1 light guard if the risk assessment allows it When connecting a category 1 light guard use TA and SA and then connect TB and SB with a wire Remember to use a reset button configuration so that the safeguard stop is latched All Rights Reserved 19 URS UNIVERSAL ROBOTS 2 3 The Safety Interface Connecting a reset button How to connect a reset button is shown above It is not allowed to have a permanently pushed reset button If the reset button is stuck a safeguard stop is generated and an error message will appear on the log screen 2 3 3 Automatic continue after safeguard stop 24V 24V GND The safeguard interface can reset itself when a safeguard stop e
11. when the robot is mounted dif ferently than specified in the setup 6 The weight of the robot is less than 18kg 7 The robot shape is smooth to reduces pressure N m per force N 8 It is possible to move the joints of an unpowered robot See section 3 4 The fact that the robot is very safe opens the possibility of either saving the safety guards or using safety guards with a low performance level As a help in convincing customers and local authorities the UR5 robot has been certified by the Danish Technological Institute which is a Notified Body under the machin ery directive in Denmark The certification concludes that the robot complies All Rights Reserved 32 URS 3 4 Emergency situations UNIVERSAL ROBOTS with article 5 10 5 of the EN ISO 10218 1 2006 This standard is harmonized under the machinery directive and it specifically states that a robot can operate as a collaborative robot i e without safety guards between the robot and the op erator if it is in compliance with the article 5 10 5 The risk assessment still needs to conclude that the overall robot installation is safe enough of course A copy of the certification report can be requested from Universal Robots The standard EN ISO 10218 1 2006 is valid untill the Ist of January 2013 In the meantime the newer version EN ISO 10218 1 2011 and the corrosponding EN ISO 10218 2 2011 addressed to the integrators are also valid Where the EN ISO 10218 1 2006 specifically
12. 3 Emergency Stop Output Connection 3 Emergency Stop Output Connection 4 EA Robot Emergency Stop Input A Positive EB Robot Emergency Stop Input B Negative EEA External Emergency Stop Input A Positive EEB External Emergency Stop B Negative 24V 24V supply connection for safety devices GND OV supply connection for safety devices The Emergency Stop interface has two inputs the Robot Emergency Stop input and the External Emergency Stop input Each input is doubled for redundancy due to the safety performance level d The Robot Emergency Stop interface will stop the robot and will set the Emer genoy Stop output intended for use by safety equipment near the robot The External Emergency Stop will also stop the robot but will not affect the Emer genoy Stop output and is only intended for connecting to other machines All Rights Reserved 16 URS 2 3 The Safety Interface UNIVERSAL ROBOTS The Simplest Emergency Stop Configuration TA TB TA TB E01 E02 d ale The simplest configuration is to use the internal emergency stop button as the only component to generate an emergency stop This is done with the configuration shown above This configuration is the default when the robot leaves the factory and thereby the robot is ready to operate However the emergency configuration should be changed if required by the risk assessment
13. 4V DOO DOI DO2 DO3 DO4 DOS DO6 DOT 24V 24V 24V 24V 24V 24V 24V 24V Al A1 AG A01 TB E01 E02 E03 E04 TA TB A EEA EEB 24V 24V GND GND SA SB A R Inside the control box there is a panel of screw terminals The leftmost part in black above is the safety interface The safety interface can be used to connect the robot to other machinery or protective equipment to make sure the robots stops in certain situations The safety interface is comprised of two parts the emergency stop interface and the safeguard stop interface further described in the following sections The table below summarizes their differences Emergency Stop Safeguard Stop Robot stops moving Yes Yes Initiations Manual Manual or automatic Program execution Stops Pauses Brakes Active Not active Motor power Off Limited Reset Manual Automatic or manual Use frequency Infrequent Every cycle to infrequent Requires re initialization Brake release only No EN IEC 60204 and NFPA 79 Stop category 1 Stop category 2 Performance level ISO 13849 1 PLd ISO 13849 1 PLd 2 3 1 The Emergency Stop Interface TA Test Output A TB Test Output B EO1 Emergency Stop Output Connection 1 Emergency Stop Output Connection 2 EO
14. N ISO 9787 2000 Partly EN ISO 9946 2000 Partly EN ISO 8373 1996 Partly EN ISO TR 14121 2 2007 EN ISO 1101 2005 EN ISO 286 1 2010 EN ISO 286 2 2010 EN 60664 1 2007 EN 60947 5 5 1998 EN 60947 5 5 A1 2005 EN 50205 2003 EN 60529 1991 A1 2000 EN 60320 2003 EN 60204 2006 Partly Note that the low voltage directive is not listed The machinery directive All Rights Reserved 39 URS UNIVERSAL ROBOTS 5 6 National Authority Contact Information 2006 42 EC and the low voltage directives are primary directives A product can only be covered by one primary directive and because the main hazards of the robot are due to mechanical movement and not electrical shock it is covered by the machinery directive However the robot design meets all rele vant requirements to electrical construction described in the low voltage direc tive 2006 95 EC Also note that the WEEE directive 2002 96 EC is listed because of the crossed out wheeled bin symbol on the robot and the control box Universal Robots reg isters all robot sales within Denmark to the national WEEE register of Denmark Every distributor outside Denmark and within the EU must make their own regis tration to the WEEE register of the country in which their company is based 5 6 National Authority Contact Information Authorised person Lasse Kieffer 45 8993 8971 kieffer universal robots com CTO Esben H stergaard 45 8993 8974 esben universal r
15. NIVERSAL ROBOTS 2 4 Controller I O Signal Communication with other Machinery or PLCs DO1 DO2 DO3 24V 24V i 24V 24V i GND GND GND GND GND GND If communication with other machinery or PLCs is needed they must use pnp technology Remember to create a common GND connection between the different interfaces An example where two UR robots A and B are communi cating with each other is illustrated above 2 4 3 Analog Outputs Parameter Min Typ Max Unit Valid output voltage in current mode 0 10 V Valid output current in voltage mode 20 20 mA Short circuit current in voltage mode 40 mA Output resistance in voltage mode 43 ohm The analog outputs can be set for both current mode and voltage mode in the range of 4 20mA and 0 10V respectively To illustrate clearly how easy it is to use analog outputs some simple exam ples are shown Using the Analog Outputs Analog controlled actuator ecc gt gt gt This is the normal and best way to use analog outputs The illus
16. Press the power button on the teach pendant All Rights Reserved 8 URS Quick start Step by Step UNIVERSAL ROBOTS 10 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Wait a minute while the system is starting up displaying text on the touch screen When the system is ready a popup will be shown on the touch screen stating that the emergency stop button is pressed Touch the ok button at the popup Unlock the emergency stop buttons The robot state then changes from Emergency Stopped to Robot Power Off Touch the On button on the touch screen Wait a few seconds Touch the Start button on the touch screen The robot now makes a noise and moves a little while unlocking the breaks Touch the blue arrows and move the joints around until every light at the right side of the screen turns green Be careful not to drive the robot into itself or anything else All joints are now oK Touch the OK button bringing you the Welcome screen Touch the PROGRAM Robot button and select Empty Program Touch the Next button bottom right so that the empty line is selected in the tree structure on the left side of the screen Go to the Structure tab Touch the Move button Go to the Command tab Press the Next button to go to the Waypoint settings Press the Set this waypoint button next to the picture On the Move screen move the robo
17. UNIVERSAL ROBOTS User Manual December 27 2012 Robot UR5 SN URS SN CB2 UNIVERSAL ROBOTS 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 2012 by Universal Robots A S The Universal Robots logo is a registered trademark of Universal Robots A S All Rights Reserved 2 URS Contents 1 Getting started TD OCMC TOMA dace ie Werl oops u Error do Oe ed BW al ee ESR de gd BENI IHR TEMP L12 Programs oea 209 Wiican Med iw ee Rx rac REOR decd ae va T 1 2 Turning On and Off 94 ugs qox S ma wo Peay o x oe 1 2 1 Turning on the Controller BOX lees L2 2 Turning on the RODOt 532 xx dcn CAR ed 12 3 Initializing the ROBOT issus kk gx x gx xn 1 2 4 Shutting Down the IRODOI x rd eec a cw RR s 1 25 Shutting Down the Controller Box llle 1 3 Quick start Step by Step es 1 4 Mounting Instructions 1 4 1 The Workspace oftheRobot 000 0 eee 1 4 2 Mounting the Robot x ee hec a mae o9 hk 1 4 3 MOUNTING the Tool uc ee be xxx 9o 9x G3 Ro wx x s 1 4 4 Mounti
18. achinery directive to insure its safety This includes the following points 1 Make sure that the product comply with all essential requirements 2 Make a risk assessment 3 Specify instructions for the operator 4 Make a declaration of conformity 5 Collect all information in a technical file 6 Put a CE mark on the robot installation In a given robot installation the integrator is responsible for the compliance with all relevant directives Universal Robots takes responsibility for the robot itself complying with the relevant EU directives See section 1 Universal Robots provides a safety guide available at http www universal robots com for integrators with little or no experience in making the necessary documentation If the robot is installed outside EU the robot integration shall comply with the local directives and laws of the specific country The integrator is responsible for this compliance It is always necessary to perform a risk assessment to ensure that the complete robot installation is sufficiently safe 3 UNIVERSAL ROBOTS 3 3 Risk assessment 3 3 Risk assessment One of the most important things that an integrator needs to do is to make a risk assessment Universal Robots has identified the potential significant hazards listed below as hazards which must be considered by the integrator Note that other significant hazards might be present in a specific robot installation Entrapment of fing
19. act Voltage DC 5 50 V EO1 EO2 EO3 EO4 Contact Voltage AC 5 250 V Note the number of safety components that should be used and how they must work depend on the risk assessment which is explained in section 3 Note that it is important to make regular checks of the safety stop functionality to ensure that all safety stop devices are functioning correctly The two emergency stop inputs EA EB and EEA EEB are potential free inputs conforming to IEC 60664 1 and EN 60664 1 pollution degree 2 overvoltage cat egory Il The emergency stop outputs EO 1 EO2 EO3 EOA are relay contacts conform ing to IEC 60664 1 and EN 60664 1 pollution degree 2 over voltage category Ill All Rights Reserved 18 URS 2 3 The Safety Interface UNIVERSAL ROBOTS 2 3 2 The Safeguard Interface TA Test Output A TB Test Output B SA Safeguard Stop Input A Positive SB Safeguard Stop Input B Negative A Automatic continue after safeguard stop R Reset safeguard stop 24V 24V supply connection for safety devices GND OV supply connection for safety devices The Safeguard Interface is used to pause the robot movement in a safe way The Safeguard Interface can be used for light guards door switches safety PLCs etc Resuming from a safeguard stop can be automatic or can be controlled by a pushbutton depending on the safeguard configuration If the Safeguard Interface is not used
20. ally be around 200 ohms and the best result is accomplished when the resistor is close to the screw terminals of the control box Note that the tolerance of the resistor and the ohmic change due to tempera ture must be added to the error specifications of the analog inputs Using Analog Inputs Non differential Current Input AV PAN 24V 24V SENSOR GND GND GND GND If the output of the equipment is a non differential current signal a resistor must be used as shown above The resistor should be around 200 ohms and the relationship between the voltage at the controller input and the output of the sensor is given by Voltage Current x Resistance Note that the tolerance of the resistor and the ohmic change due to tempera ture must be added to the error specifications of the analog inputs 2 5 Tooll O At the tool end of the robot there is a small connector with eight connections All Rights Reserved 26 URS 2 5 Tool I O UNIVERSAL ROBOTS Color Signal Red OV GND Gray OV 12V 24V POWER Blue Digital output 8 DO8 Pink Digital output 9 DO9 Yellow Digital input 8 DI8 Green Digital input 9 DI9 White Analog input 2 Al2 Brown Analog input 3 AI3 This connector provides power and control signals for basic gr
21. and of course limited by the reach of the robot 850mm from the center of the base 1 1 2 Programs A program is a list of commands telling the robot what to do The user interface PolyScope described in the PolyScope manual allows people with only little programming experience to program the robot For most tasks programming is done entirely using the touch panel without typing in any cryptic commands Since tool motion is such an important part of a robot program a way of teaching the robot how to move is essential In PolyScope the motions of the tool are given using a series of waypoints Each waypoint is a point in the robot s workspace Waypoints A waypoint is a point in the workspace of the robot A waypoint can be given by moving the robot to a certain position or can be calculated by software The robot performs a task by moving through a sequence of waypoints Various options regarding how the robot moves between the waypoints can be given in the program Defining Waypoints Moving the Robot The easiest way to define a waypoint is to move the robot to the desired position This can be done in two ways 1 By simply pulling the robot while pressing the Teach button on the screen see the PolyScope manual 2 By using the touch screen to drive the tool linearly or to drive each joint individually Blends Per default the robot stops at each waypoint By giving the robot free dom to decide how to move near the waypoin
22. e of purchase shall be required as evi dence for invoking the Warranty Claims under the Warranty must be submitted within two months of the Warranty default becoming evident Ownership of de vices or components replaced by and returned to Universal Robots shall vest in Universal Robots Any other claims resulting out of or in connection with the device shall be excluded from this Warranty Nothing in this Warranty shall at tempt to limit or exclude a Customer s Statutory Rights nor the manufacturer s liability for death or personal injury resulting from its negligence The duration of the Warranty shall not be extended by services rendered under the terms of the Warranty Insofar as no Warranty default exists Universal Robots reserves the right to charge the customer for replacement or repair The above provisions do not imply a change in the burden of proof to the detriment of the customer In case of a device exhibiting defects Universal Robots shall not cover any consequential damage or loss such as loss of production or damage to other production equipment 4 2 Disclaimer Universal Robots continues to improve reliability and performance of its prod ucts and therefore reserves the right to upgrade the right to upgrade the prod uct without prior warning Universal Robots takes every care that the contents of this manual are precise and correct but takes no responsibility for any errors or missing information 35 UNIVERSAL ROBOTS 4
23. erformed in accordance with the following standards EN ISO 10218 1 2011 5 10 item 5 10 5 EN ISO 10218 2 2011 5 11 item 5 11 5 5 EN ISO 10218 1 2006 5 10 item 5 10 5 ANSI RIA ISO 10218 1 2007 5 10 item 5 10 5 The robot is tested in a limited workspace and a force limit of 150N at the tool center point TCP of the robot is used during testing The following results are found during testing Max force N Reason for end of test Stop code 14 Security stop URcontroller C113A0 48 Security stop URcontroller C113A0 68 Security stop C43A0 Elbow 50 Security stop URcontroller C113A0 51 Security stop URcontroller C113A0 16 Security stop URcontroller C113A0 50 Security stop URcontroller C113A0 26 Security stop URcontroller C113A0 eo i ov ca o t 1o 28 Security stop URcontroller C113A0 5l Security stop URcontroller C113A0 65 Security stop URcontroller C113A0 63 Security stop C113A0 Elbow 35 Security stop URcontroller C113A0 64 Security stop URcontroller C113A0 23 Security stop URcontroller C113A0 32 Security stop URcontroller C113A0 The test has verified that the robot is in compliance with the former mentioned items of the standards All the forces measured during testing are below the chosen force limit of 150N at the TCP Yours faithfully Centre for Materials Testing Spin l T
24. ers between robot foot and base joint O 2 Entrapment of fingers between the arm and wrist joint 4 3 Penetration of skin by sharp edges and sharp points on tool or tool con nector 4 Penetration of skin by sharp edges and sharp points on obstacles near the robot track 5 Bruising due to stroke from the robot 6 Sprain or bone fracture due to strokes between a heavy payload and a hard surface 7 Consequences due to loose bolts that holds the robot arm or tool 8 Items falling out of tool E g due to a poor grip or power interruption 9 Electrical shock or fire due to malfunction of power supplies if the mains connection is not protected by a main fuse a residual current device and a proper connection to earth See section 1 4 7 10 Mistakes due to different emergency stop buttons for different machines Use common emergency stop function as descriped in section 2 3 However the URS is a very safe robot due to the following reasons 1 Control system conforms to ISO 13849 1 performance level d 2 The control system of the robot is redundant so that all dangerous failures forces the robot to enter a safe condition 3 High level software generates a protective stop if the robot hits something This stop force limit is lower than 150N 4 Furthermore low level software limits the torque generated by the joints permitting only a small deviation from the expected torque 5 The software prevents program execution
25. homas Greve M Sc Dir tel 45 7220 2321 E mail TGR teknologisk dk All Rights Reserved 44 URS
26. ion is shown below Parameter Min Typ Max Unit Input voltage 200 230 260 VAC External mains fuse 8 10 A Input frequency 47 50 63 Hz Stand by power 0 5 W Nominal operating power 110 150 750 W Use the screw connection marked with earth symbol inside the controller box when potential equalization with other machinery is required Note It is technically possible to use 110V mains supply However when the robot moves at high speed or high acceleration the mains current will exceed its maximum rating causing cables plugs and the main fuse to be overloaded Also the fan runs at a lower speed All Rights Reserved 13 URS UNIVERSAL ROBOTS 1 4 Mounting Instructions All Rights Reserved 14 URS Chapter 2 Electrical Interface 2 1 Introduction The robot is a machine that can be programmed to move a tool around in the robots workspace Often it is desired to coordinate robot motion with nearby machines or equipment on the tool The most straightforward way to achieve this is often by using the electrical interface There are electrical input and output signals 1 Os inside the control box and at the robot tool flange This chapter explains how to connect equipment to the I Os Some of the I Os inside the control box are dedicated to the robot safety functionality and some are general purpose l Os for connecting with other machines and equipment The genera
27. ippers and sen sors which may be present on a specific robot tool This connector can be used to reduce wiring between the tool and the control box The connector is a stan dard Lumberg RSMEDG8 which mates with a cable named RKMV 8 354 Note that the tool flange is connected to GND same as the red wire Internal Power Supply Specifications Parameter Min Typ Max Unit Supply voltage in 24V mode TBD 24 TBD V Supply voltage in 12V mode TBD 12 TBD V Supply current in both modes 600 mA Short circuit current protection 650 mA Capacitive load TBD uF Inductive load TBD uH The available power supply can be set to either OV 12V or 24V at the I O tab in the graphical user interface Take care when using 12V since an error made by the programmer can cause a voltage change to 24V which might damage the equipment and even cause a fire The internal control system will generate an error to the robot log if the current exceeds its limit The different Os at the tool is described in the following three subsections 2 5 1 Digital Outputs Parameter Min Typ Max Unit Voltage when open 0 5 26 V Voltage when sinking 1A 0 05 020 V Current when sinking 0 A Current through GND A Switch time 1000 us Capacitive load TBD uF Inductive load TBD uH The digital outputs are impleme
28. is only valid with a common mode voltage of OV To make it clear how easy it is to use analog outputs some simple examples are shown Using Analog Inputs Differential Voltage Input AV MAN 24V 24V Al Al SENSOR IGND GND GND GND The simplest way to use analog inputs The equipment shown which could be a sensor has a differential voltage output Using Analog Inputs Non differential Voltage Input 24V 24V If it is not possible to achieve a differential signal from the equipment used a solution could look something like the setup above Unlike the non differential analog output example in subsection this solution would be almost as good as the differential solutions All Rights Reserved 25 URS UNIVERSAL ROBOTS 2 5 Tool I O Using Analog Inputs Differential Current Input 24V 24V SENSOR When longer cables are used or if it is a very noisy environment current based signals are preferred Also some equipment comes only with a current output To use current as inputs an external resistor is needed as shown above The value of the resistor would norm
29. l purpose I Os can be manipulated directly on the I O tab in the user interface see the PolyScope Manual or by the robot programs For additional I O Modbus units can be added via the extra Ethernet con nector in the control box 2 2 Important notices Note that according to the IEC 61000 and EN 61000 standards cables going from the control box to other machinery and factory equipment may not be longer than 30m unless extended tests are performed Note that every minus connection OV is referred to as GND and is connected to the shield of the robot and the control box However all mentioned GND con nections are only for powering and signaling For PE Protective Earth use one of the two M6 sized screw connections inside the control box If FE Functional Earth is needed use one of the M3 screws close to the screw terminals Note that in this chapter all unspecified voltage and current data are in DC It is generally important to keep safety interface signals seperated from the nor mal I O interface signals Also the safety interface should never be connected to a PLC which is not a safety PLC with the correct safety level If this rule is not followed it is not possible to get a high safety level since one failure in a normal I O can prevent a safety stop signal from resulting in a stop 15 UNIVERSAL ROBOTS 2 3 The Safety Interface 2 3 The Safety Interface TA TB TA 24V 2
30. nd a built in 24V power supply Digital inputs and outputs are pnp technology and constructed in compliance with IEC 61131 2 and EN 61131 2 24V and GND can be used as input for the I O module or output as a 24V power supply When the control box is booting it checks if voltage is applied to the 24V connection from an external power supply and if not it automatically connects the internal 24V power supply All Rights Reserved 2 URS UNIVERSAL ROBOTS 2 4 Controller I O Electrical specifications of the internal power supply Parameter Min Typ Max Unit Internal 24V voltage tolerance 15 20 Current from internal 24V supply 2x A Overload protection 1 4 A External power supply voltage 10 30 V Note that the safeguard yellow 24V connections are sourced by the same internal 24V power supply as the 24V connections of the normal I O and that the maximum of 1 2 A is for both power sources together If the current load of the internal 24V power supply is exceeded an error message is printed on the log screen The power supply will automatically try to recover after a few seconds 2 4 1 Digital Outputs Parameter Min Typ Max Unit Source current per output 0 2 A Source current all outputs together 0 4 A Voltage drop when ON 0 0 2 V Leakage current when OFF O 0 0 1 mA The outputs can be used to drive equipment di
31. ng the Controller BOX lens 1 45 Mounting the Teach Pendant llle MTM Em 2 Electrical Interface 2 1 Introd ction as vu uo re E Rx Yum do Eok Ge wo Xo X oc 2 2 Important notices aa aa a 2 3 IheSafetyInterface ooo 2 3 1 The Emergency Stop Interface lesse See crn ee 2 3 8 Automatic continue after safeguard stop TEOWEUTTUEESSENNSSETVIR D ok eS eS 2 4 1 Digital Outputs usus doctos ds he ae dodo utn Be oh hae et 2 4 2 Digital Inputs cater don Kos dices or ecce xc do eR CE A 2 4 3 Analog Outputs uix the ow a eR ee amp ee we X xcd 2 4 4 Analog Inpuls dace sw Sev Y ose yea UR ed eS RICETTE 2 5 1 Digital COUDEITSI acus dee dato dodo atn dox oh hae aei d 2 5 2 Digital PS ur diced Kak dca Eo mex curie ec doe ERR Re ed 2 5 3 Analog TNO ues dee d wee cae ae amp nox xU RS X A 3 Safety Sek Introduction uxor xum we eom ew x ans Forex xo uw P Poe x x3 3 2 Statutory documentation ns 3 3 Risk Assessment oh UNIVERSAL ROBOTS Contents 3 4 Emergency situations uos oro oc 39s ORC ee ee Ia 33 4 Warranties 35 4 Product Warranty ns 35 4 2 Disclaimer rns 35 37 5 1 Totreduction iuis ier do woher don ek o Roh S UR RU ena 37 5 2 Product manufacturer duce eared a3 953 doy 9o ede E E AL A 37 Lee 37 5 4 Description and Identification of Product sss 37 5 5 Essential Requirements es 38 III 40
32. nted so that they can only sink to GND OV and not source current When a digital output is activated the corresponding connection is driven to GND and when it is deactivated the corresponding connection is open open collector open drain The primary difference be tween the digital outputs inside the control box and those in the tool is the re duced current due to the small connector All Rights Reserved 27 UR5 UNIVERSAL ROBOTS 2 5 Tool I O Note that the digital outputs in the tool are not current limited and overriding the specified data can cause permanent damage To illustrate clearly how easy it is fo use digital outputs a simple example is shown Using Digital Outputs POWER GRAY This example illustrates how to turn on a load when using the internal 12V or 24V power supply Remember that you have to define the output voltage at the I O tab Keep in mind that there is voltage between the POWER connection and the shield ground even when the load is turned off 2 5 2 Digital Inputs Parameter Min Typ Max Unit Input voltage O05 26 V Logical low voltage 2 0 V Logical high voltage 5 5 V Input resistance 47k Q The digital inputs are implemented with weak pull down resistors This means that a floating input will always read low The digital inputs at the tool are imple mented in the same way as the digital inputs inside the control bo
33. ntial free input conforming to IEC 60664 1 and EN 60664 1 pollution degree 2 over voltage category ll Note that the yellow 24V connections is sourced by the same internal 24V power supply as the 24V connections of the normal I O and that the maximum of 1 2 A is for both power sources together 2 4 Controller I O DO7 24V 24V 24V 24V 24V 24v 24V 24V JAL A13 AG AO1 ITA TB TA TB E01 E02 03 E04 PIB TA 24v 24v DOO Do1 Do2 Do3 Do4 DOS poe GND GND GND GND GND GND GND GND GND GND DIO DI1 DI2 DI3 Di4 DI5 DI6 DI7 A0 AO JAG AOO0 Inside the control box there is a panel of screw terminals with various I O parts as shown above The rightmost part of this panel is general purpose 1 0 24V 24V supply connection GND OV supply connection DOx Digital output number x DIx Digital input number x AOx Analog output number x plus AG Analog output GND Ax Analog input number x plus Ax Analog input number x minus The I O panel in the control box has 8 digital and 2 analog inputs 8 digital and 2 analog outputs a
34. obots com CEO Enrico Krog Iversen 45 8993 8973 eki universal robots com 5 7 Important Notice The robot may not be put into service until the machinery into which it is to be incorporated has been declared to be in conformity with the provisions of the Machinery Directive 2006 42 EC and with national implementing legislation 5 8 Place and Date of the Declaration Place Universal Robots A S Sivlandvaenget 1 5260 Odense S Denmark Date 1 December 2011 All Rights Reserved 40 URS 5 9 Identity and Signature of the Empowered Person UNIVERSAL ROBOTS 5 9 Identity and Signature of the Empowered Person Name Lasse Kieffer Address Sivlandvaenget 1 5260 Odense S Denmark Phone number 45 8993 8971 E mail address kieffer universal robots com Signature All Rights Reserved Al URS UNIVERSAL ROBOTS 5 9 Identity and Signature of the Empowered Person All Rights Reserved 42 URS Appendix A Certifications 43 UNIVERSAL ROBOTS Universal Robots ApS Attn Lasse Kieffer Svendborgvej 102 DK 5260 Odense S Test of UR5 Robot Danish Technological Institute Centre for Materials Testing has tested a URS robot for Universal Robots ApS see report 1302213 424098 DANISH TECHNOLOGICAL INSTITUTE Teknologiparken Kongsvang All 29 OK 8000 Arhus C Tel 445 72 20 1000 Fax 45 72 20 10 19 16 March 2012 1302213 424098 TGR BBJ The test is p
35. rectly e g pneumatic relays or they can be used for communication with other PLC systems The outputs are constructed in compliance with all three types of digital inputs defined in IEC 61131 2 and EN 61131 2 and with all requirements for digital outputs of the same standards All digital outputs can be disabled automatically when a program is stopped by using the check box Always low at program stop on the I O Name screen see the PolyScope manual In this mode the output is always low when a program is not running The digital outputs are not current limited and overriding the specified data can cause permanent damage However it is not possible to damage the out puts if the internal 24V power supply is used due to its current protection Note that the control box and the metal shields are connected to GND Never send I O current through the shields or earth connections The next subsections show some simple examples of how the digital outputs could be used Load Controlled by Digital Output DO3 DO4 DOS DO6 GND GND GND This example illustrates how to turn on a load All Rights Reserved 22 URS 2 4 Controller I O UNIVERSAL ROBOTS Load Controlled by Digital Output External Power 24V 24V DOQ DO3 DO4 DOS DO6 OOOO GND GND GND GND GND GND GND
36. rned on and if all emer gency stop buttons are not activated Turning the robot on is done at the ini tialization screen by touching the ON button at the screen and then pressing Start When a robot is started a noise can be heard as the brakes unlock After the robot has powereded up it needs to be initialized before it can begin to perform work 1 2 3 Initializing the Robot After the robot is powered up each of the robot s joints needs to find its ex act position in order to do so the joints need to move The amount of motion needed depends on the joint position and type Small joints need to move be tween 22 5 and 45 large joints need to move half as much the direction of rotation is unimportant The Initialization screen shown in figure 1 1 gives ac cess to manual and semi automatic driving of the robot s joints The robot can not automatically avoid collision with itself or the surrounds during this process Therefore caution should be exercised The Auto button near the top of the screen drives all joints until they are ready When released and pressed again all joints change drive direction The Manual buttons permit manual driving of each joint A more detailed description of the initialization screen is found in the PolyScope manual All Rights Reserved 7 URS UNIVERSAL ROBOTS 1 3 Quick start Step by Step Initialise Robot e Push Auto until all lights turn green
37. robot arm Each joint break has a friction clutch which enables movement during high forced torque Forced backariving is intended for urgent emergencies only and might damage the joint gears and other parts Do not turn any joints more than necessary and beware of gravity and heavy payloads All Rights Reserved 33 URS UNIVERSAL ROBOTS 3 4 Emergency situations All Rights Reserved 34 URS Chapter 4 Warranties 4 1 Product Warranty Without prejudice to any claim the user customer may have in relation to the dealer or retailer the customer shall be granted a manufacturer s Warranty un der the conditions set out below In the case of new devices and their components exhibiting defects result ing from manufacturing and or material faults within 12 months of entry into service maximum of 15 months from shipment Universal Robots shall provide the necessary spare parts while the user customer shall provide working hours to replace the spare parts either replace the part with another part reflecting the current state of the art or repair the said part This Warranty shall be in valid if the device defect is attributable to improper treatment and or failure to comply with information contained in the user guides This Warranty shall not apply to or extend to services performed by the authorized dealer or the customer themselves e g installation configuration software downloads The purchase receipt together with the dat
38. rved 1 URS UNIVERSAL ROBOTS 1 4 Mounting Instructions SECTION A A H7 0 015 6 0 0 563 0 05 h8 75 Figure 1 4 The tool output flange ISO 9409 1 50 4 M6 This is where the tool is mounted at the tip of the robot All measures are in mm All Rights Reserved 1 4 Mounting Instructions UNIVERSAL ROBOTS 1 4 4 Mounting the Controller Box The controller box can be hung on a wall or it can be placed on the ground A clearance of 50mm on each side allows for sufficient airflow 1 4 5 Mounting the Teach Pendant The teach pendant can be hung on a wall or on the controller box Extra fittings can be bought 1 4 6 Connecting the Robot Cable The cable from the robot must be plugged in to the connector at the button of the controller box Ensure that the connector is properly locked Connecting and disconnecting the robot cable may only be done when the robot power is turned off 1 4 7 Connecting the Mains Cable The mains cable from the controller box has a standard IEC plug in the end Connect a country specific mains plug or cable to the IEC plug If the current rating of the specific plug is insufficient or if a more permanent solution is prefered then wire the controller box directly The mains supply shall be equiped with the following as a minimum 1 Main fuse 2 Residual current device 3 Connection to earth Mains input specificat
39. t it is possible to drive through the desired path faster without stopping This freedom is given by setting a blend radius for the waypoint which means that once the robot comes within a cer tain distance of the waypoint the robot can decide to deviate from the path A blend radius of 5 10 cm usually gives good results All Rights Reserved 6 URS 1 2 Turning On and Off UNIVERSAL ROBOTS Features Besides moving through waypoints the program can send I O signals to other machines at certain points in the robot s path and perform commands like if then and loop based on variables and I O signals 1 1 3 Safety Evaluation The robot is a machine and as such a safety evaluation is required for each installation of the robot Chapter 3 1 describes how to perform a safety evalua tion 1 2 Turning On and Off How to turn the different parts of the robot system on and off is described in the following subsections 1 2 1 Turning on the Controller Box The controller box is turned on by pressing the power button at the front side of the teach pendant When the controller box is turned on a lot of text will appear on the screen After about 20 seconds the Universal Robot s Logo will appear with the text Loading After around 40 seconds a few buttons appear on the screen and a popup will force the user to go to the initialization screen 1 2 2 Turning on the Robot The robot can be turned on if the controller box is tu
40. t by pressing the various blue arrows or move the robot by holding the Teach button placed on the backside of the teach pendant while pulling the robot arm Press OK Press Add waypoint before Press the Set this waypoint button next to the picture On the Move screen move the robot by pressing the various blue arrows or move the robot by holding the Teach button while pulling the robot arm Press OK Your program is ready The robot will move between the two points when you press the Play symbol Stand clear hold on to the emergency stop button and press Play Congratulations You have now produced your first robot program that moves the robot between the two given positions Remember that you have to carry out a risk assessment and improve the overall safety condi tion before you really make the robot do some work All Rights Reserved 9 URS UNIVERSAL ROBOTS 1 4 Mounting Instructions Front Tilted Figure 1 2 The workspace of the robot The robot can work in an approxi mate sphere 170cm around the base except for a cylindrical volume directly above and directly below the robot base 1 4 Mounting Instructions The robot consists essentially of six robot joints and two aluminum tubes con necting the robot s base with the robot s fool The robot is built so that the tool can be translated and rotated within the robot s workspace The next subsec tions describes the basic things to know when mo
41. tration shows a setup where the robot controller controls an actuator like a conveyor belt The best result is accomplished when using current mode because it is more immune to disturbing signals Using the Analog Outputs Non Differential Signal av pa Analog controled actuator 24V 24V i AO1 IGND GND GND GND All Rights Reserved 24 URS 2 4 Controller I O UNIVERSAL ROBOTS If the controlled equipment does not take a differential input an alternative solution can be made as shown above This solution is not very good in terms of noise and can easily pick up disturbing signals from other machinery Care must be taken when the wiring is done and it must be kept in mind that disturbing signals induced into analog outputs may also be present on other analog I O 2 4 A Analog Inputs Parameter Min Typ Max Unit Common mode input voltage 33 33 V Differential mode input voltage 33 33 V Differential input resistance 220 kohm Common mode input resistance 55 kohm Common mode rejection ratio 75 dB The analog inputs can be set to four different voltage ranges which are implemented in different ways and therefore can have different offset and gain errors The specified differential mode input voltage
42. unting the different parts of the robot system 1 4 1 The Workspace of the Robot The workspace of the UR5 robot extends to 850 mm from the base joint The workspace of the robot is shown in figure It is important to consider the cylindrical volume directly above and directly below the robot base when a mounting place for the robot is chosen Moving the tool close to the cylindrical volume should be avoided if possible because it causes the robot joints to move fast even though the tool is moving slowly 1 4 2 Mounting the Robot The robot is mounted using 4 M8 bolts using the four 8 5mm holes on the robot s base If very accurate repositioning of the robot is desired two 28 holes are pro vided for use with a pin Also an accurate base counterpart can be purchased as accessory Figure 1 3 shows where to drill holes and mount the screws 1 4 3 Mounting the Tool The robot tool flange has four holes for attaching a tool to the robot A drawing of the tool flange is shown in figure 1 4 All Rights Reserved 10 URS 1 4 Mounting Instructions UNIVERSAL ROBOTS Surface on which the robot is fitted It should be flat within 0 05mmm E ex m Outer diameter of robot LL pis mounting flange m T bord L gt ELLA Nr sili 132 0 5 149 Figure 1 3 Holes for mounting the robot scale 1 1 Use 4 M8 bolts All mea surements are in mm All Rights Rese
43. vent is gone How to enable automatic reset functionality is shown above This is also the recommended configuration if the safeguard interface is not used However it is not recommended to use automatic reset if a reset button configuration is possible Automatic reset is intended for special installations and installations with other machinery Electric Specifications To understand the safeguard functionality a simplified internal schematics of the circuitry is shown below Any failure in the safety system will lead to a safe stop of the robot and an error message on the log screen Eus All Rights Reserved 20 URS 2 4 Controller I O UNIVERSAL ROBOTS Parameter Min Typ Max Unit 24V Voltage tolerance 15 42096 Current available from 24V supply 2x A Overload protection 1 4 A TA TB AT RT Voltage 10 5 12 12 5 V TA TB AT RT Current 120 mA TA TB AT RT Current protection 400 mA SA SB Input voltage 30 30 V SA SB Guaranteed OFF if 30 7 V SA SB Guaranteed ON if 10 30 V SA SB Guaranteed OFF if 0 3 mA SA SB ON Current 10 30V 7 14 mA A RJ Input voltage 30 30 V AL RJ Input guaranteed OFF if 30 7 V A RJ Input guaranteed ON if 10 30 V Al RJ Guaranteed OFF if 0 5 mA Al RL ON Current 10 30V 6 10 mA The safeguard stop input SA SB is a pote
44. x Using Digital Inputs POWER GRAY DI8 YELLOW The above example shows how to connect a simple button or switch 2 5 3 Analog Inputs The analog inputs at the tool are very different from those inside the control box The first thing to notice is that they are non differential which is a draw back compared to the analog inputs at the controller I O The second thing to notice is that the tool analog inputs have current mode functionality which is an advantage compared with the controller I O The analog inputs can be set to different input ranges which are implemented in different ways and therefore can have different offset and gain errors All Rights Reserved 28 URS 2 5 Tool I O UNIVERSAL ROBOTS Parameter Min Typ Max Unit Input voltage in voltage mode 0 5 26 V Input voltage in current mode 0 5 5 0 V Input current in current mode 25 25 mA Input resistance range OV to 5V 29 kQ Input resistance range OV to 10V 15 kQ Input resistance range 4mA to 20mA 200 Q An important thing to realize is that any current change in the common GND connection can result in a disturbing signal in the analog inputs because there will be a voltage drop along the GND wires and inside connectors Note that a connection between the tool power supply and the analog inputs will permanently damage the O functionality if the analog inputs are set
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