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Service Manual UR10

1. e Pull the Base joint and Shoulder joint apart and gently twist the two parts in opposite directions around 10 mm until a mechanical stop is met holes are keyhole type All rights reserved 15 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Pull away the Base joint from Shoulder joint e Replace Base joint and gently insert Base joint with screws and washers into the Shoulder joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the Base joint and Shoulder joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 8Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with O 8Nm e Reconnect connectors as illustrated e Mount blue lid on Base joint and tighten with 0 5Nm e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 16 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 5 Replacement of Shoulder joint How to replace Shoulder joint Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface Shut down the controller For separating Base joint from Shoulder joint consult chapter 3 1 4 Replacement of Base joint Remove blue lid on Shoulder joint D
2. Low Level Control Runtime Java Version 1 6 Kinematics Calibration 0 26 Java 3D version 1 5 2 fcs build4 vendor specification version 1 5 specification vendor renderer OpenGL Return to Normal Renderer Software Rasterizer Renderer version 2 1 Mesa 7 7 1 Java Heap size 42 938368MiB Java Max memory 255 459328MiB UNIVERSAL ROBOTS e Select the Firmware tab mark All joints and press UPDATE firmware 2 Universal Robots Graphical Programming Environment JO jl J2 J3 J4 J5 Tool Masterboard Masterboard General Move Calibration Tool Firmware Power On Off Current joint UPDATE Firmw STATUS Set ID of current joint to o S Ali joints O Skip bootloader update v Exchange IDs Set it Back Info Setting stepsize to 0 0005 rad sec Info Setting stepsize to 0 01 rad sec Info Switching to velocity control Info Setting stepsize to 0 01 rad sec Info Setting current joint to 0 e Firmware update is being processed await message that robot firmware updated successfully It is strictly forbidden to turn off controller during this update e After successful update press Back All rights reserved 60 Servicemanual UR10 en 2 0 2 Back in Expert Mode press Return to Normal 2Q06 Universal Robots Graphical Programming Environment PolyScope Expert Mo
3. e Software should only be updated after consulting Distributor from where the robot has been purchased or if representing a Distributor after consulting Universal Robots e Universal Robots do not recommend updating software without proper instruction in how to update software e When updating firmware it is strictly forbidden to turn off controller during update e Universal Robots can be no means be held responsible for any failed update caused by improper operation Go to www support universal robots com download for downloading software updates Login is required only applicable for Distributors Please note If representing an end customer contact the Distributor from where the robot has been purchased for requesting software updates Instruction for updating software e Download software update Carefully read requirements on support site relating to which software must be installed on robot prior to updating to the downloaded version e Save it in the root folder on a USB stick e Insert USB stick into USB connector on right hand side of teach pendant e Goto main screen of PolyScope All rights reserved 57 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 2Q06 Universal Robots Graphical Programming Environment e PolyScope Robot User Interface Please select RUN Program UNIVERSAL ROBOTS me SETUP Robot SHUT DOWN Robot About e Press button SETUP Robot e Inl
4. to encoder mounting Status warning general modus change After 3 consecutive errors result of preceding errors Generated by controller safety system Security limit exceeded Generated by controller safety system Security limit exceeded Robot movement blocked Collision or mechanical failure Acceleration too high in user program TCP and payload settings incorrect Warning prior to error code 113 Force Limit Protective Stop Can be related to different causes Wrong setting in urcontrol conf file Defective 48V PSU Defective Masterboard Defective Current Distributor pcb Possible CPU overload due to structure of user program Incorrect TCP and payload setting Too high acceleration typically when running robot in positions with full reach and full payload Incorrect TCP and payload setting Too high acceleration typically when running robot in positions with full reach and full payload Incorrect TCP and payload setting Too high velocity typically in linear movements close to singularity Incorrect TCP and payload setting Incorrect Mounting setting Too high acceleration Incorrect setting of Modbus addr or 65 UNIVERSAL ROBOTS program Replace joint if necessary Check preceding errors in log history Check preceding errors in log history Replace joint if necessary Check preceding errors in log history Check preceding errors in log history Use Teach Mode for checking manual jog with joint Open blue
5. Added First revision 1 0 released 24 may 2013 UR10 en 1 0 1 Added Company details added Added Description of new Magic Files added Corrected Spare part list corrected 3 sep 2013 UR10 en 1 0 2 Corrected Error code descriptions corrected Added Illustration for base plate connections added 22 feb 2014 UR10 en 2 0 1 Added Changelog added Corrected Error code C115 Cause and remedy corrected Corrected Spare part list new part numbers implemented Added Spare part list additional part numbers added Corrected New company address added 31 mar 2014 UR10 en 2 02 Added Additional instructions on replacement of tool flange are added as additional parts have been added to tool flange All rights reserved 78 Servicemanual UR10 en 2 0 2
6. Info Setting stepsize to null Setting stepsize to 0 0005 rad sec Setting stepsize to 0 01 rad sec Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 e Press Arm current joint for releasing the brake on the selected joint JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 37 90 e Jl INITIALIZING P 0 0000 S 0 000 C 2 204 V 47 6 TM 21 80 TE 37 60 J2 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 40 90 J3 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 22 60 TE 35 80 J4 READY P 0 0000 S 0 000 C 0 000 V 47 5 TM 22 90 TE 37 80 J5 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 70 TE 36 50 Tool ON DI 00 Al 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 All 0 0 AI2 0 0 AO1 0 0 AO2 0 0 Masterboard OK V 48 1 CR 0 00 mA CIO 4 00 mA T 23 00 General Move Calibration Firmware Joint ID Power On Off Current joint Joint 1 Shoulder Arm robot Arm current joint Backdrive current joint Back Setting stepsize to null Setting stepsize to 0 0005 rad sec Setting stepsize to 0 01 rad sec Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 Arming joint 1 e Select Move tab and press
7. ae on ae tee ken atann adan kana pasa taste tee 9 Blk ARO arm con eurai ON t ian l a al a tn atant no e ik a a ke a e etan a la e bn ae ka e lou ae Seni 9 SE BEIKO F ay O a EN ee E E 10 Das R plhacement or pase pi E oeer ia m e die pati m b e ap kibo es ke DU abo dekole kaa 11 Jak AKE PIIEE MENI or Base JOE et it n ala bd otaj tell la ls ka kk a a at e a ke a a il ke at aie Jal a epi ta 14 31 5 Replacement of Shoulder JO AL fasil pe ik tat ket an ae kek tk l n et e e e e ae a pap aj ann A e a kel a da 17 3e GREPI EEIMENk OF DON JONN ea tet atra e ie a n a bi n De Se e lo e ont ae e l do A ii dou 19 3 1 G REPIICEMENE OL VANSE LON at e ks ka tap toc a ei nn a tk a bu e a kis e pal kt ja n n a e ka saint pei fat 22 3 1 4 Replacement of VWWFISE 2 VOM izin id n a a ko e n a vl a n a pk e E 27 3 1 8 Replacement of Wrist 3 jOINt LLv0eetteeeeettteeetttteeeettteeesttooeeosooooeeooooooeoeoooouosooooooooooooooooooonoooooooooooooonne 31 kI REDI COME Or LOO N ANE eti ate ti vin np ti kant tl on okt rit n a pi pena eka te pap akt ae AE 35 SALTO TOFQUE YA MES sas t t vit owa bati ti at a et a a e e at os a a pe e a ka pi a e ok ae to ini kt 39 fe fo Ud L ALONE 9 ON O FI ti l kat ta ti ere nn E fa pa ian een ot po n n a a n a an apt kika al a ao 40 BZ CON TRO N T ce nsy a gaan da ate s a a EE nt ri E a e e e a kt E Get on po ko kata a it bete 46 3 2 1 Replacement OF COACH pendan aw ei aj dry kl ke ee kk ao ka e E 46 3 22 Replacement
8. brake pin consult chapter 3 1 2 Reduce acceleration in user program Verify payload is correct Replace joint if necessary Check green 2 wire connectors and wires in joints Servicemanual UR10 en 2 0 2 46 47 48 50 51 53 55 56 57 59 61 62 66 70 Loose gearbox or bad encoder mounting AD Converter hit low limit Powerbus voltage drop detected Robot power up failure Emergency relay failure IO Master or Tool overcurrent Safety system error Overvoltage shutdown Joint speed deviation Overcurrent shutdown Missed joint index mark Thermal shutdown Version mismatch error Close to gearbox shear All rights reserved Mechanical problem in gear related to encoder mounting EMC issue external or electronics internal Error on 48V powerbus Electrical error control box Masterboard error Too high current consumption Safety system malfunction Voltage exceeded 55V External blocking encoder brake gear acceleration too high payload too high Overcurrent in joint Encoder too far off shaft Joint temperature exceeded 80 deg C Masterboard version not matching config file info Acceleration deceleration to high 64 UNIVERSAL ROBOTS Replace joint Check grounding and shielding for EMC problems Check 48V output from PSU Check Current Distributor pcb Replace 48V PSU or Curernt Distributor is necessary Remove all external connections to O int
9. cracks or damages replace blue lids if cracked or damaged e Inspect that screws for blue lids are in place and properly tightened Replace screws tighten properly if necessary Correct torque value for screws on blue lids are 0 5Nm If any damages are observed on a robot within the warranty period contact the distributor from where the robot has been purchased All rights reserved 8 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 Service and Replacement of parts 3 1 Robot arm 3 1 1 Robot arm configuration J5 Wrist 3 Tool flange J3 Wrist 1 J4 Wrist 2 Lower arm D TERE J2 ummy join Elbow Upper arm J1 Shoulder Baseplate All rights reserved 9 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 2 Brake release If required the brake on a joint can be released without power connected IMPORTANT NOTICE Before releasing a brake it is extremely important to dismount any dangerous tooling for avoiding any hazardous situations If releasing the brake on Base joint Shoulder joint or Elbow joint it is important to make proper mechanical support prior to releasing the brake Always make sure no personnel are located under the arm when releasing the brake Do not move the joint more than necessary absolute max is 180 degrees in order for the robot to find its original physical position Procedure for releasing the joint Shut down Controller Remove blue lid on joint Push pin brake
10. down for releasing joint can then be rotated Brake on Base Shoulder and Wrist joints Brake on Elbow joint Make sure to mount blue lid properly on joint before turning on Controller All rights reserved 10 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 3 Replacement of base plate How to replace base plate e Move robot to a comfortable position for replacing the base If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove grease plug e Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint housing All rights reserved 11 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS Slide the grey Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screw with a 7 mm open ended spanner about two full rounds approximately 3 mm for each screw Pull the base plate and Base joint apart and gently twist the two parts in opposite directions around 10 mm until a mechanical stop is met holes are keyhole type Disconnect wires between base plate and Base joint 2 x red wire 48V DC 2 x black wire GND Black green conn bus cable All rights reserved 12 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Replace base plate and reconnect wires according to illustration e Gently insert base plate with screws and washers into the Base joint e Make su
11. en 2 0 2 UNIVERSAL ROBOTS e Await that state of the joint changes to OK then press STOP Index mark has now been found index mark is not the same position as zero position JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 39 90 jl OK P 1 1129 S 0 000 C 1 666 V 47 6 TM 21 80 TE 39 90 J2 READY P 0 0000 S J3 READY P 0 0000 S JA READY P 0 0000 S J5 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 0 000 C 0 000 V 47 6 TM 0 000 C 0 000 V 47 6 TM 0 000 C 0 000 V 47 6 TM Tool ON DI 00 A1 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 AI2 0 0 AO1 0 0 AO2 0 0 21 80 TE 42 50 22 90 TE 37 90 22 90 TE 39 90 21 80 TE 38 30 Masterboard OK V 48 1 CR 0 00 mA CIO 3 00 mA T 23 30 General Move Calibration Current Control Step size Firmware f Joint ID Power On Off e Velocity control 0 01 rad sec v Up Down Info Info Info Info Info Info Info Info Info Info Info Info Back U UI Tau set Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 Arming joint 1 Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Setting velocity to 0 0300 rads sec Sending stop all command Setting velocity to 0 0100 rads sec
12. fully inserted and located on the correct side this is important before gently twisting Wrist 1 joint and Wrist 2 joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 1 3Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm e Replace Wrist 1 and reconnect connectors as illustrated into Wrist 2 e Mount blue lid on Wrist 2 joint and tighten with O 5Nm All rights reserved 25 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS gt New Wrist 1 joint and Wrist 2 joint has now been assembled proceed for assembling new Wrist 1 joint and lower arm e Gently insert Wrist 1 joint with screws and washers into the lower arm e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting Wrist 1 joint and lower arm in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 1 3Nm e Gently put back the gasket e Mount the grease plug and tighten with 0 8Nm e Reconnect wires between lower arm and Wrist 1 joint correctly e Mount blue lid on Wrist 1 joint and tighten with O 5Nm e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 26 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 7 Replacement of Wrist 2 joint H
13. lid on joint and check brake pin consult chapter 3 1 2 Reduce acceleration in user program Verify payload is correct Use Teach Mode for checking manual jog with joint Reduce acceleration in user program Verify payload is correct Check settings in config file Replace 48V PSU Masterboard or Current Distributor pcb if necessary Restructure user program Verify TCP and payload settings Reduce acceleration in user program Verify TCP and payload settings Reduce acceleration in user program Verify TCP and payload settings Reduce speed or modify positions in user program Verify TCP payload and Mounting settings Reduce acceleration in user program Verify settings and Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS comm lost between robot and device communication 191 Force mode error Incorrect settign of Force Mode Verify settings Robot TCP close to singularity 194 Conveyor speed too high Conveyor speed higher than robot is Adjust conveyor tick count able to run accordingly 195 MoveP speed too high Too high speed in relation to blend Reduce speed or increase radius blend radius in user program All rights reserved 66 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 5 2 Error phenomena 5 2 1 ControlBox NO CONTROLLER displayed in Initializing ControlBox NO CONTROLLER displayed at INITIALIZING screen Replace ethernet cable between motherboard Defective ethernet cable and Masterboard and verify problem
14. located on the correct side this is important before gently twisting the Elbow joint and dummy joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with respectively 3Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with O 8Nm e Reconnect connectors as illustrated e Mount blue lid on Elbow joint and tighten with O 5Nm e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 21 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 6 Replacement of Wrist 1 joint How to replace Wrist 1 joint Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface Shut down the controller Remove blue lid on Wrist 1 joint Disconnect wires between lower arm and Wrist 1 joint 1 x red wire 48V DC 1 x black wire GND Green connector bus cable Gently remove black flexible gasket between lower arm and Wrist 1 joint with a tiny screwdriver or similar tool and twist it around the lower arm All rights reserved 22 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e 10 screws become visible 5 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e Pull the
15. lower arm and Wrist 1 joint apart and gently twist the two parts in opposite directions around 8 mm until a mechanical stop is met holes are keyhole type e Pull away the lower arm from Wrist 1 joint gt Lowerarm and Wrist 1 joint has now been separated proceed for separating Wrist 1 from Wrist 2 e Remove blue lid on Wrist 2 joint e Disconnect wires between Wrist 1 joint and Wrist 2 joint 1 x red wire 48V DC 1 x black wire GND Green connector bus cable All rights reserved 23 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Gently remove black flexible flat ring between Wrist 1 and Wrist 2 with a tiny screwdriver or similar tool and twist it around the joint housing e Slide the grey Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e Pull Wrist 1 joint and Wrist 2 joint apart and gently twist the two parts in opposite directions around 8 mm until a mechanical stop is met holes are keyhole type All rights reserved 24 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Pull away Wrist 1 joint from Wrist 2 joint gt Wrist 1 joint and Wrist 2 joint has now been separated proceed for assembling new Wrist 1 joint with Wrist 2 joint e Replace Wrist 1 and gently insert Wrist 1 joint with screws and washers into Wrist 2 joint e Make sure the washers are
16. mA T 23 70 General Move Calibration Firmware Joint ID Power On Off Zero current joint position Zero all joint positions Motor calibrate joint motor son n mro Setting Stepsize to U UI raa sec A Info Switching to velocity control Info Setting stepsize to 0 01 rad sec Info Setting current joint to 0 Info Setting current joint to 1 Info Arming joint 1 Info Setting velocity to 0 0100 rads sec Info Setting velocity to 0 0200 rads sec Info Setting velocity to 0 0300 rads sec Info Sending stop all command Info Setting velocity to 0 0100 rads sec Info Setting velocity to 0 0200 rads sec Info Sending stop all command Back in Expert Mode press Return to Normal 2 Universal Robots Graphical Programming Environment PolyScope Expert Mode e Please select Expert Mode EDIT Text File About Low Level Control System Information Java info Kinematics Calibration Runtime Java Version 1 6 0 26 Java 3D version 1 5 2 fcs build4 vendor specification version 1 5 specification vendor renderer OpenGL Renderer Software Rasterizer Renderer version 2 1 Mesa 7 7 1 Java Heap size 42 938368MiB Java Max memory 255 459328MiB Verify zero position by moving the robot to HOME If not satisfied with the zero position perform the procedure once again All rights reserved 45 S
17. of Masterboard italik tl avi kk ty tl ant kak kl sl n ap ka oi sa ak ss ati a 48 3 2 3 Replacement of motherboOaFrQ 0Ltveeeetteetttteeaetttaaeatotteeostooeeeooooooeoeoooouosoooooooooooooooooooooooooooneoooooone 49 3 2 4 Replacement of 48V power supply L 0 0tLieeettteeeettttaeattttaeattooeeeoooooeeseoooeooooooeooooooonooooonooooooonoooooonnen 51 3 2 5 Replacement of 12V power supply l 0 0ttieeeteteeeetttteeattttaeatttoeesooooeeooooooeoooooooooooooonooooooooooooooooooooonnee 54 3 2 6 Replacement of current distriDUTO kikit alopesi ak kn fk ka pa n an 55 All rights reserved 2 Servicemanual UR10 en 2 0 2 4 UNIVERSAL ROBOTS SIT FO ia dire cece E kn eves on eon oa a ti n ka t te a n e a vate equa E e area ee a ke DE eti 57 A 1 UDOALE SOTI AN A tate it an et e n ey e e nO aa e ko a Oa ke lo abit 57 42 Update Joint TWAT E vwati ia key ia yn a ti ky a e ni nines se eo er ip e n a a e sp a 59 A Gene MINE CAMS S keu took ak atra di tt n sat E ik b n e da a e a basen S 62 A FO UD OS MOONE ei det tt tt kap tt tl wi ke A Ete pt ao e oo a Deta laa k 63 Del TED OM ONG 5 kas viraj l t sete tt af a e parca e at ft l a an e e e e ek n ta a at e at a A Ek a e e kl ings a e tl e ba 63 5 2 Error PNENOM NA wo w we asosi aa d a al a ka aki at EE n ele ko kan soap de en pa a asa ki 67 5 2 1 ControlBox NO CONTROLLER displayed in InitialiZiNS vveeeeveeeetereeeosoooeeosoooooosooooooooooooooooooooooooe 67 5 2 2 NO CABLE displayed du
18. sign on main screen of PolyScope 2 Universal Robots Graphical Programming Environment PolyScope Robot User Interface e Please select RUN Program ROBOTS oo SETUP Robot SHUT DOWN Robot All rights reserved 40 Servicemanual UR10 en 2 0 2 Enter password lightbot and press OK 2 Universal Robots Graphical Programming Environment Enter password You are now in Expert Mode press Low Level Control 2 Universal Robots Graphical Programming Environment lightbot Cancel PolyScope Expert Mode Expert Mode About System Information Java info Runtime Java Version 1 6 0 26 Java 3D version 1 5 2 fcs build4 vendor specification version 1 5 specification vendor renderer OpenGL Renderer Software Rasterizer Renderer version 2 1 Mesa 7 7 1 Java Heap size 42 938368MiB Java Max memory 255 459328MiB Please select EDIT Text File Low Level Control Kinematics Calibration Return to Normal UNIVERSAL ROBOTS Select Power On Off tab and press Turn power on for enabling power to motors JO BROKEN COMMUNICATION ERROR J1 BROKEN COMMUNICATION ERROR J2 BROKEN COMMUNICATION ERROR J3 BROKEN COMMUNICATION ERROR J4 BROKEN COMMUNICATION ERROR J5 BROKEN COMMUNICATION ERROR Tool BROKEN COMMUNICATION ERROR Masterboard DI 00000000 DO 00000000 AI1 Masterboard
19. INITIALIZING V 20 0 CR General Move Calibration Tool l Firmware Power On Off Turn power on Turn power off e 0 0 AI2 Q 9 A01 9 89 A02 0 0 0 00 mA CIO 1 00 mA T 22 80 J2 BROKEN COMMUNICATION ERROR J3 BROKEN COMMUNICATION ERROR J4 BROKEN COMMUNICATION ERROR J5 BROKEN COMMUNICATION ERROR BROKEN COMMUNICATION ERROR a All rights reserved 41 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Select General tab and select the desired joint by either using the dropdown list or directly press on the joint state line JO READY P 0 0000 S 0 000 C 0 000 V READY P 0 0000 S C 0 000 V J2 READY P 0 0000 S 0 000 C 0 000 V J3 READY P 0 0000 S 0 000 C 0 000 V J4 READY P 0 0000 S 0 000 C 0 000 V J5 READY P 0 0000 S 0 000 C 0 000 V Tool ON DI 00 Al 47 6 TM 21 70 TE 35 40 47 6 TM 21 70 TE 47 6 TM 21 70 TE 38 80 47 6 TM 21 70 TE 33 40 47 6 TM 22 40 TE 35 40 47 6 TM 20 90 TE 34 40 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 AI2 0 0 AO1 0 0 AO2 0 0 Masterboard OK V 48 1 CR 0 00 mA CIO 4 00 mA T 22 80 Calibration Firmware Joint ID Power On Off Arm robot Arm current joint Backdrive current joint Back Info Info Info Info Info Info
20. NM gqh es W RW NS mann pi va pa a a A A L eee ZE YOY YA W SOx vi EN y LST AOVSIVVSSOO SLOSS WI JI e Remove 15 screws holding the Masterboard e Replace Masterboard with new and tighten the 15 screws to hold the board e Insert all connectors and plugs in correct positions e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 screws e Connect power and verify that teach pendant works properly All rights reserved 48 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 2 3 Replacement of motherboard How to replace motherboard in Controller box Note use the same procedure for power down and removing the alu cover plate as in chapter 3 2 1 Replacement of teach pendant e Remove Flash card and RAM block FY j A e Disconnect cable connections from motherboard 2x RJ45 network cables Black USB cable DVI cable Black cable for RS232 connection White plug with white brown yellow and green wires m UR10 Compact Flash Disk Matches Robot Arm no fa 201 a a l We l ki manman All rights reserved 49 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Remove the 4 screws of the 2 holding brackets e Replace Motherboard with new e If controller is equipped with long hole brackets make sure to replace them with circular hole brackets Tighten the 4 screws gently e Insert the 6 cables in correct positions e Re install Flash card and RAM bl
21. Setting velocity to 0 0200 rads sec Sending stop all command e Use the Up and Down buttons for navigating the joint to the correct zero position according to the following illustrations Press STOP when the joint is in the correct position JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 39 90 JI OK P 1 1129 S 0 000 C 1 666 V 47 6 TM 21 80 TE 39 90 J2 READY P 0 0000 S J3 READY P 0 0000 S JA READY P 0 0000 S J5 READY P 0 0000 S Tool ON DI 00 A1 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 AI2 0 0 AO1 0 0 AO2 0 0 0 000 C 0 000 V 47 6 TM 21 80 TE 42 50 0 000 C 0 000 V 47 6 TM 22 90 TE 37 90 0 000 C 0 000 V 47 6 TM 22 90 TE 39 90 0 000 C 0 000 V 47 6 TM 21 80 TE 38 30 Masterboard OK V 48 1 CR 0 00 mA CIO 3 00 mA T 23 30 General Move Calibration Current Control Step size Firmware f Joint ID Power On Off e Velocity control 0 01 rad sec v Info Info Info Info Info Info Info Info Info Info Info Info E anl Back U UI Tau set Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 Arming joint 1 Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Setting velocity to 0 0300 rads sec Sending sto
22. UNIVERSAL ROBOTS Service Manual Revision UR10_en_ 2 0 2 Robot UR10 with CB2 controller UNIVERSAL ROBOTS Contents 1 2 GETS Fal WTOP O op a eti pa pon E ene ta atan e kk E a e e A n ke e ti Pe Is p 4 LEPU Er rere aa io ern kanta Fa Sa ek a et ep a rer er e a e n a n e a pann ere im aa en n errr av 4 ZE OMIP ANY AL L ANS ee fran len raj ea ae fe tak st en a nn e ap ok ee ee ke pa epe n ee a e te n e ne 5 Fi BIS T fi Gate lao cite a risk ian tk il a anal in ka e a l aa ol A it E aa a ab e a a a anban mes AN ies 5 PREVENTIVE Maintenance a size asse ize it ii li loan ks ik ke kk e e kI a a a El e Ba e ik pa kisal 6 2 CON N MEN kte EEE EE pann l ie e ieee page vg antan si anl n at Zan EE e pt a a en en ok a kata were 6 k A IS OO acy PEGU N k y il aa ak kal ka on a tk ae E a ta a a E pk ok a al Ge e ke ie ea bab a pan 6 2 1 2 Cleaning and replacement Of filters 00000riieooooeeotoooeeettooeaestoaoaeatoooaeosooooeosoooooeosoooooooooooooooooooooooooooneen 7 D2 RODOE avi k s afe fouye ea E ao foi rare aa e e p a e e n re e e na bi 6 oak e taa a ou to kestion ion 8 2 2E WAS L AS P 61 ONA tij it sea E to kot a ke A N e at kap ep e e e ok e saf at a a ote a ii at 8 Service and Replacement OF DAIS sise se sses so adasetite ss step a s v kile kant vw lo k ae ena ea aa ke Na bale pe e ped aialenak usa a son kijossai na Si 9 Azil KODOL ANN gen doue tata von nen Padone onet io tea e ande aaa Fesa n a ao alon e aa
23. ange consult chapter 3 1 9 Replacement of tool flange e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 34 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 9 Replacement of tool flange How to replace tool flange e Move robot to a comfortable position for replacing the tool flange If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove grease plug e Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it around the joint housing All rights reserved 35 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Slide the grey Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e Pull the tool flange and Wrist 3 joint apart and gently twist the two parts in opposite directions around 8 mm until a mechanical stop is met holes are keyhole type e Pull away the tool from Wrist 3 joint e Disconnect the two connectors All rights reserved 36 Servicemanual UR10 en 2 0 2 IR UNIVERSAL ROBOTS e Assembly of replacement tool flange e Insert carefully O ring into the Tool Plate and place cover on top e Final assembly of replacement tool flange e Replace tool flange and reconnect connectors as il
24. ck noises appear observed check brake pin Start the robot program in reduced speed and verify robot is running as intended All rights reserved 73 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 5 3 Schematic drawing ee AK N AN UR PC Motherboard Remote ON OFF Optional Shir UR Screen P 8 g a Li 2 A lt f 3 8 Ti 2e l s a ki N a S ye gt Te a A a e w tea z amp fe a 5 a 2 o a gt a is a ta gig Cc o o 9 9 ji e 2 6 sa 8 z jis 8 2 g 8 di GIN F a x 6 Version CONFIDENTIAL a O N o oO na 5 m Oo lt ui a lu a gt Date Current Distributor All rights reserved 74 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 6 Spare parts 6 1 Spare part list Item no Controller 122550 122810 106700 123670 122090 122500 122805 122600 122700 177002 177003 172080 122740 173203 170400 164204 107601 171021 171030 164219 164200 177503 Robot arm 111010 122102 122202 122302 122104 122204 122304 122060 122070 103402 103404 All rights reserved Item designation Controller excl Teach Pendant UR10 Controller incl Teach Pendant UR10 Euromap E67 kit includes E67 module bypass plug cable Euromap E67 cable 6m Teach Pendant incl Touchscreen and power cables UR5 and UR10 Controller excl Teach Pendant UR5 C
25. de e Expert Mode About System Information Java info Runtime Java Version 1 6 0 26 Java 3D version 1 5 2 fcs build4 vendor specification version 1 5 specification vendor renderer OpenGL Renderer Software Rasterizer Renderer version 2 1 Mesa 7 7 1 Java Heap size 42 938368MiB Java Max memory 255 459328MiB Please select EDIT Text File Low Level Control Kinematics Calibration Return to Normal Firmware has now been updated All rights reserved 61 UNIVERSAL ROBOTS Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 4 3 Using Magic files For easy backup Universal Robots provides Magic files for automatic copy of data from controller to USB stick These files are available Function e URmasgic log file copies the entire log history file to USB stick e URmagic backup programs copies all programs and installation files to USB stick e URmagic configuration files copies all configuration files to USB stick e URmagic upload programs copies all programs and installation files from USB stick e URmagic screenshot generates a screenshot of GUI when USB stick is inserted Go to www support universal robots com download for downloading Magic files Login is required only applicable for Distributors Please note If representing an end customer contact the Distributor from where the robot has been purchased for requiring Magic f
26. e gently twisting the Wrist 1 joint and Wrist 2 joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 1 3Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm e Reconnect connectors as illustrated into Wrist 2 All rights reserved 29 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Mount blue lid on Wrist 2 joint and tighten with O 5Nm gt Wrist 1 joint and Wrist 2 joint has now been assembled Perform same procedure for assembling Wrist 2 joint and Wrist 3 joint e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 30 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 8 Replacement of Wrist 3 joint How to replace Wrist 3 joint e Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove blue lid on Wrist 3 joint e Disconnect wires between Wrist 2 joint and Wrist 3 joint 2 x red wire 48V DC 2 x black wire GND Green connector bus cable All rights reserved 31 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Gently remove black flexible flat ring between Wrist 2 and Wrist 3 with a tiny screwdriver or similar tool and twist it around the joint housing e Slide the gre
27. each pendant e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 screws e Connect power and verify that teach pendant works properly All rights reserved 53 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 2 5 Replacement of 12V power supply How to replace 12V power supply in Controller box Note use the same procedure for power down and removing the alu cover plate and cables for teach pendant as in chapter 3 2 1 Replacement of teach pendant For replacing the 12V power supply follow exactly the same steps as for the procedure in chapter 3 2 4 Replacement of 48V power supply e The 12V power supply is placed in top of rack The screws holding it in the frame are placed on the sides e Replace 12V power supply with new e Reconnect the wires for the 12V power supply e Re install Controller module in reverse order and connect the 2 wires for the fan and cables for the teach pendant e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 Screws e Connect power and verify that teach pendant works properly All rights reserved 54 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 2 6 Replacement of current distributor How to replace current distributor in Controller box Note use the same procedure for power down and removing the alu cover plate and cables for teach pendant as in chapter 3 2 1 Replacement of teach pendant F
28. eft side menu select UPDATE Robot Universal Robots Graphical Programming Environment SETUP Robot e Please select INITIALIZE Robot LANGUAGE Select UPDATE Robot Set PASSWORD CALIBRATE Screen PolyScope 1 6 8719 Jul 30 2012 15 59 40 Setup NETWORK BACK e Press button Search for searching after software update on USB stick 2Q06 Universal Robots Graphical Programming Environment SETUP Robot e Update robot software Please select INITIALIZE Robot LANGUAGE Select Click Search to download a list of possible updates for this robot UPDATE Robot Description Set PASSWORD CALIBRATE Screen Setup NETWORK BACK Update e Mark the found software update and press UPDATE e Press YES for updating the software e Await robot update software after successful update controller will automatically shut power off e Remove USB stick and boot robot All rights reserved 58 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 4 2 Update joint firmware Each joint on robot arm is provided with firmware for controlling the joint For normal operation firmware update is not required Software can be updated on robot without updating the firmware IMPORTANT NOTICE e Firmware should only be updated after consulting Distributor from where the robot has been purchased o
29. either Up or Down for the joint to find its index mark For every time the button is pressed the velocity of joint will be increased JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 39 90 e Jl OK P 1 1129 S 0 000 C 1 666 V 47 6 TM 21 80 TE 39 90 J2 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 42 50 J3 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 22 90 TE 37 90 J4 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 22 90 TE 39 90 J5 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 38 30 Tool ON DI 00 Al 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 AI2 0 0 AO1 0 0 AO2 0 0 Masterboard OK V 48 1 CR 0 00 mA CIO 3 00 mA T 23 30 General Move Calibration Firmware Joint ID Power On Off Current Control Velocity control a D raiser Info Info Info Info Info Info Info Info Info Info Info Info Back U UI Taa set Switching to velocity control Setting stepsize to 0 01 rad sec Setting current joint to 0 Setting current joint to 1 Arming joint 1 Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Setting velocity to 0 0300 rads sec Sending stop all command Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Sending stop all command All rights reserved 42 Servicemanual UR10
30. erboard OK V 48 1 CR 0 00 mA CIO 4 00 mA T 23 50 General Move Calibration Firmware Joint ID Power On Off Zero current joint position Zero current joint position Zero all joint positions Motor calibrate joint motor e Back U UI Taa sect a Info Setting stepsize to 0 01 rad sec Info Setting current joint to 0 Info Setting current joint to 1 Info Arming joint 1 Info Setting velocity to 0 0100 rads sec Info Setting velocity to 0 0200 rads sec Info Setting velocity to 0 0300 rads sec Info Sending stop all command Info Setting velocity to 0 0100 rads sec Info Setting velocity to 0 0200 rads sec Info Sending stop all command mro Setting srepsIZe to U Info Switching to velocity control A Press Back for exiting Low Level Control JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 40 90 e JI OK P 1 1129 S 0 000 C 1 663 V 47 6 TM 22 40 TE 41 90 J2 READY P 0 0000 S 0 000 C 0 000 V 47 5 TM 21 80 TE 43 60 J3 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 23 00 TE 39 20 J4 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 23 60 TE 41 00 J5 READY P 0 0000 S 0 000 C 0 000 V 47 5 TM 22 10 TE 39 90 Tool ON DI 00 Al 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 AI2 0 0 AO1 0 0 AO2 0 0 Masterboard OK V 48 1 CR 0 00 mA CIO 3 00
31. erface of Masterboard Check for short circuit Argument of error code specifies in details what causes the error Replace Masterboard Remove all external connections to O interface of Masterboard Check for short circuit Check Motherboard Masterboard Screenboard Current distributor Euromap if installed Bypass safety connections to O interface of Masterboard Check Energy Eaters Replace Energy Eater Use Teach Mode for checking manual jog with joint Open blue lid on joint and check brake pin consult chapter 3 1 2 Reduce acceleration in user program Verify payload is correct Check for short circuit Check program for singularity issues Replace joint if necessary Adjust encoder with appropriate tool Replace joint if necessary Reduce acceleration in user program Check ambient temperature Replace joint if necessary Edit config file contact distributor Reduce acceleration in user Servicemanual UR10 en 2 0 2 limit 100 Robot changed mode 107 Joint has too many errors ina row 109 Security Stop 110 Joint Security Stop 113 Force limit protective stop 114 High Measured Force Warning 115 Wrong robot type 116 Real time part warning 150 SECURITY CHECK Position change too large 151 SECURITY CHECK Joint limit violation 153 SECURITY CHECK Speed limit violation 156 SECURITY CHECK Torque limit violation 190 Modbus error All rights reserved Mechanical problem in gear related
32. ervicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 2 Controller 3 2 1 Replacement of teach pendant How to replace Teach Pendant on Controller e Shut down the controller and disconnect the power cable open the controller cabinet and loosen the 5 Torx screws and remove the alu cover plate e Remove black USB plug from motherboard and push the alu cover to the right and pull out alu cover for removal All rights reserved 46 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Disconnect 4 cables Red plug with black cable Black USB cable Black DVI cable Black cable for RS232 connection to touchscreen e Remove the bracket foot of the controller box that holds the cable inlet and pull out the cables and plugs through this hole e Replace teach pendant with new insert cable in cable inlet and perform reconnection of all plugs and mounting of alu cover in reversed order of the above description e Connect power and verify that teach pendant works properly All rights reserved 47 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 2 2 Replacement of Masterboard How to replace Masterboard in Controller box Note use the same procedure for power down and removing the alu cover plate as in chapter 3 2 1 Replacement of teach pendant e Carefully remove all plugs and connectors it is recommended to mark the cable positions or take a picture of them kak HUNN iiitit a 9 a f i ne ANN 3
33. iles Instruction for using Magic files e Download Magic file e Save it in the root folder on a USB stick e Insert USB stick into USB connector on right hand side of teach pendant e After afew seconds a red USB sign will appear on the screen this is a warning not to remove the USB stick while the file will do its magic e Await a green lt USB sign appears on the screen then you can safely remove the USB stick e Remove USB stick and you re done The Magic file creates a folder on USB stick named after the serial number of robot If more than one magic file is on USB stick they will be run in sequence the warnings will then appear for each file Do not remove the USB stick before after the last file has been run Multiple folders will be created and named after serial number added with a sequential no like 201220xxx4_0 201220xxx4_1 etc All rights reserved 62 Servicemanual UR10 en 2 0 2 5 Troubleshooting 5 1 Error codes Code Error description 4 Broken communication error 7 Joint encoder index interrupt drift error detected 11 Bad CRC error 15 Master sniffed message addressed to invalid node ID 17 In buffer overflow error in Master from PC 19 Master had no data to send to joints 25 Joint Encoder index drift detected 26 Motor Encoder index drift detected 29 Ethernet package loss detected from PC to robot 31 Caught wrong message not from master 37 In buffer parse error 40 AD Converte
34. is solved Replace Masterboard and verify problem is solved Defective Masterboard Replace motherboard and verify problem is solved Defective motherboard All rights reserved 67 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 5 2 2 NO CABLE displayed during power up NO CABLE displayed during power up gt controller shuts off after few seconds Measure that 230V AC is present on power input Replace current distributor connector on 12V power supply Measure that 12V DC is present on 12V_IN connector on Masterboard and diode marked 12V Replace 12V power supply in top right corner of Masterboard is lit During power up within first few seconds check that the top four diodes in top right corner of Replace Masterboard Masterboard are lit before they turns off again Replace motherboard All rights reserved 68 Servicemanual UR10 en 2 0 2 5 2 3 Force limit protective stop Force Limit Protective Stop Payload and tcp settings in Installation Mounting must correspond with actual tool Are settings incorrect Is center of mass very different from tcp point Are waypoints positioned very close to cylindrical area around base of robot where robot can not operate Are robot moving with excessive speed or accelerating very hard Press teach button on back of TP and check the teach function of all joints any abnormal friction or behavior observed Contact distributor from where robot has been purchased All right
35. isconnect wires between Shoulder joint and upper arm 1 x red wire 48V DC 1 x black wire GND Green connector bus cable Gently remove black flexible gasket between Shoulder and upper arm with a tiny screwdriver or similar tool and twist it around the upper arm All rights reserved 17 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e 10 screws become visible 5 on each side of joint Untighten gently the screw with a 10 mm open ended spanner about two full rounds approximately 3 mm for each screw e Pull the Shoulder joint and upper arm apart and gently twist the two parts in opposite directions around 10 mm until a mechanical stop is met holes are keyhole type e Pull away the Shoulder joint from upper arm e Replace Shoulder joint and gently insert Shoulder joint with screws and washers into the upper arm e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the Shoulder joint and upper arm in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 8Nm e Gently put back the gasket e Mount the grease plug and tighten with O 8Nm e Reconnect wires correctly e Mount blue lid on Shoulder joint and tighten with O 5Nm e Proceed to chapter 3 1 11 Joint calibration for calibrating the joint All rights reserved 18 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 6 Replacement of Elbow
36. joint How to replace Elbow joint e Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Procedure for separating upper arm from Elbow joint is similar to separation of upper arm and Shoulder joint consult chapter 3 1 5 Replacement of Shoulder joint e Remove blue lid on dummy joint e Disconnect wires between Elbow joint and dummy joint 1 x red wire 48V DC 1 x black wire GND Green connector bus cable e Remove grease plug at Elbow joint All rights reserved 19 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS Gently remove black flexible flat ring between Elbow and dummy joint with a tiny screwdriver or similar tool and twist it around the joint housing e Slide the grey Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screw with a 7 mm open ended spanner about two full rounds approximately 3 mm for each screw e Pull Elbow joint and dummy joint apart and gently twist the two parts in opposite directions around 10 mm until a mechanical stop is met holes are keyhole type All rights reserved 20 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Pull away the Elbow joint from dummy joint e Replace Elbow joint and gently insert Elbow joint with screws and washers into the dummy joint e Make sure the washers are fully inserted and
37. lustrated All rights reserved 37 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Replace base plate and reconnect wires correctly e Gently insert tool flange with screws and washers into the Wrist 3 joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the tool flange and Wrist 3 joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 1 3Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with 0 8Nm All rights reserved 38 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 10 Torque values UR10 torque values CONNECTION TORQUE HEAD SIZE BASE PLATE JO BASE 8Nm 10 mm JO BASE J 1 Shoulder 8Nm 10 mm DUMMY JOINT HIGHER ARM 2 3Nm 7mm J4 WRIST 2 J5 WRIST 3 1 3Nm 5 5 mm J5 WRIST 3 TOOL 1 3Nm 5 5mm 1 3Nm 1 3Nm 2 3Nm 8Nm All rights reserved 39 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 11 Joint calibration After replacement of joint it is required to calibrate the new joint in order to find the correct zero position of joint Instruction for calibrating a joint e Jog robot to HOME position Illustration shows the HOME position which is defined as zero position of all joints e Drag a finger from left to right across the UNIVERSAL
38. may have been dropped on the floor when relocating or have run with a load not recommended by Universal Robots Any improper use of the robot will invalidate the guarantee Universal Robots recommends that you do not attempt repair adjustment or other intervention in the mechanical or electrical systems of the robot unless a problem has arisen Any unauthorized intervention will invalidate the guarantee Service related operations and troubleshooting should only be performed by qualified personnel Before performing service related operations always make sure to stop the robot program and disconnect supply to any potential dangerous tool attached on the robot arm and in the work cell In the event of a defect Universal Robots recommends ordering new parts from the Universal Robot distributor from where the robot has been purchased Alternatively you can order parts from your nearest distributor whose details you can obtain from Universal Robots official website at www universal robots com All rights reserved 4 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 1 2 Company details Universal Robots A S Energivej 25 DK 5260 Odense Denmark Tel 45 89 93 89 89 Fax 45 38 79 89 89 1 3 Disclaimer The information contained herein is the property of Universal Robots A S and shall not be reproduced in whole or in part without prior written approval of Universal Robots A S The information herein is subject to change without notice and should
39. 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 2014 by Universal Robots A S The Universal Robots logo is a registered trademark of Universal Robots A S All rights reserved 5 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 2 Preventive Maintenance 2 1 Controller 2 1 1 Visual inspection e Disconnect power cable from controller e Open cabinet door e Check connectors are properly inserted on printed circuit boards e Check for any dirt dust inside of controller e Ifany dirt dust is present gently use vacuum cleaning for removing particles All rights reserved 6 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 2 1 2 Cleaning and replacement of filters e Controller box contains two filters one on each side of controller e Remove filters from controller box and clean them thoroughly using compressed air Replace filters if necessary All rights reserved 7 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 2 2 Robot arm 2 2 1 Visual inspection e Move robot arm to HOME position if possible e Turn off and disconnect power cable from controller e Inspect cable between controller and robot arm for any damages e Inspect flat rings for wear and damages replace flat rings if worn out or damaged e Inspect blue lids on all joints for any
40. ock e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 screws e Connect power and verify that teach pendant works properly All rights reserved 50 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 2 4 Replacement of 48V power supply How to replace 48V power supply in Controller box Note use the same procedure for power down and removing the alu cover plate and cables for teach pendant as in chapter 3 2 1 Replacement of teach pendant e Remove the handle on Controller box by loosen the 2 screws holding it O 3 e Removes the 2 wires for the fan e Remove the 2 nuts in the bottom of Controller module All rights reserved 51 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Gently take out the controller module from the Controller box without disconnecting the robot cable and power cable e Power supplies are located in the rack under the controller module the two 48V power supplies are the lower ones in the rack Before dismounting the 48V power supply mark and disconnect the cables from that supply All rights reserved 52 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Remove the screws respectively of the defective 48V power supply from the side of the rack e Replace 48V power supply with new e Reconnect the wires for the 48V power supply e Re install Controller module in reverse order and connect the 2 wires for the fan and cables for the t
41. ontroller incl Teach Pendant UR5 Motherboard kit Masterboard kit Power Supply Unit 12V Power Supply Unit 48V Current distributor PCB Energy Eater incl Fan Cable f Teach Pendant Touchscreen display Emergency stop switch Power button incl wire bundle Flash card RAM module Wire bundle controller output UR5 Teach button incl connectors Filter kit for controller UR10 robotarm stand alone Joint Size 2 Wrist 1 UR10 Joint Size 2 Wrist 2 UR10 Joint Size 2 Wrist 3 UR10 Joint Size 4 Base UR10 Joint Size 4 Shoulder UR10 Joint Size 3 Elbow UR10 Tool Mounting Bracket UR10 Base Mounting Bracket UR10 Lid set Lowerarm UR10 incl Seal 3x lid for size 2 Lid set Upperarm UR10 incl Seal 2x lid for size 4 1x lid for size 3 75 Servicemanual UR10 en 2 0 2 103310 105201 164061 164062 Accessories 131510 132033 132407 173100 UNIVERSAL ROBOTS Sealing set UR10 external Screw set UR10 Wire bundle Upperarm UR10 Wire bundle Lowerarm UR10 Bracket f mounting robotarm UR10 Item amp Bosch profile Bracket f mounting Teach Pendant Bracket f mounting Controller Cable f tool external 6 2 Tool part list Item no Tools 109010 109101 109102 109110 109103 109104 109105 109106 109107 109109 108001 All rights reserved Item designation Tool kit UR10 kit includes all of the below part no s Spanner Hex 5 5mm Spanner Hex 7 0mm Spanner Hex 10 0mm Screwdriver torx T10 Allen ke
42. or replacing the current distributor follow exactly the same steps as for the procedure in chapter 3 2 4 Replacement of 48V power suppl e Current distributor is placed on top of rack e Before dismounting the current distributor mark and disconnect the cables from the circuit board All rights reserved 55 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Replace current distributor with new e Reconnect the wires for the current distributor e Re install Controller module in reverse order and connect the 2 wires for the fan and cables for the teach pendant e Carefully put back the grey alu cover plate make sure to mount it correct and fix it with the 5 screws e Connect power and verify that teach pendant works properly All rights reserved 56 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 4 Software 4 1 Update software Universal Robots software is named PolyScope This software can be updated when new releases of software become available When updating software on robot with older version it is required to install each update in sequence i e if robot using software v1 5 must be updated to v1 7 it is required to first update to v1 6 and then update to v1 7 If it ain t broken don t fix it If a robot is operating in an existing application Universal Robots do not recommend updating software unless the use of new functions in a newer software release is required for this application IMPORTANT NOTICE
43. ow to replace Wrist 2 joint e Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e Remove blue lid on Wrist 2 joint e Disconnect wires between Wrist 1 joint and Wrist 2 joint 2 x red wire 48V DC 2 x black wire GND Green connector bus cable All rights reserved 27 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Gently remove black flexible flat ring between Wrist 1 and Wrist 2 with a tiny screwdriver or similar tool and twist it around the joint housing e Slide the grey Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e Pull Wrist 1 joint and Wrist 2 joint apart and gently twist the two parts in opposite directions around 8 mm until a mechanical stop is met holes are keyhole type All rights reserved 28 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Pull away Wrist 1 joint from Wrist 2 joint gt Wrist 1 joint and Wrist 2 joint has now been separated Perform same procedure for separating Wrist 2 joint and Wrist 3 joint and proceed when done e Replace Wrist 2 and gently insert Wrist 1 joint with screws and washers into Wrist 2 joint e Make sure the washers are fully inserted and located on the correct side this is important befor
44. p all command Setting velocity to 0 0100 rads sec Setting velocity to 0 0200 rads sec Sending stop all command All rights reserved 43 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Zero position illustrations Base Shoulder Elbow Wrist 1 Base zero position is aligned to Shoulder Elbow and Wrist 1 zero positions are connector in back of robot base Vertical aligned if Base if horizontal Make sure that base of robot is positioned horizontal use leveler for aligning joints Wrist 2 Wrist 3 Wrist 2 zero position is aligned similar Wrist 3 zero position is aligned so tool connector to Base joint is pointing upward Mount two bolts in tool holes and use leveler for aligning joint All rights reserved 44 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS Select Calibration tab and press Zero current joint position for calibrating the joint JO READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 40 80 JI OK P 1 1129 S 0 000 C 1 643 V 47 6 TM 22 00 TE 40 90 J2 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 21 80 TE 42 90 J3 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 22 90 TE 38 90 J4 READY P 0 0000 S 0 000 C 0 000 V 47 6 TM 23 10 TE 40 80 J5 READY P 0 0000 S 0 000 C 0 000 V 47 5 TM 21 90 TE 39 00 Tool ON DI 00 Al 0 0 A2 0 0 C 0 00 mA V 45 50 Masterboard DI 00000000 DO 00000000 AIl 0 0 AI2 0 0 AO1 0 0 AO2 0 0 Mast
45. r hit high limit 43 Could not track target position 44 CRC error likely from joint All rights reserved Issue concerning error Serial communication problem with one or more joints Mechanical problem or firmware in joint Serial communication problem with joint Serial communication problem with joint Communication error between Masterboard and Motherboard Possible CPU overload due to structure of user program Problem with reading encoder position in joint Joint mechanical problem Possible CPU overload due to structure of user program Serial communication problem with joint Serial communication problem with joint EMC issue external or electronics internal External blocking encoder brake gear acceleration too high payload too high Serial communication problem with joint 63 UNIVERSAL ROBOTS How to fix Check green 2 wire connectors and wires in joints Update firmware or replace joint Check green 2 wire connectors and wires in joints Check green 2 wire connectors and wires in joints Check ethernet connection between circuit boards Restructure user program Adjust encoder with appropriate tool or replace joint Replace joint Restructure user program Check green 2 wire connectors and wires in joints Check green 2 wire connectors and wires in joints Check grounding and shielding for EMC problems Use Teach Mode for checking manual jog with joint Open blue lid on joint and check
46. r if representing a Distributor after consulting Universal Robots e Universal Robots do not recommend updating firmware without proper instruction in how to update firmware e When updating firmware it is strictly forbidden to turn off controller or to remove cable between controller and robot arm during update e Universal Robots can be no means be held responsible for any failed update caused by improper operation Instruction for updating firmware Prior to updating firmware it is required to update the robot software Please refer to chapter 4 2 for updating software When updating robot software the firmware will automatically be copied to a folder on the controller e Drag a finger from left to right across the UNIVERSAL sign on main screen of PolyScope Universal Robots Graphical Programming Environment PolyScope Robot User Interface Please select RUN Program UNIVERSAL ROBOTS aa SETUP Robot About SHUT DOWN Robot All rights reserved 59 Servicemanual UR10 en 2 0 2 e Enter password lightbot and press OK 2 Universal Robots Graphical Programming Environment Enter password e You are now in Expert Mode press Low Level Control 2Q06 Universal Robots Graphical Programming Environment PolyScope Expert Mode L lightbot e Please select Expert Mode EDIT Text File About System Information Java info
47. re the washers are fully inserted and located on the correct side this is important before gently twisting the base plate and Base joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 8Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with O 8Nm All rights reserved 13 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 3 1 4 Replacement of Base joint How to replace Base joint e Move robot to a comfortable position for replacing the joint If necessary dismount entire robot arm from work cell and place arm on solid surface e Shut down the controller e For separating base plate from Base joint consult chapter 3 1 3 Replacement of base plate e Remove blue lid on Base joint e Disconnect wires between Base joint and Shoulder joint 2 x red wire 48V DC 2 x black wire GND Green connector bus cable e Remove grease plug at Shoulder joint All rights reserved 14 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Gently remove black flexible flat ring between Base and Shoulder with a tiny screwdriver or similar tool and twist it around the joint housing e Slide the grey Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screw with a 7 mm open ended spanner about two full rounds approximately 3 mm for each screw
48. ring power UP L0L0ettteeetttteetttteeesttoeeastoooeeooooooeoooooooooooooooooooooooooooooooooooonnese 68 iD OVE NAN f Ke VYE L a ei kn fbk ka n at cogs ee ese Seas se parse cease oc 69 a OWE Ol Lane A AN IA LI ZING op rit woo aki al a e ti sp id e n tib ia Oo Oki net t io n kite ip ad ek ae aa oo t 70 SAS CIECKIISE OTO aC O IISIOM a at kas at n a at ka ke ane a 6 e l ko ere B l e kek a im nen 73 DONE af IUE ANA W AE en tl tk kafe een ee ee ee ee ee 74 DANE PAKE iya pr ka t ky e a ri pentane on ip ik aa ti a E ab sp k kole pire ban a k akite 15 Gal SIU E ii a e te ii te wan e an gene ka e n ii n ab a a ok ki a aa e bak De in dan 15 GAZ TOI PALM oer nO Oe ka e kou ten Sao ik ke lt opera ae boat 76 FACIE OT FO DOU etone bote sikse a tet pote vein E a ne n a e a ee on ob pk pot w pe e pe ni ake 77 ENANSE OL ates vle vo PEA AIEEE ptet ant tn ap al ok ri kn tice e EEEE ba e deta a a be be kob 18 BA NDE SON ai a ot retire nati po eta aoe OCP ene ek pa nee eee iben 18 All rights reserved 3 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 1 General information 1 1 Purpose The main purpose of this manual is to help the user safely perform service related operations and troubleshooting Universal Robots industrial robots are designed using high quality components designed for long lifetime However any improper use of robot can potentially cause failures on the robot For example the robot may have been overloaded on an overrun or it
49. s reserved UNIVERSAL ROBOTS Adjust payload and tcp settings Adjust center of mass using script code set payload software v1 7 or newer Adjust waypoints away from this area or reduce speed acceleration Reduce speed or acceleration Inspect joint with abnormal behavior joint might have mechanical failure Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 5 2 4 Power on failure in Initializing If power turns off a few seconds after Robot Power is turned On in the Initializing window there are many possible causes for this phenomenon Most likely it is a control box failure or a communication failure with a joint or the tool Control box failure Check log history for error messages and consult the section Error Codes for detailed explanation Power controller OFF ON During power up within the first three seconds of Replace 48V power supply power up measure that 230V AC is present on 48V_PSU1 connector on current distributor PCB Measure that 12V DC is present in the red n Replace current distributor connector flatcable on the current distributor Replace Masterboard All rights reserved 70 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS Communication failure with a joint or the tool connector Check log history for error messages and consult the section Error Codes for detailed explanation Go to LOW LEVEL CONTROL in EXPERT MODE consult chapter 4 2 for how to access EXPERT MODE Go
50. to tab POWER ON OFF and press TURN Unmount tool and check POWER ON Does state of tool switch from green comm connector is BROKEN COMM ERROR to READY fully inserted in pcb Does state of tool switch to READY NO Continue to next page Replace tool All rights reserved 71 Servicemanual UR10 en 2 0 2 Go to tab POWER ON OFF and press TURN POWER ON Does state of all joints JO J5 switch from BROKEN COMM ERROR to READY YES Communication ok to joints and tool All rights reserved 72 NO YES UNIVERSAL ROBOTS Remove blue lid of joint and check green comm connector is fully inserted Does state of joint switch to READY NO Replace joint Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 5 2 5 Checklist after a collision Checklist after a collision Check log history for error messages and consult the section Error Codes for detailed explanation Stop robot program and eventually press the Emergency button prior to entering the work cell Visually inspect robot arm Remove lid and inspect Are any parts visually damaged like damages on parts inside of joint one of the blue lids Press teach button on back of TP and check the Inspect joint with abnormal teach function of all joints gt any abnormal friction behavior or behavior observed Press teach button on back of TP and check the Inspect joint with abnormal teach function of all joints gt any excessive noise noise If cli
51. y Teflon ring apart 10 screws become visible 5 on each side of joint Untighten gently the screws with a 5 5 mm open ended spanner about two full rounds approximately 3 mm for each screw e Pull Wrist 2 joint and Wrist 3 joint apart and gently twist the two parts in opposite directions around 8 mm until a mechanical stop is met holes are keyhole type All rights reserved 32 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Pull away Wrist 2 joint from Wrist 3 joint gt Wrist 2 joint and Wrist 3 joint has now been separated e For separating Wrist 3 joint from tool flange consult chapter 3 1 9 Replacement of tool flange e Replace Wrist 3 and gently insert Wrist 2 joint with screws and washers into Wrist 3 joint e Make sure the washers are fully inserted and located on the correct side this is important before gently twisting the Wrist 2 joint and Wrist 3 joint in opposite directions until a mechanical stop is met e Tighten the 10 screws lightly then tighten in cross order with 1 3Nm e Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring e Mount the grease plug and tighten with O 8Nm e Reconnect connectors as illustrated into Wrist 3 All rights reserved 33 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS e Mount blue lid on Wrist 3 joint and tighten with O 5Nm gt Wrist 2 joint and Wrist 3 joint has now been assembled e For assembling Wrist 3 joint and tool fl
52. y torx T10 Torque wrench Hex 5 5mm Size 1 and Size 2 Torque wrench Hex 7 0mm Size 3 Torque wrench Hex 10 0mm Size 4 Calibration tool size 3 Bypass cable for setting joint ID 76 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 7 Packing of robot Packing of robot and controller box for shipment e Remove any external tooling and external electrical connections e Load program Put_into_box_ur10 urp and follow instructions while removing mounting bolts gt Universal Robots Graphical Programming Environment Program Installation Move WO Log Put_into_box_UR10 Command Graphics Structure Y Robot Program IS a Action 9 V Move Home Popup Waypoint_26 Waypoint_3 Popup Waypoint_l Popup Waypoint_2 G Simulation a gt LI Li Speed 10094 Previous Next gt Real Robot While robot folds together hold a piece of bubble wrap between Shoulder joint and wrists Note If robot cannot run or power is not available it is possible to manually release the brakes for each joint individually and pack the robot accordingly For brake release see chapter 3 1 2 e Power down disconnect power and disconnect robot arm from controller e Pack robot arm and Controller box in designated boxes All rights reserved 77 Servicemanual UR10 en 2 0 2 UNIVERSAL ROBOTS 8 Changelog 8 1 Changelog Date Revision Action Changes 3 jan 2013 UR10 en 1 0

Service Manual UR10

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