Service Manual: "Original Instructions"

Service Manual
"Original instructions"
Revision:
UR10_en_3.2.7
Robot:
UR10with CB3.0/3.1/3.2-controller
CB3.0 valid from robot s/n 2014300001 to 2016301178

CB3.1 valid from robot s/n 2016301179 to 2019301731
CB3.2 valid from robot s/n 2019301732
Valid from robot s/n: 2014330001

1. Service Manual
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 © 2009–2019 by Universal Robots A/S
The Universal Robots logo is a registered trademark of Universal Robots A/S.
2. Content
1. Service Manual 2
2. Content 3
3. General Information 1
3.1. Purpose 1
3.2. Company Details 1
3.3. Disclaimer 1
3.4. Warning Symbols in this Manual 2
4. Recommended Inspection Activities 3
4.1. Controller 3
Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

4.1.1. Inspection Plan 3
4.1.2. Safety Functions 4
4.1.3. Visual Inspection 5
4.1.4. Cleaning and Replacement of Filters 5
4.2. Robot Arm 10

4.2.1. Inspection Plan 10
4.2.2. Functional Inspection 10
4.2.3. Visual Inspection 11
5. Service and Replacement of Parts 12

5.1. Handling ESD-sensitive parts 12
5.1.1. Recommended Tools 15
5.2. Robot Arm 16

5.2.1. Before Returning Any Part to Universal Robots 16
5.2.2. Robot Arm Configuration 17
5.2.3. Brake Release 17
5.2.4. General Guidance to Separate Joint from Counterpart 18
5.2.5. Torque values 22
5.2.6. Base joint – Base mounting bracket 23
5.2.7. Shoulder joint – Base joint 25
5.2.8. Upper arm – Shoulder joint 26
5.2.9. Elbow joint – Upper arm 27
5.2.10. Elbow counterpart – Elbow joint 33
5.2.11. Wrist 1 joint – Lower arm 34
5.2.12. Wrist 2 joint – Wrist 1 joint 35
5.2.13. Wrist 3 joint – Wrist 2 joint 37
User Manual UR10

5.2.14. Tool flange – Wrist 3 joint 37
5.2.15. Instructions for calibrating a joint 39
5.2.16. Dual Robot Calibration 45
5.2.17. Change Joint ID 45
5.2.18. Joint Spare Part Adaptation 47
5.2.19. Wire Bundle Installation Guide 48
5.3. Controller 52
5.3.1. Replacement of Motherboard 3.0 52
5.3.2. Replacement of Motherboard 3.1 54
5.3.3. Upgrading of Motherboard 3.0 with 3.1 57
5.3.4. Replacement of Safety Control Board 63
5.3.5. Replacement of Teach Pendant 66
5.3.6. Replacement of 48V power supply 69
5.3.7. Replacement of 12V power supply 76

5.3.8. Replacement of Current distributor 77
6. Software 79
6.1. Software update 79
6.2. Update joint firmware 81
6.3. Using Magic files 88
6.4. Backup of data 88
6.4.1. Hardware requirements 89
6.4.2. Software requirements 89
6.4.3. How to access Linux partition from Windows 89
6.4.4. Copy the Data from CF-card to UR-USB 90
7. Troubleshooting 97
7.1. Error codes 97
7.2. LED indicators and Fuses on Safety Control Board 147
7.2.1. Normal startup sequence for a CB3.x UR10 148
7.3. Error Phenomena 149

7.3.1. Control Box: NO CONTROLLER displayed in Initializing 149
7.3.2. NO CABLE displayed during power up 150
7.3.3. Protective Stop 150
7.3.4. Power on failure in Initializing 152
7.3.5. Checklist After a Collision 154
7.3.6. Communication to joints and tool 155
7.3.7. Complete Rebooting Sequence 157
7.4. Electrical Documentation 158
UR10 User Manual

7.4.1. Schematic Overview 158
7.4.2. E-Plan diagrams 165
8. Spare parts 173

9. Packing of robot 177
10. Change log 178
User Manual UR10

UR10
User Manual
3. General Information
3.1. 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 to ensure a long
lifetime.
However, any improper use of robot can potentially cause failures. If for example, the robot is
overloaded, run with a load not recommended by Universal Robots, dropped during relocation,
damaged by collision or any other improper usage, the warranty will be void.
Universal Robots recommends that the user does not attempt repair, adjustment or other
intervention in the mechanical or electrical systems of the robot without first consulting a UR

certified service engineer. Any unauthorized intervention will void the warranty. 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 the main power to any potential dangerous tool on the robot or in the work cell.
In the event of a defect, Universal Robots recommends ordering new parts from the Universal
Robot distributor where the robot was purchased from.
Alternatively, parts can be ordered from the nearest distributor, details of which can be obtained
from Universal Robots official website at www.universal-robots.com
3.2. Company Details

Universal Robots A/S
Energivej 25
DK-5260 Odense Denmark
Tel.: +45 89 93 89 89
Fax: +45 38 79 89 89
3.3. Disclaimer
Universal Robots continues to improve reliability and performance of its products, and therefore
reserves the right to upgrade the product 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.
User Manual 1 UR10

3.4. Warning Symbols in this Manual

DANGER, WARNING, CAUTION, NOTICE and SAFETY INSTRUCTION statements are used
throughout this manual to emphasize important and critical information.
You MUST read these statements to help ensure safety and to prevent product damage.
The statements are defined below.
DANGER
These warnings mean a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
These warnings mean a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
These warnings mean a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
These warnings mean damage to property may occur if no precautions are taken.
CAUTION
This warning sign contain references to safety-relevant information or general
safety measures.
This warning sign do not refer to individual hazards or individual precautionary
measures.
UR10 2 User Manual

4. Recommended Inspection Activities

It is recommended to perform preventive maintenance on the control box and
robot at least once per year. In case of use in dirty or dusty environments it is
recommended to increase the frequency.
In case dust/dirt/oil is observed on the controller or robot arm, it can be wiped away using a cloth
with cleaning agent. Cleaning agent: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10%
Naphtha.
In very rare cases, very small amounts of grease can seep from the joint. This does not affect
the specified function or lifetime of the joint.
NOTICE

Never use compressed air to clean the controller or robot arm as it can damage
the seals and internal components
4.1. Controller
4.1.1. Inspection Plan

Set forth below is a check list of inspections that Universal Robots recommends be performed
according to the marked time interval. If upon inspection, the referenced parts are not in an
acceptable state, please rectify immediately.
User Manual 3 UR10

Use the following sections as guide:

2.1.2 Safety Functional
Monthly Bi-annually Annually
2.1.3 Visual Inspection
3.2 Control Box
Check Emergency stop on Teach Pendant F X
Check Backdrive mode F X
Check Freedrive mode F X
Check safety inputs and outputs
F X
(if connected)
Check Teach Pendant cable V X
Check and clean air filters on Control Box V X
Check terminals in Control Box F X
Check electrical grounding 1< Ω to Control Box F X
Check main power to Control Box F X
V = Visual inspection F = Functional inspection
4.1.2. Safety Functions

The robot safety functions must be tested at least once a year to ensure correct function. The
following tests must be performed.
• Backup data from the storage device - See section 4.4 Backup of data
• Test that the Emergency Stop button on the Teach Pendant functions:
• Press the Emergency Stop button on the Teach Pendant.
• Observe that the robot stops and turns off the power to the joints.
• Power on robot again.
• Test Freedrive mode:
• Unmount attachment or set TCP/Payload/CoG according to tool specifications.
• Set the robot in Free drive mode by holding the black Freedrive button on the back of
the Teach Pendant.
• Move the robot to a position stretched out horizontally to the edge of its workspace.
• Monitor that the robot maintains its position unsupported while the Freedrive button
is still pressed.
• Test Backdrive mode:
If the robot is close to collision, the BACKDRIVE function can be used to move the robot to
a safe position before initializing.
• Press ON to enable power, state will change to Idle.
• Press and hold Freedrive -> status will change to BACKDRIVE.
• Move the robot by hand as in Freedrive.
UR10 4 User Manual

• In BACKDRIVE mode brakes will only be released on individual joints when they are
moved, and will remain released as long as the Freedrive button is pushed. Robot will
be “heavy” to move around compared to Freedrive mode.
• Be sure to test each joint individually, to ensure the brake release as expected.
• Verify safety settings:
• Verify that the safety settings of the robot comply with the Risk Assessment of the
robot installation.
• Test that additional safety inputs and outputs are still functioning:
• Check which safety inputs and outputs are active and test that they can be triggered.
4.1.3. Visual Inspection

• Disconnect power cable from controller
• Check that the terminals on the Safety Control Board are properly inserted and do not have

loose wires
• Check all connections on Motherboard and connection between Safety Control Board and
Motherboard
• Check for any dirt/dust inside of controller, clean with ESD vacuum cleaner if needed
NOTICE
Never use compressed air to clean inside the controller as it can damage
componentss
4.1.4. Cleaning and Replacement of Filters
Original control box

• Controller box has two filters, one mounted on each side of the box.
User Manual 5 UR10

• Remove filters from controller box and clean them thoroughly using low pressure air.
• Replace filters if necessary.
• Gently remove the outer plastic frame and maintain the filter.
UR10 6 User Manual

Merge Control Box

• Controller box has two filters, one mounted on each side of the box.
User Manual 7 UR10

• Remove filters from controller box and clean them thoroughly using low pressure air.
• Replace filters if necessary.
• Gently remove the outer plastic frame and maintain the filter.
UR10 8 User Manual

Cleaning the Robot in Relation to COVID

You can wipe away any dust/dirt/oil observed on the robot arm using a cloth and one of the
following cleaning agents: Water, Isopropyl alcohol, 10% Ethanol alcohol or 10% Naphtha. In rare
cases, very small amounts of grease can be visible from the joint. This does not affect the
function, use, or lifetime of the joint.
Due to the added focus on cleaning your robot, Universal Robots recommends cleaning with 70%
isopropyl alcohol (rubbing alcohol).
User Manual 9 UR10

1. Wipe the robot with a hard twisted micro fiber cloth and 70% isopropyl alcohol (rubbing
alcohol).
2. Let the 70% isopropyl alcohol dwell on the robot for 5 minutes, and then clean the robot
using standard cleaning procedure.
DO NOT USE BLEACH. Do not use bleach in any diluted cleaning solution.
NOTE
The above standard cleaning recommendation is still valid with the addition of
the COVID-19 cleaning recommendation.
4.2. Robot Arm

4.2.1. Inspection Plan

Set forth below is a check list of inspections that Universal Robots recommends be performed
according to the marked time interval. If upon inspection, the referenced parts are not in an
acceptable state, please rectify immediately.
Use the following sections as guide: Monthly Bi-annually Annually

2.2.2 Visual Inspection
3.1 Robot Arm
Check blue lids* V X
Check blue lid screws F X
Check flat rings V X
Check robot cable V X
Check robot cable connection V X
Check Robot Arm mounting bolts* F X
Check Tool mounting bolts* F X
Check screws/bolts that is connecting joints* F X
V = Visual inspection F = Functional inspection * = Must also be checked after heavy
collision
4.2.2. Functional Inspection

The purpose of the functional inspection is to ensure that screws, bolts, tools and robot arm are
not loose. The screws/bolts mentioned in the inspection plan should be checked with a torque
wrench with the correct torque, specified in 5.2.5. Torque values on page 22
UR10 10 User Manual

For the robot arm mounting bolts, these specifications can be found in the User Manual under
the Mounting section.
4.2.3. Visual Inspection
NOTICE
Never use compressed air to clean the robot as it can damage the seals and
internal components
• Move robot arm to HOME position (if possible).

• Turn off and disconnect power cable from controller.
• Inspect cable between controller and robot arm for any damage.
• Inspect flat rings for wear and damage.

• Replace flat rings if worn out or damaged.
• Inspect blue lids on all joints for any cracks or damage.
• Replace blue lids if cracked or damaged.
• Inspect that screws for blue lids are in place and properly tightened.
• Replace screws, tighten properly if necessary.
• Correct torque value for screws on blue lids are 0.4Nm.
If any damage is observed on a robot within the warranty period, contact the distributor from
which the robot has been purchased.
User Manual 11 UR10

5. Service and Replacement of Parts

5.1. Handling ESD-sensitive parts
To prevent damage to ESD-sensitive parts, follow the instructions below. These are in addition to
standard precautions such as turning off power before removing circuit boards.
Keep the ESD-sensitive part in its original shipping container. (a special "ESD bag") until the part
is ready to be installed.
Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This
discharges any static electricity in your body to ground.
UR10 12 User Manual

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

Hold the ESD-sensitive part by its edges. Do not touch its pins!
User Manual 13 UR10

Do not place the ESD-sensitive part on nonconductive material or on a metal table. If the ESD-
sensitive part needs to be put down for any reason, then first put it into its special ESD bag
UR10 14 User Manual

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

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

Robot arm:
• Service kit – part no.: 109010.
Control box:
Below tool should be ESD safe tools.
Slotted screwdriver
• 0.5 (For terminals on Current Distributor)
Philips screwdriver
• PH2 (For terminals on power supplies)
Torx screwdriver
• TX10 (For external connections i.e. main power connection)
• TX20 (For shield in front of PCB’s)
• TX45 (For Control box handle)
Hex screwdriver
• Size 4 (For Safety Control Board and Motherboard)
Spanner
• Size 7 (for energy eater)
User Manual 15 UR10

Socket screwdriver
• Size 10 (For component bracket and grounding nuts)
• Bit extinction (To access nuts that are hard to reach)
Other
• Flathead Plier (for removing terminals on Safety Control Board and Current
Distributor)
5.2. Robot Arm

5.2.1. Before Returning Any Part to Universal Robots
• Remove all external non-UR equipment such as grippers, hoses, cables and so on.
Universal Robots cannot be held responsible for damage caused to non-UR equipment
mounted on the robot.
• Backup all relevant files before sending the robot/part to UR. Universal Robots cannot be
held responsible for loss of programs, data or files stored in the robot.
NOTICE
If the robot/part has been in contact with, or working in environments, where
dangerous chemicals or materials are present, the robot must be cleaned before
shipment. If this is not possible, the shipment must be accompanied by an MSDA
(Material Safety Data Sheet) in English and instructions for cleaning the
chemicals. The amount of labor hours needed for cleaning will be billed at the
standard rate.
If UR finds the robot/part unsafe to service, UR reserve the right to get the
robot/part cleaned or decline the case and send the part back, at customers
expense.
Note: Please note that the robot will be updated to newest software/firmware when repaired.
New parts will also be updated to newest version (hardware/software). Therefore, updating
PolyScope may be necessary when new parts are mounted.
• You will find packing down procedure in section - Packing of robot
UR10 16 User Manual

5.2.2. Robot Arm Configuration
Tool flange Tool flange – Wrist 3 joint
J Size 0 Wrist 3 joint – Wrist 2 joint
Wrist 2 joint – Wrist 1 joint
J3 Size 0 Wrist 1 joint – Lower arm
5.2.10. Elbow counterpart – Elbow joint on

J3 Size 0
page 33
J3 Size 0 Elbow joint – Upper arm
J2 Size 1 Upper arm – Shoulder joint

J1 Size 2 Shoulder joint – Base joint
J0 Size 2 Base joint – Base mounting bracket
5.2.3. Brake Release

If required, the brake on a joint can be released without power connected.
CAUTION
Before releasing a brake, it is extremely important to dismount any dangerous
parts to avoid any hazardous situations.
If releasing the brake on Base joint, Shoulder joint or Elbow joint, it is important to
make proper mechanical support prior to releasing the brake.
Always make sure personnel are in no risk when releasing the brake.
Do not move the joint more than is necessary. Not more than 160 degrees to
ensure the robot can find its original physical position.
Procedure for releasing the joint

1. Shut down Controller.
2. Remove blue lid on joint.
3. Push brake pin down to release, joint can then be rotated.
User Manual 17 UR10

Brake on Base and Shoulder

Brake on Elbow joint Brake on Wrist joints
joints
4. Make sure to replace blue lid onto joint correctly and fasten screws before turning on
controller.
5. Correct torque value for screws on blue lids are 0.4Nm
5.2.4. General Guidance to Separate Joint from Counterpart

Disassemble:
1. Ensure that the necessary tools and documentation are available before starting the repair.
1. Service kit with torque tools, ESD Wristband, etc.
2. Thoroughly read and understand this guide.
2. Move the robot to a comfortable position for disassembly or if necessary dismount entire
robot arm from work cell and place on a solid surface.
3. Shut down the controller.
4. Remove blue lid.
5. Reattach one of the screws from the blue lids, and connect the Alligator Clip from the ESD
wristband to it, as shown below.
6. Gently unplug the cable connectors without bending the printed circuit board.
Some connectors have a lock that must be engaged before it is pulled out of the printed
circuit board. Example below.
UR10 18 User Manual

7. Disconnect wires
8. Remove alignment screw (Not present on newer joint housings).

9. Gently remove black flexible flat ring with a small flathead screwdriver or similar tool and
pull it back over joint housing away from its original position.
10. Slide the grey Teflon ring back.

10 screws become visible, 5 on each side of joint.
Loosen the screws with an open-ended spanner approximately two full turns each.
11. Pull the two parts apart and gently twist them counter-clockwise around 5 degrees, until a
mechanical stop is met (holes are keyhole-type). They can then be completely separated.
User Manual 19 UR10

Assemble:
After replacing a joint do as follows to assemble the robot arm.
1. Gently insert a screw with washer into each of the ten threaded holes in the joint housing
(the joint will most likely have these already inserted).
CAUTION
It’s important that the correct screws are placed in the correct hole.
The blue marked screws are shorter than the rest.
Ensure the alignment taps are aligned before assembly. If the taps are
opposite each other (180 degree offset), the joints cannot be merged
properly and there is a risk the joint will loosen itself over time.
UR10 20 User Manual

MANDATORY ACTION: Ensure the UR10 Elbow Lock is installed between

upper arm and elbow joint.
See Special assembly instructions for Elbow joint – upper arm
2. Make sure all washers are flush against the head of the bolt (this is important) before
gently twisting the parts clockwise roughly 5 degrees until a mechanical stop is met.

3. Gently tighten the screws, until they are almost in the correct position then tighten in cross
order (as shown in the numbered diagram below).
ALWAYS start with the screws at the alignment tap.
Tighten with the correct torque, to ensure that that the two faces are parallel.
See Torque values for more information.
4. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon
ring.
5. Mount the alignment screw (if present) and tighten with 0.4Nm.
6. Twist the communication cable 1.5 to 2 full rounds before connecting to reduce electrical
noise in the system.
User Manual 21 UR10

7. Mount the blue lid on the joint and tighten with 0.4Nm.
8. Proceed to chapter Dual Robot Calibration for calibrating the robot.
5.2.5. Torque values

UR10 torque values
CONNECTION TORQUE HEAD SIZE
Base mounting bracket J0 BASE 8.0Nm 10 mm.
[J0] Base [J1] Shoulder 8.0Nm 10 mm.
[J1] Shoulder Upper arm 8.0Nm 10 mm.
Upper arm [J2] Elbow 2.6Nm 7 mm.
[J2] Elbow Elbow counter part 2.6Nm 7 mm.
Elbow counter part Lower arm 2.6Nm 7 mm.
Lower arm [J3] Wrist 1 1.3Nm 5.5 mm.

[J3] Wrist 1 [J4] Wrist 2 1.3Nm 5.5 mm.
[J4] Wrist 2 [J5] Wrist 3 1.3Nm 5.5 mm.
[J5] Wrist 3 Tool mounting bracket 1.3Nm 5.5 mm.
Alignment screw 0.4Nm Torx T10
Blue lid 0.4Nm Torx T10
Tool Connector 0.3Nm Finger/Hand
UR10 22 User Manual

5.2.6. Base joint – Base mounting bracket

Disassemble
For details and photos please see: General Guidance to Separate Joint from Counterpart
User Manual 23 UR10


2. Remove alignment screw.
3. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it
around the joint housing.
4. Slide the grey Teflon ring back. 10 screws become visible, 5 on each side of joint. Loosen
the screws with a 7 mm. open-ended spanner about two full turns, approximately 3 mm. for
each screw.
5. Pull the base mounting bracket and Base joint apart and gently twist the two parts in
opposite directions around 10 mm. until a mechanical stop is met (holes are keyhole-type).
6. Pull away the base mounting bracket from Base joint.
7. Disconnect wires between base plate and Base joint.
1 x red wire = 48V DC

1 x black wire = GND
Black connector = bus cable (note connector orientation)
Assemble
1. Replace base mounting bracket and reconnect wires according to illustration:
2. Twist the communication cable 1.5 to 2 full rounds before it is connected to reduce
electrical noise in the system.
3. Gently insert base mounting bracket with screws and washers into the Base joint.
4. Make sure the washers are fully inserted and flush against the head of the bolt (this is
important) before gently twisting the parts in opposite directions until a mechanical stop is
met.
5. Gently tighten the 10 screws, and then tighten in cross order with 8.0Nm.
6. Slide the grey Teflon ring into place and gently put the flat ring back on top of the Teflon
ring.
7. Mount the alignment screw and tighten with 0.4Nm.
8. Mount blue lid on Base joint and tighten with 0.4Nm.
UR10 24 User Manual

5.2.7. Shoulder joint – Base joint

Disassemble

2. Remove blue lid on Base joint.
3. Connect ESD wristband

4. Disconnect wires between Base joint and Shoulder joint

5. Remove alignment screw

6. Gently remove black flexible flat ring between Base and Shoulder with a tiny screwdriver or
similar tool and twist it around the joint housing.
each screw.
8. 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).
9. Pull away the Base joint from Shoulder joint.
Assemble
User Manual 25 UR10

1. Gently insert Base joint with screws and washers into the Shoulder joint.
2. 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.
3. Tighten the 10 screws lightly, and then tighten in cross order with 8.0Nm.
4. Slide the grey Teflon ring in place and gently put back the flat ring on top of the Teflon ring.
6. Reconnect connectors as illustrated.
8. Mount blue lid on Base joint and tighten with 0.4Nm.
5.2.8. Upper arm – Shoulder joint

Disassemble

2. Remove blue lid on Shoulder joint.
4. Disconnect wires between Upper arm and Shoulder joint.

UR10 26 User Manual

6. Gently remove black flexible gasket between Upper arm and Shoulder with a tiny
screwdriver or similar tool and twist it around the upper arm.
7. 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.
8. Pull the Shoulder joint and upper arm apart and gently twist the two parts in opposite
9. Pull away the Shoulder joint from upper arm.
Assemble

1. Gently insert Shoulder joint with screws and washers into the upper arm.
met.
4. Gently put back the gasket.
7. Reconnect wires correctly.
Twist the communication cable 1.5 to 2 full rounds before it is connected to reduce
8. Mount blue lid on Shoulder joint and tighten with 0.4Nm.

5.2.9. Elbow joint – Upper arm

Disassemble and assemble
User Manual 27 UR10

Procedure for separating Elbow joint from Upper arm is similar to separation of Upper arm and
Shoulder joint, consult chapter Upper arm – Shoulder joint
Disassemble

2. Remove blue lid on Elbow counterpart.
3. Disconnect wires between Elbow joint and Elbow counterpart

4. Remove alignment screw(only on older houses).

5. Gently remove black flexible flat ring between Elbow and Elbow counterpart with a tiny
screwdriver or similar tool and twist it around the joint housing.
each screw.
7. Pull Elbow joint and Elbow counterpart apart and gently twist the two parts in opposite
8. Pull away the Elbow joint from Elbow counterpart.
UR10 28 User Manual

Special Assembly Instructions for Elbow Joint – Upper Arm
WARNING
The UR10 elbow lock MUST be added.
Replace UR10 elbow lock if damaged.
All 10 plugs must be added.
When assembling the elbow joint and upper arm, it’s important to add the “UR10 elbow lock”.
The reason for this is described in Product Alert: Safety alert CB3 UR10.
The Product Alert can be found on the Universal Robots Support site under FAQ.
https://www.universal-robots.com/how-tos-and-faqs/faq/
The UR10 Elbow lock should only be used between the elbow joint and the upper arm.

The UR10 Elbow lock contains the following parts.
UR10 Elbow lock – 103810

NO. QTY. DESCRIPTION
1 3 Locking collar
2 12 Plug
User Manual 29 UR10

3 1 Flatring
4 1 Tweezer
NOTE
Only 10 plugs and 2 collars are needed, the rest is spares.
Adding the plugs and collars is done in 5 easy steps.

Orient robot with elbow lower than base joint. This will ease insertion of plugs.
1. Remove the flatring between the elbow joint and upper arm.
Tweezer is well suited for this purpose. Take care not to damage the flatring.
2. Ensure all bolts are tightened to 2.6Nm
UR10 30 User Manual

3. Add a plug in each of the 10 keyholes, as shown on the image.

The flat plane should be facing up, and the recess in the flat plane should be oriented
towards the screw. It should not be possible to insert incorrectly. The tweezer is well
suited for this purpose.
* If robot cannot be oriented with elbow lower than base joint, a small amount of silicone
grease can be used to ensure plugs stay in place
User Manual 31 UR10

WARNING
If the plug cannot be mounted into the hole, the joint may be out of position. This
must be corrected.
See General Guidance to Separate Joint from Counterpart, Elbow joint – Upper
arm
4. Add the 2 collars on top of the plugs. The collar must be pressed in, as deeply as possible.
Note, the wide tab on the collar fits into the wide slot between two screws.
It should not be possible to insert incorrectly.
UR10 32 User Manual

5. Place the flatring in its original position. If the flat ring shows sign of damage/looseness, it
must be replaced with the flatring supplied in the kit.

5.2.10. Elbow counterpart – Elbow joint
Assemble
1. Gently insert Elbow joint with screws and washers into the Elbow counterpart.
met.
6. Reconnect connectors as illustrated.
User Manual 33 UR10

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

5.2.11. Wrist 1 joint – Lower arm

Disassemble

2. Remove blue lid on Wrist 1 joint.
4. Disconnect wires between lower arm and Wrist 1 joint.


6. 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.
7. 10 screws become visible, 5 on each side of joint. Loosen the screws with a 5.5 mm. open-
ended spanner about two full turns, approximately 3 mm. for each screw.
8. Pull the lower arm and Wrist 1 joint apart and gently twist the two parts in opposite
9. Pull away the lower arm from Wrist 1 joint.
Assemble
UR10 34 User Manual

1. Gently insert Wrist 1 joint with screws and washers into the lower arm.
met.
4. Gently put back the gasket.

7. Reconnect wires between lower arm and Wrist 1 joint correctly.
9. Mount blue lid on Wrist 1 joint and tighten 2 pc M3x6 and 1 pc M3x10 with 0.4Nm.
5.2.12. Wrist 2 joint – Wrist 1 joint

Disassemble
User Manual 35 UR10


2. Remove blue lid on Wrist 1 joint.
3. Disconnect wires between Wrist 1 joint and Wrist 2 joint


4. 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.
the screws with a 5.5 mm. open-ended spanner about two full turns, approximately 3 mm.
for each screw.
6. Pull Wrist 1 joint and Wrist 2 joint apart and gently twist the two parts in opposite
7. Pull away Wrist 1 joint from Wrist 2 joint.
Assemble
1. Gently insert Wrist 1 joint with screws and washers into Wrist 2 joint.
met.
7. Replace Wrist 1 and reconnect connectors as illustrated into Wrist 2.
UR10 36 User Manual

9. Mount blue lid on Wrist 1 joint and tighten 2 pc M3x6 and 1 pc M3x10 with 0.4Nm.
5.2.13. Wrist 3 joint – Wrist 2 joint

Disassemble and assemble

Procedure for separating Wrist 3 joint from Wrist 2 is similar to separation of Wrist 2 joint and
Wrist 1 joint, consult chapter Wrist 2 joint – Wrist 1 joint
5.2.14. Tool flange – Wrist 3 joint

Disassemble

3. Gently remove black flexible flat ring with a tiny screwdriver or similar tool and twist it
around the joint housing.
the screws with a 5.5 mm. open-ended spanner about two full turns, approximately 3 mm.
for each screw.
5. Pull the tool flange and Wrist 3 joint apart and gently twist the two parts in opposite
6. Pull away the tool flange from Wrist 3 joint.
7. Connect ESD wristband.
8. Disconnect the two connectors.
User Manual 37 UR10

Assemble

2. Replace tool flange and reconnect connectors as illustrated.
4. Gently insert tool flange with screws and washers into the Wrist 3 joint.
met.
UR10 38 User Manual

5.2.15. Instructions for calibrating a joint

After replacement, calibration of the new joint is required to find the correct zero position.
If it is possible (a dual robot calibration kit and second robot of the same model are available)
and necessary (highest possible positional accuracy, and minimal deviation from positions
taught prior to joint replacement are required), perform the 3.1.16 Dual Robot calibration
Alternatively perform a simple joint calibration as shown below.
Instructions for calibrating a joint:
1. Jog robot to HOME position

Illustration shows the HOME position, which is defined as zero position of all joints.
2. Swipe from left to right across the UNIVERSAL ROBOTS logo on main screen of PolyScope.
3. Enter password lightbot and press OK.
User Manual 39 UR10

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

WARNING
In Low Level Control, only the safety settings in the Polyscope Installation tab are
active. The protective stop is NOT active.
Set all safety settings to their lowest settings before moving the robot.
5. Press Turn power on to enable power to joints.
UR10 40 User Manual

6. Press Go to Idle to put joints into ready mode.

7. Select the desired joint by directly clicking the status line for that joint. Currently selected
joint is highlighted in blue.
8. Press Arm current joint to release the brake on the selected joint.
User Manual 41 UR10

Use the Up and Down buttons in the Move window to rotate the joint to the correct zero position
according to the following illustrations.
Press STOP when the joint is in the correct position.
9. Zero position illustrations
Base: Shoulder, Elbow, Wrist 1:
UR10 42 User Manual


Shoulder, Elbow and Wrist 1 zero output flange
Base zero position is aligned so that
vertically aligned (assuming Base is
the output flange is offset 180 degrees from
horizontal). Make sure that base of robot is
the cable at the back of the robot base.
horizontal, use spirit level to align joints.
Wrist 2: Wrist 3:
Wrist 2 zero position is aligned similar to Wrist 3 zero position is aligned so tool
Base joint, with tool flange parallel with wrist connector is pointing upward. Mount two bolts
1 output flange. in tool holes and use spirit level to align joint.
10. Select Calibration tab and press Zero current joint position to calibrate the joint.
User Manual 43 UR10

11. Press Back to exit Low Level Control.

12. Press Return to Normal.
13. Verify zero position by moving the robot to HOME.

If not satisfied with the zero position, perform the procedure once again.
UR10 44 User Manual

5.2.16. Dual Robot Calibration

Dual Robot Calibration kit (Part no: 185500)
The Dual Robot Calibration process calibrates the robot across its full workspace. All robots are
Dual Robot Calibrated before leaving the factory.
If a joint has been replaced, then the factory calibration is no longer valid.
There are 2 options:
• Performing a Dual Robot Calibration after replacement of a joint will allow the robot to
continue in the production line without modifying waypoints in the robot program.
To perform a Dual Robot Calibration, you need: 2 robots (same size and same generation),
calibration Horse and calibration tool connector.
Go to www.universal-robots.com/support/ to download the Calibration Manual in PDF format.

• Simple Joint calibration (as described in Instructions of calibrating a joint). After replacing

a joint the zero position of the joint can be adjusted but the quality of calibration will not be
as good as that achieved by the Dual Robot Calibration method. Adjustment of program
waypoints will likely be required.
5.2.17. Change Joint ID

Each joint has a unique ID no. Having two joints with the same ID on a robot will cause
communication problems and the robot will not be able to operate.
ID Joint
J0 Base
J1 Shoulder
J2 Elbow
J3 Wrist 1
J4 Wrist 2
J5 Wrist 3
Example:
Wrist 1 (J3) needs to be replaced. Spare joint is a Wrist 3 (J5)
User Manual 45 UR10

1. Disconnect the joint with correct ID no.

2. Enter Low Level Control
3. Press Turn power on and the connected joints enter BOOTLOADER mod
4. Press Go to Idle and the connected joints enter READY mode

5. Select Joint ID tab

6. Select J5 (The one to be changed)
7. Uncheck “Exchange IDs” box
8. In dropdown box, select ID no. 3
9. Press Set it
UR10 46 User Manual

10. Confirm Change ID
11. When the robot is powered on again, J5 will be displayed as J3.

5.2.18. Joint Spare Part Adaptation
The UR5 and UR10 consist of four different joint sizes, some of which are interchangeable
between different positions/robots.
Recommended spare joints for UR5 and UR10 are marked.
User Manual 47 UR10

* When using a joint in a different location i.e. UR5 base as UR5 Elbow, it may be necessary to
change ID, connect all joints electrically, turn the joint 180 degrees in low level control by using
the Move Tab Up/Down function, before mechanically assembling the robot. The robot then
needs to be zero positioned or dual robot calibrated - Instructions for calibrating a joint
5.2.19. Wire Bundle Installation Guide

General
As well as the Wire bundle kit for the correct joint size, the Following ESD approved tools are
recommended for this replacement:
• Tool for pressing in the pins
• Small flat nose plier
• Cable tie tension and cutting tool
• Small flathead screwdriver
• Tweezers
• Crimping tool for cable shoes
Time expected: 20min (joint disassembly time not included)
Size 2 – part number: 103502
• Inset wire bundle as shown on photo,

with the cable tie towards the flange.
• Mount the grommet into the flex plate

with the tweezers or the small flat nose
screwdriver.
UR10 48 User Manual

• Hold the heat shrink with tweezers while

sliding down the grommet.

• Mount a cable tie on top of the grommet.
• Tighten and cut it off with the cable tie
tool.
• The two power cables (two thicker, red

and black wires) needs to be stripped
(approx. 5mm).
• Mount the cable shoes
• Use the clamping tool as described by
the manufacture.
• Check that the wire is secure in the
cable shoes.
User Manual 49 UR10

• Take the communication connector:

• When inserting the connector pins, make
sure the barbs, shown with green arrows,
are located as shown on the photo. If
not, they will not hook inside the
connector and will fall out.
• Inset the black connector pin into the
plug hole marked “MX”. Remember to
orientate the barbs as described above.
A “click” will be heard when inserted
correctly.
• Inset the white pin in the other plug hole.
• When done, check that the connector
pins are firmly hooked inside the plug by
pulling gently in the wires.

• If not, check that the orientation of the
barbs is correct. If inserted correctly,
use a tool to press on the pins to ensure
they are pushed all the way in.
Size 4 – part number: 103504
• Remove the two grommets from the

wire bundle.
Base
• Mount the grommets in the brackets.

• Pull the wire bundle through the joint.
Please be aware that the wires need to
Shoulder
be arranged differently on the shoulder
and base joint. See photo example.
UR10 50 User Manual

Lower arm – part number: 103508
NOTE
The lower arm wire bundle kit contains wire bundle for multiple robot types.
Please be sure use the correct length.
• Turn the lower arm to where the size 2

joint(wrist) will be mounted.
• Slide the wire bundle through the lower
arm so that the longer wire section is
towards this end.
• Push the grommet onto the bracket.

• Turn the lower arm to the other end
• Place it on the side so the wires do not
get squeezed.
• Push the grommet onto the bracket and
secure it with a cable tie. Use the cable
tie gun to tighten and cut the cable tie.
Upper arm – part number: 103509
NOTE
The lower arm wire bundle kit contains wire bundle for multiple robot types.
Please be sure use the correct length.
• Slide the wire bundle through the upper

arm with the short-exposed
communication wires in the end with a
bracket
• Push the grommet onto the bracket.
User Manual 51 UR10

• Secure it, as shown on the photo, with a

cable tide.
• Use a cable tie gun to tighten and cut
the cable tie.
5.3. Controller
5.3.1. Replacement of Motherboard 3.0
WARNING
Before replacing ANY components inside the control box, it is IMPORTANT to do
a complete shutdown.
Follow the first 3 steps in section Complete rebooting sequence.
When completing the following replacement, please follow the guidelines laid out in section
Handling ESD-sensitive parts
NOTICE
Motherboard 3.0 uses compact flash memory card.
Motherboard 3.1 uses USB memory stick.
UR10 52 User Manual

1. Shut down the controller and disconnect the power cable, open the controller cabinet and
remove the 3 torx screws

2. Remove the aluminum cover plate
3. Disconnect cable connections from motherboard:

1. White plug with white, brown, yellow and green wires, 12 V Power
2. Black USB cable for Teach Pendant USB connector
3. Ethernet cable to external connector
4. Ethernet cable to Safety Control Board SCB
User Manual 53 UR10

5. DVI-cable for Teach Pendant screen

6. Black cable for RS232-connection for Teach Pendant touch
4. Remove the 4 screws from the 2 holding brackets.
5. If controller is equipped with long-hole brackets, make sure to replace them with circular-
hole brackets
6. Replace Motherboard and tighten the 4 screws gently
7. Insert the 6 cables in correct positions. Special attention on the Ethernet cable to the
Safety Control Board. It must be connected to the right connector on the mother board
8. Re-install flash card and RAM block
9. Carefully put back the aluminum cover plate, make sure to mount it correct and fix it with
the 3 screws
10. Connect power and verify that teach pendant functions correctly.
5.3.2. Replacement of Motherboard 3.1
UR10 54 User Manual

WARNING
How to replace motherboard 3.1

1. Shut down the controller and disconnect the power cable, open the controller cabinet, and
remove the 3 torx screws (4 screws on Merge Control Box)
2. Remove the aluminum cover plate
User Manual 55 UR10

3. Disconnect cable connections from motherboard

1. White plug with white, brown, yellow and green wires, 12 V Power
2. DVI-cable for TP screen
3. Ethernet cable to Safety Control Board SCB
4. Ethernet cable to external connector

5. Black USB cable for TP USB connector
6. Grey flat cable for RS232-connection for TP touch
4. Remove the 4 screws from the 2 holding brackets
5. Replace Motherboard.
UR10 56 User Manual

6. Insert the 6 cables in correct connectors. Pay special attention to the Ethernet cable to the
Safety Control Board. It must be connected to the right connector on the mother board
7. Re-install USB stick for UR system Software.
8. Carefully put back the aluminum cover plate, make sure to mount it correctly and fix it with
the 3 screws
5.3.3. Upgrading of Motherboard 3.0 with 3.1
WARNING
Introduction

• This section provides guidelines for exchanging an existing CB3 motherboard with a new
CB3.1 motherboard.
• It is solely intended for advanced integrators of UR robots.
Parts and check list
122430 CB3.0 to CB3.1 Upgrade Kit QNT

Standoff for mounting cover M4x35 – hex 7 3
Screws for cover mounting M4x8 torx T20 3
Standoff for mounting Motherboard M3x6x25mm – hex 5 4
Screws for mounting Motherboard M3x6 torx T10 4
Grommet 1
USB drive with image 1
Disposable ESD-wrist strap 1
Safety Control Board cover assembly 1
Improved motherboard power cable for CB3 1
Tools needed (not incl. in the kit):

• ESD-wrist strap
• Hex 7 key
• Hex 5 key
• T20 torx
• T10 torx
• 2.5 Allen key
User Manual 57 UR10

• Compact flash card reader

• Laptop with USB port, running Windows (7 or higher) or Linux (10 or higher) operating
system
Time needed: Approx. 1 hour

Hardware
• Always use an ESD wristband when working on the controller.
Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This
discharges any static electricity in your body to ground
• Remove shields by removing the 7 x T20 torx screws
• Remove all cables attached to the motherboard and the compact flash card
• Remove the cable that connects the motherboard and Safety Control Board. This cable is
no longer needed and should be disposed of.
UR10 58 User Manual

• Unscrew the motherboard by loosening the 4 x 2.5mm hex screws and the 4 x 5,5 hex
standoffs that hold the RS232 and DVI connectors
• Mount the smaller standoffs where the motherboard screws were before. Place the black
cable from the Teach Pendant and the Ethernet cable on the left side of the Standoff as
shown on the photo. Note: If your Ethernet cable has a black plug (Figure 1) at one end,
then this end must be connected to the Safety Control Board.
User Manual 59 UR10

Figure 1
• Unscrew the 3 standoffs that hold the cover for the motherboard and mount the new larger
standoffs.
• Mount the motherboard onto the standoffs. Please note that the two screws toward the
outside of the controller may be more difficult to get into position.
UR10 60 User Manual

• Now take the new cover for the motherboard and navigate the flat cable under the
motherboard and to the connector as shown in the photo below.

• Plug the new power cable from the SCB to the CB 3.1 motherboard as shown.
User Manual 61 UR10

• Screw on the new cover. Please note that the screw toward the outside of the controller
may be difficult to get into position.
• Mount the new cover for the Safety Control Board.
• Mount all the connectors again according to the sticker on the cover and photo below.
The USB stick should be plugged into the blue USB port.
Software
UR10 62 User Manual

NOTICE
Do not downgrade a robot with a CB3.1 motherboard, to a Software version below
3.1.1.7336. Doing so may cause unexpected behavior of the robot.
Universal Robots assumes no responsibility for the outcome of this process.
The instructions in this document shall be considered as general guidelines. It is
assumed that the integrator has a high level of technical knowledge.
• The following files need to be copied from the existing compact flash card, onto the new
USB.
• root/ur-serial
• root/log_history.txt
• root/histogram.properties
• root/.urcontrol/urcontrol.conf

• root/.urcontrol/calibration.conf
• root/.urcontrol/calibration.log
• root/.urcontrol/robot_calibration_summary.txt
• programs/ [all of the following files: .urp, .txt, .script, .installation, .variable, .old]
• Detailed description on backup of data can be found in backup of data.
• If the old CB 3.0 motherboard is defective, use a flash card reader and install a Linux
partition reader for Windows to read the Linux partition on the flash card.
• Polyscope must be minimum software version 3.1.1.7336
5.3.4. Replacement of Safety Control Board
WARNING
To replace Safety Control Board in Controller box:
User Manual 63 UR10

1. Check that the software on the robot is not older than the firmware version on the SCB.
If the software on the robot is older, error C203A0 will be displayed.
The SCB firmware version can be found on the Ethernet connector.
This can also be found in the “About” menu.

Shortcut to “About”, by clicking on the UR logo in the top right corner of the screen is
available from software version 3.2.18642
2. Shut down the controller and disconnect the power cable, open the controller cabinet then
carefully remove all plugs and connectors.
UR10 64 User Manual

3. Remove the 5 torx screws and followed by the aluminum cover.
4. Carefully remove all plugs and connectors from the Safety Control Board.

5. Remove the 14 screws holding the board in place.
6. Replace Safety Control Board with new one and tighten the 14 screws to fasten the board
in place.
7. Insert all connectors and plugs back into their correct positions.
User Manual 65 UR10

8. Carefully attach the aluminum cover, making sure to mount it correct and fix it with the 5
screws.
5.3.5. Replacement of Teach Pendant
Original Control Box
WARNING
a complete shutdown. Follow the first 3 steps in section Complete rebooting
sequence.
NOTE
Use the same procedure for power down and removing the aluminum cover plates
as in chapter Replacement of Motherboard 3.0,
Replacement of Motherboard 3.1 or Replacement of Safety Control Board.
1. Disconnect 4 cables:
1. Red plug with black cable 12 V Power
2. Black DVI cable for the TP screen
3. Black USB cable For the TP USB connector
4. Black cable for RS232-connection for the TP touchscreen
UR10 66 User Manual

2. Remove the bracket (foot of the controller box) that holds the cable inlet and pull out the
cables and plugs through this hole.
3. To install new teach pendant, thread cables through inlet, plug connectors into correct
positions, then mount aluminum cover into place.
See diagram: Schematic overview

Merge Control Box
WARNING
a complete shutdown. Follow the first 3 steps in section 5.3.7 Complete
rebooting sequence.
NOTE
as in chapter Replacement of Motherboard 3.0,
Replacement of Motherboard 3.1 or Replacement of Safety Control Board.
1. Disconnect 4 cables:
1. Red plug with black cable
2. Black DVI cable
3. Black USB cable
User Manual 67 UR10

4. Black cable for RS232-connection to touchscreen
2. Remove the bracket by removing the 8 torx screws and that hold it in place.
3. Pull the two plates apart
UR10 68 User Manual

4. To install new teach pendant, thread cables through inlet, plug connectors into correct

positions, then mount aluminum cover into place.
5.3.6. Replacement of 48V power supply
Original Control Box
WARNING
Handling ESD-sensitive parts.
NOTE
as in chapter Replacement of Motherboard 3.0, Replacement of Motherboard 3.1
or Replacement of Safety Control Board
To replace 48V power supply in controller box:
User Manual 69 UR10

1. Remove teach pendent cable – see previous section

2. Detach the controller box handle by removing the 2 screws holding it in place.
3. Disconnect the 2 wires for the energy eater and fan.

4. Remove the 2 nuts (M6) in the bottom of controller module.
5. Gently take out the controller module from the controller box.
6. Turn the module 90° counterclockwise and place it on the controller edge.
UR10 70 User Manual

7. Cut the cable tie that tied to the robot cable, unplug the connectors from the Safety Control
Board and remove the cable.
8. Turn the module 180° clockwise and place it on the controller edge.
9. Remove the power connection on the current distributor.
The module is not loose from the controller.

10. Power supplies are located in the rack under the controller module, the two 48V power
supplies are the lower ones in the rack (UR3 and UR5 has one and UR10 has two 48V power
supplies).
Before removing the 48V power supply, label the wires then disconnect them from that
supply.
User Manual 71 UR10

11. Remove the screws keeping the defective 48V power supply in place from the side of the
rack.
12. Replace the defect 48V power supply with the new one.
13. Reconnect the wires for the 48V power supply.
14. Reinstall controller module in reverse order and reconnect the 2 wires for the fan and
cables for the teach pendant.
15. Carefully put back the aluminum cover plate, making sure to mount it correctly and fix into
place with the screws.
16. Connect power and verify that teach pendant works properly.
Merge Control Box
WARNING
UR10 72 User Manual

NOTE
as in chapter Replacement of Motherboard 3.0, Replacement of Motherboard 3.1
or Replacement of Safety Control Board
To replace 48V power supply in controller box:

1. Remove teach pendent cable – see previous section
2. Disconnect all the marked wires from the SCB.
User Manual 73 UR10

3. Remove the 4 nuts (M6) in the top and bottom of controller module.
4. Gently take out the controller module from the controller box.
5. Turn the module 90° counterclockwise and place it on the controller edge.
6. Cut the cable tie that ties the robot cable, unplug the connectors from the Safety Control
Board and remove the cable.
7. Turn the module 180° clockwise and place it on the controller edge.
UR10 74 User Manual

8. Remove the power connection on the current distributor.

The module is now loose from the controller.

9. Power supplies are located in the rack under the controller module, the two 48V power
supplies are the lower ones in the rack (UR3 and UR5 has one and UR10 has two 48V power
supplies).
Before removing the 48V power supply, label the wires then disconnect them from that
supply.
10. Remove the screws keeping the defective 48V power supply in place from the side of the
rack.
11. Replace the defect 48V power supply with the new one.
User Manual 75 UR10


13. Reinstall controller module in reverse order attached all wire and mount the 4 bolts with
2,25 Nm.
14. Carefully put back the aluminum cover plate, making sure to mount it correctly and fix into
place with the screws.
15. Connect power and verify that teach pendant works properly.
5.3.7. Replacement of 12V power supply
WARNING
sequence.
NOTE
Use the same procedure for power down and removing the aluminum cover plate
and cables for teach pendant as in chapter Replacement of Teach Pendant
To replace the 12V power supply follow the same steps as for the procedure in chapter
Replacement of 48V power supply
UR10 76 User Manual

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

2. Replace 12V power supply with new one.
4. Re-install controller module in reverse order and connect the 2 wires for the fan and cables
for the teach pendant.
5. Carefully put back the aluminum cover plate, make sure to mount it correctly and fix it in
place with the 5 screws.
5.3.8. Replacement of Current distributor
WARNING
sequence.
Handling ESD-sensitive parts.
User Manual 77 UR10

NOTE
Use the same procedure for power down and removing the aluminum cover plate
and cables for teach pendant as in chapter Replacement of Teach Pendant
To replace the current distributor, follow the same steps as for the procedure in chapter
Replacement of 48V power supply
How to replace current distributor in controller box:
1. Current distributor is placed on top of the rack.
2. Before dismounting the current distributor, mark and disconnect the cables from the circuit
board.
3. Replace current distributor with new one.

4. Reconnect the wires for the current distributor.
5. Re-install controller module in reverse order and connect the 2 wires for the fan and cables
for the teach pendant.
6. Carefully put back the aluminum cover plate, make sure to mount it correctly and fix it in
place with the 5 screws.
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6. Software
6. Software
6.1. Software update
NOTE
Read the complete section prior to updating your software.
Controller power MUST NOT be turned off during software update process.
Universal Robots assume no responsibility for any failed update caused by
improper operation.
Universal Robots software is named PolyScope.

NOTICE
Read the complete section prior to updating your software.
Controller power MUST NOT be turned off during software update process.
improper operation.
Updating the software may cause changes to some functionality. Always check with the release
notes on the Universal Robots support site.www.universal-robots.com/support/
1. Do not downgrade the software to earlier version than the version the robot was produced
with.
2. We advise you only to update, if you can benefit from the new features or the fixed issues.
3. We advise you to thoroughly read the release notes before performing an update, to avoid
unexpected behavior, caused by changed or added functionality.
4. In case of concerns related to your actual or planned applications, please contact your
supplier for advice and assistance.
Instructions to update software:

1. Download software update. When updating, it must be done in steps i.e. from 3.3 to 3.4 to
3.5.
2. Save it in the root folder on a USB-stick.
3. Insert USB-stick into USB-connector on right-hand side of teach pendant.
User Manual 79 UR10

6. Software
4. Go to main screen of PolyScope.
5. Press SETUP Robot.

6. In left side menu, select Update Robot.
7. Press button Search to search for software update files on USB-stick.
8. Select the desired software update and press UPDATE.
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6. Software
9. Press YES to update the software.

10. Wait for update too complete, after successful update controller will automatically reboot.
11. Remove USB-stick and initialize the robot.
6.2. Update joint firmware

NOTICE
Read the complete section prior to updating your firmware.
Controller power MUST NOT be turned off during firmware update process.
improper operation.
Software version 3.1.16828 and newer:

When the software is updated on a robot the firmware is automatically updated.
After replacement of a joint on a robot the firmware is automatically updated.
Software version before 3.1.16828:
Instructions for updating firmware:
Prior to updating firmware, robot software must be updated.
Please refer to chapter Software. When updating robot software, the firmware will automatically
be copied to a folder on the controller.
User Manual 81 UR10

6. Software

UR10 82 User Manual

6. Software
4. Press Turn power on to go into BOOTLOADER
5. Select the Firmware tab, mark All joints and press UPDATE Firmware.

6. Firmware update is being processed, await message that robot firmware updated
successfully.
Controller MUST NOT be powered off during this update.
7. After successful update, press Back.
8. Back in Expert Mode, press Return to Normal.
9. Firmware has now been updated
User Manual 83 UR10

6. Software

lightbot
UR10 84 User Manual

6. Software

4. Press Turn power on to go into BOOTLOADER
User Manual 85 UR10

6. Software
5. Select the Firmware tab, mark All joints and press UPDATE Firmware.
6. Firmware update is being processed, await message that robot firmware updated
successfully.
Controller MUST NOT be powered off during this update.
7. After successful update, press Back.
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6. Software
8. Back in Expert Mode, press Return to Normal.

Firmware has now been updated.
User Manual 87 UR10

6. Software
6.3. Using Magic files

For easy backup, Universal Robots provides Magic files to automatically copy data from
controller to USB-stick.
Function
These files are available
URmagic log file Copies the entire log history file to USB-stick
Copies all programs and installation files to
URmagic backup programs
USB-stick
URmagic configuration files Copies all configuration files to USB-stick
Copies all programs and installation files from
URmagic upload programs
USB-stick
Generates a screenshot of GUI when USB-stick
URmagic screenshot
is inserted
Go to www.universal-robots.com/support/ to download Magic files.

Instruction for using Magic files.
1. Download Magic file.
2. Save it in the root folder on a USB-stick.
If more than one Magic file is on USB-stick, they will be run in sequence; the warnings will
then appear for each file. Do not remove the USB-stick until after the last file has been run.
Multiple folders will be created and named with serial number plus a sequential no, e.g.
201430xxxx_0, 201430xxxx_1etc.
3. Insert USB-stick into USB-connector on right-hand side of teach pendant.
4. After a few seconds a red ! USB ! -sign will appear on the screen, this is a warning not to
remove the USB-stick, while the file will do its magic.
5. Await a green <- USB -sign appears on the screen, if there is more than one Magic file on
the USB-stick then go to step 4.
6. After the last Magic file is completed the USB-stick can be safely removed.
7. Remove USB-stick and the process is complete.
The Magic file creates a folder on USB-stick named with the serial number of the robot.
6.4. Backup of data

NOTICE
When copying/moving files and folders, incorrect action might corrupt the file
system.
UR10 88 User Manual

6. Software
This section explains the process of moving required files when upgrading from motherboard
with compact flashcard to motherboard with USB.
6.4.1. Hardware requirements

The following hardware is needed:
Compact Flash Card from the old motherboard
A standard flash card reader that can read the CF-card (not included in motherboard upgrade kit).
The USB stick from the motherboard upgrade kit
Part no. 122430 (CB3.0 to CB3.1 upgrade kit)

6.4.2. Software requirements
A Linux software file system driver is required; Universal robots recommend the free Linux-
partition driver Ext2Fsd but other windows Linux reader can be used as well (these are however
not tested by Universal Robots).
6.4.3. How to access Linux partition from Windows

Download and install Ext2Fsd.
Ensure to enable Read and Write Support for Ext2 and Ext3.
User Manual 89 UR10

6. Software
Reboot the computer to allow the changes to take effect.
6.4.4. Copy the Data from CF-card to UR-USB

1. Take CF-card from control box and insert the CF-card in card reader and the UR-USB in one
of the computers USB ports.
2. CB3:
Open windows explorer navigate to the CF-card open the folder “programs”, select all the
files in the folder, right click and select Copy.
UR10 90 User Manual

6. Software
3. Navigate to the UR-USB right-click on the folder “programs” and select Paste.
User Manual 91 UR10

6. Software
4. Navigate to the root folder on the CF-Card

UR10 92 User Manual

6. Software
User Manual
93
UR10
6. Software
5. In the root folder view select the folders and files highlighted in yellow, then right-click and
select Copy.
If the .urpass.file or .ursafetypass.file is not visible on the CF-card, then the files don’t need
to be saved
UR10 94 User Manual

6. Software
6. Navigate to the UR-USB right-click on the folder root and select paste.

7. A prompt will popup when the files are being copied, in the prompt choose Copy and
replace.
8. Check the checkbox marked yellow.
User Manual 95 UR10

6. Software
9. All required files are copied. UR-USB can now be inserted in new motherboard and booted
UR10 96 User Manual

7. Troubleshooting
7. Troubleshooting
In the error codes, different words have been used for the same thing:
• On the Safety Control Board: Processor A = A uP = SafetySys1
• On the Safety Control Board: Processor B = B uP = SafetySys2
Abbreviations in the troubleshooting chapter:

• PSU = Power Supply
• PC = Controller
Open log files with Support Log Reader(SLR).

Go to www.universal-robots.com/support/ to download Support Log Reader

7.1. Error codes
Code Error description Explanation How to fix
C0 No error
C1 Outbuffer overflow
error
C1A1 Buffer of stored
warnings overflowed
C1A2 Outbuffer to RS485
overflowed (problem
with PCs message)
C2 Inbuffer overflow error
C3 Processor overloaded Processor in any part could
error give this error.
C4 Broken a) Check Ethernet cable
communication between Safety Control
Board and Motherboard,
check that a script or UR+
software is not overloading
the communication
between the Safety Control
Board and Motherboard.
b) Do a Complete rebooting
sequence as per section
5.3.7
c) Update the software
User Manual 97 UR10

7. Troubleshooting
C4A1 Communication with Between Safety Control a) Check Ethernet cable

PC lost. Board and Motherboard between Safety Control
Board and Motherboard,
check that a script or UR+
software is not overloading
the communication
between the Safety Control
Board and Motherboard.
5.3.7
C4A2 Communication with If either processor A or a) Check TCP/IP
Safety Control Board processer B is connection between
A uP lost communicating, the Safety Motherboard and Safety
Control Board or cable Control Board.

between the Motherboard b) Do a Complete rebooting
and Safety Control Board is sequence as per section
defect 5.3.7
c) Exchange Safety Control
Board
C4A3 Communication with If either processor A or a) Check TCP/IP
Safety Control Board processer B is connection between
B uP lost communicating, the Safety Motherboard and Safety
Control Board or cable Control Board.
between the Motherboard b) Do a Complete rebooting
and Safety Control Board is sequence as per section
defect 5.3.7
c) Exchange Safety Control
Board
C4A4 Communication with If either processor A or a) Check RS485-12V
primary Teach processer B is connection between
Pendant uP lost communicating, the Teach Motherboard and Teach
Pendant or cable between Pendant.
the Motherboard and Teach b) Do a Complete rebooting
Pendant is defect sequence as per section
5.3.7
c) Exchange Teach
Pendant
UR10 98 User Manual

7. Troubleshooting
C4A5 Communication with If either processor A or a) Check RS485-12V

secondary Teach processer B is connection between
Pendant uP lost communicating, the Teach Motherboard and Teach
Pendant or cable between Pendant.
the Motherboard and Teach b) Do a Complete rebooting
Pendant is defect sequence as per section
5.3.7
c) Exchange Teach
Pendant
C4A6 Communication with If either processor A or a) Check Euromap67
primary EUROMAP67 processer B is connection between
uP lost communicating, Euromap67 Motherboard and
or cable between the Euromap67.
Motherboard and Euromap is b) Do a Complete rebooting
defect sequence as per section

5.3.7
c) Exchange Euromap67
C4A7 Communication with If either processor A or a) Check Euromap67
secondary processer B is connection between
EUROMAP67 uP lost communicating, Euromap67 Motherboard and
or cable between the Euromap67.
Motherboard and Euromap is b) Do a Complete rebooting
defect sequence as per section
5.3.7
c) Exchange Euromap67
C4A8 Primary EUROMAP67 Incorrect safety a) Update the
uP present, but configuration miscellaneous settings in
euromap67 is the Safety Configuration
disabled b) Do a Complete rebooting
5.3.7
C4A9 Secondary Incorrect safety a) Update the
EUROMAP67 uP configuration miscellaneous settings in
present, but the Safety Configuration
euromap67 is b) Do a Complete rebooting
disabled sequence as per section
5.3.7
C4A10 Primary Teach Incorrect safety a) Update the
Pendant present, but configuration miscellaneous settings in
Teach Pendant safety the Safety Configuration
is disabled b) Do a Complete rebooting
5.3.7
User Manual 99 UR10

7. Troubleshooting
C4A11 Secondary Teach Incorrect safety a) Update the

Pendant uP present, configuration miscellaneous settings in
Teach Pendant safety the Safety Configuration
is disabled b) Do a Complete rebooting
5.3.7
C4A12 Communication with More than 1 package lost a) Verify that the
joint 0 lost communication cables are
connected properly
5.3.7
connected properly
5.3.7
connected properly
5.3.7
connected properly
5.3.7
connected properly
5.3.7
connected properly
5.3.7
UR10 100 User Manual

7. Troubleshooting
tool lost communication cables are
connected properly
5.3.7
C4A65 Lost package from 1 package lost – warning If this appears often in the
Primary Teach log, then:
Pendant a) Verify that the
communication cables are
connected properly
5.3.7

Secondary Teach log, then:
Pendant a) Verify that the
connected properly
5.3.7
Primary Euromap67 log, then:
a) Verify that the
connected properly
5.3.7
Secondary log, then:
Euromap67 a) Verify that the
connected properly
5.3.7
User Manual 101 UR10

7. Troubleshooting
Secondary log, then:
Masterboard a) Verify that the
connected properly
5.3.7
C4A70 Lost package from Serial communication If this appears often in the
joint 0 problem with one or more log, then:
joints a) Verify that the
connected properly
5.3.7
connected properly
5.3.7
connected properly
5.3.7
connected properly
5.3.7

7. Troubleshooting
connected properly
5.3.7
connected properly

5.3.7
tool problem with one or more log, then:
connected properly
5.3.7
uPA to joints log, then:
a) Verify that the
connected properly
5.3.7
uPA to Teach pendant log, then:
a) Verify that the
connected properly
5.3.7

7. Troubleshooting
uPA to uPB log, then:
a) Verify that the
connected properly
5.3.7
uPB log, then:
a) Verify that the
connected properly
5.3.7
C4A81 Packet counter Safety processor 1 in Teach If this appears often in the
disagreement in pendant has a packet log, then:
packet from Primary disagreement a) Verify that the
Screen communication cables are
connected properly
5.3.7
C4A82 Packet counter Safety processor 2 in Teach If this appears often in the
disagreement in pendant has a packet log, then:
packet from disagreement a) Verify that the
Secondary Screen communication cables are
connected properly
5.3.7
C4A83 Packet counter If this appears often in the
disagreement in log, then:
packet from Primary a) Verify that the
Euromap67 communication cables are
connected properly
5.3.7

7. Troubleshooting

packet from a) Verify that the
Secondary communication cables are
Euromap67 connected properly
5.3.7
packet from Safety a) Verify that the
Control Board B communication cables are
connected properly

5.3.7
packet from joint 0 a) Verify that the
connected properly
5.3.7
connected properly
5.3.7
connected properly
5.3.7

7. Troubleshooting

connected properly
5.3.7
connected properly
5.3.7
connected properly
5.3.7
packet from tool a) Verify that the
connected properly
5.3.7
processor A to joints communication cables are
connected properly
5.3.7

7. Troubleshooting

processor A to B communication cables are
connected properly
5.3.7
processor A to Teach communication cables are
Pendant and connected properly
EUROMAP b) Do a Complete rebooting

5.3.7
C4A100 Communication lost If this appears often in the
due to Packet counter log, then:
disagreements a) Verify that the
connected properly
5.3.7
C5 Heavy processor load If this appears often in the
warning log, then:
a) Verify that the
connected properly
5.3.7
C5A1 Heavy processor load If this appears often in the
warning:1 log, then:
a) Verify that the
connected properly
5.3.7

7. Troubleshooting
C5A2 Heavy processor load If this appears often in the

warning:2 log, then:
a) Verify that the
connected properly
5.3.7
C10 Broken PC a) Do a Complete rebooting
communication error sequence as per section
5.3.7
b) Update the software
C10A1 Lost packet from PC a) Do a Complete rebooting
5.3.7

C10A101 PC packet received a) Do a Complete rebooting
too early sequence as per section
5.3.7
C10A102 Packet counter does a) Do a Complete rebooting
not match sequence as per section
5.3.7
C10A103 PC is sending a) Do a Complete rebooting
packets too often sequence as per section
5.3.7
C11 Bad CRC error Serial communication Check black 2-wire
problem with joint connectors and wires in
joints. Eventually 2 joints
with the same ID.
C12 Unknown message
error
C14 Debug message
C14A1 {float} Should not occur in the field If you see this error on a
robot, report it to Universal
Robots.
C14A2 {signed} Should not occur in the field If you see this error on a
Robots.

7. Troubleshooting
C14A3 {unsigned} Should not occur in the field If you see this error on a
Robots.
C17 Inbuffer overflow in Communication error a) Check Ethernet
package from PC between Safety Control connection between circuit
Board and Motherboard boards.
5.3.7
C26 Motor Encoder index Joint mechanical problem a) Do a Complete rebooting
drift detected sequence as per section
5.3.7
b) If this happens more
than two times in a row,

replace joint
C27 Calibration data is a) Do a Complete rebooting
invalid or does not sequence as per section
exist, selftest is 5.3.7
needed! b) If this happens more
replace joint
C29 Online Calibration Calibration data is not in the a) Do a Complete rebooting
data checksum failed joint sequence as per section
5.3.7
replace joint
C30 Master received data
from too many joints
C31 Caught wrong Serial communication Check black 2-wire
message (not from problem with joint connectors and wires in
master) joints
C32 Flash write verify Debug message Ignore
failed
C33 Calibration flash
checksum failed
C34 Program flash Update Firmware
checksum failed
C34A0 Program flash Update Firmware
checksum failed
during bootloading

7. Troubleshooting
C34A1 Program flash Update Firmware

checksum failed at
runtime
C35 Joint ID is undefined
C36 Illegal bootloader Debug message Ignore
command
C37 Inbuffer parse error Serial communication Check black 2-wire
problem with joint connectors and wires in
joints
C38 Online RAM test Check the log file for what
failed item is reporting this error.
Replace the reporting item
C38A1 Data-bus test failed Check the log file for what
item is reporting this error.

C38A2 Address-bus stuck- Check the log file for what
high test failed item is reporting this error.
C38A3 Address-bus stuck- Check the log file for what
low test failed item is reporting this error.
C38A4 Address-bus shorted Check the log file for what
test failed item is reporting this error.
C38A5 Memory-cell test Check the log file for what
failed item is reporting this error.
C39 Logic and Temporal
Monitoring Fault
C39A1 Max current deviation a) Do a Complete rebooting
failure sequence as per section
5.3.7
replace joint
C39A2 Max joint-encoder a) Do a Complete rebooting
speed exceeded sequence as per section
5.3.7
replace joint

7. Troubleshooting
C39A3 Max motor-encoder a) Do a Complete rebooting

speed exceeded sequence as per section
5.3.7
replace joint
C39A4 Illegal state change in
joint detected
C39A5 A timing issue Too fast state change in Do a Complete rebooting
occurred during joint detected sequence as per section
startup. Please 5.3.7
restart to proceed
C39A6 5V regulator voltage a) Do a Complete rebooting
too low sequence as per section
5.3.7

replace joint
C39A7 5V regulator voltage a) Do a Complete rebooting
too high sequence as per section
5.3.7
replace joint
C39A100 Watchpoint fault:
ADC task timeout
Motor-Control task
timeout
Motor-encoder task
timeout
Joint-encoder task
timeout
Communication task
timeout
RAM-test task
timeout

7. Troubleshooting

CalVal-test task
timeout
ROM-test task
timeout
C40 AD-Converter hit high EMC issue external or Check grounding and
limit joint electronics internal shielding for EMC
problems
C44 CRC check failure on Serial communication a) Check black 2-wire
primary bus problem with joint or connectors and wires in
secondary bus node joints
5.3.7
c) If this happens more

contact your local service
provider for assistance
C44A0 Joint 0 CRC check Serial communication a) Check black 2-wire
failure on primary bus problem with joint or connectors and wires in
5.3.7
5.3.7

7. Troubleshooting

5.3.7

5.3.7
5.3.7
5.3.7

7. Troubleshooting
C44A6 Tool CRC check Serial communication a) Check black 2-wire

failure on primary bus problem with tool or connectors and wires in
5.3.7
C44A80 CRC Check failure on Most likely an interference a) Check black 2-wire
primary bus on the communication bus connectors and wires in
joints
5.3.7
provider for assistance.
C45 AD-Converter error
C46 Loose gearbox or bad Mechanical problem in gear a) Do a Complete rebooting
encoder mounting related to encoder mounting sequence as per section
5.3.7
replace joint
C47 AD-Converter hit low EMC issue external or Check grounding and
limit electronics internal shielding for EMC
problems.
C48 Powerbus voltage Error on 48V powerbus to Check 48V output from
drop detected. robot arm Power supply. Check
current-distributor PCB.
Replacement of 48V Power
supply or current-
distributor is necessary
C49 RS485 receive
warning
C49A200 Secondary RS485 bus Bus for: Teach Pendant, Check TCP/IP-12V cable to
is down Processor A and Processor B Teach Pendant
on the Safety Control Board.

7. Troubleshooting
C50 Robot powerup failure Electrical error control box Remove all external
connections to I/O-
interface on the Safety
Control Board. Check for
short circuit.
C50A1 Voltage detected at
24V rail before
startup
C50A2 Voltage present at
unpowered robot
C50A5 Power supply voltage voltage is below 40V Check 48 V cable between
too low Power supply and Safety
Control Board.
C50A6 Power supply voltage Voltage is above 56V

too high
C50A11 Voltage not detected 24 V to the I/O interface in
at 24V rail after the controller
startup
C50A15 Warning, waiting for SafetySYS2 = Processor B on
SafetySYS2 Safety Control Board
C50A16 The Teach Pendant Loose wire or incorrect a) Check the Teach
does not respond safety configuration. Pendant cable and
connections.
b) Check the settings in the
miscellaneous tab in the
Safety menu.
C50A17 The Euromap67 Loose wire or incorrect a) Check the Euromap 67
interface does not safety configuration cable and connections.
respond b) Check the settings in the
miscellaneous tab in the
Safety menu.
C50A18 Warning, waiting for SafetySYS1 = Processor A
SafetySYS1 on Safety Control Board
C50A19 Warning, Waiting for a
valid "euromap67
activated" status bit
from secondary
Safety Control Board
C50A20 5V, 3V3 or ADC error
(5V too high)
(5V too low)

7. Troubleshooting
C50A22 Robot current sensor

reading too high
C50A23 Robot current sensor
reading too low
C50A24 48V not present This error can have several root causes and you have to
(Check internal measure the voltage some places.
connection) There are 3 different components that could be the root
cause and you have to measure the voltage to determine
which one of them that is the faulty one.
- 48 V power supply
- Current distributor
- Safety Control Board.
Find the schematic drawing in this service manual
C50A25 Robot voltage present
at 48V Power supply
powerup
C50A26 Voltage present on
unpowered 48V power
supply
(12V too high)
(12V too low)
C50A29 Analog I/O error (-12V
too high)
C50A30 Analog I/O error (-12V
too low)
C50A31 The other safetySYS
do not initialize
C50A40 Wrong voltage from
Power supply1
C50A41 Wrong voltage from
Power supply2
C50A42 Voltage will not
disappear from Power
supply
C50A43 Warning, waiting for
CB2 type answer from
primary processor
C50A50 Processor A 3.3V
supply voltage out of
bounds

7. Troubleshooting
C50A51 Robot voltage below

threshold
C50A52 Robot voltage above
threshold
C50A53 58V generator
deviation error
C50A54 5V regulator too low
C50A55 5V regulator too high
C50A56 -4V generator too low
C50A57 -4V generator too high
C50A80 Last CPU reset
caused by Low-
Power-Reset

caused by Window-
Watchdog-Reset
caused by
Independent-
Watchdog-Reset
C50A83 Last CPU reset The Safety Control Board
caused by Software- was reset on explicit
Reset request.
caused by External-
Pin-Reset
caused by Brown-Out-
Reset
C50A99 Wrong software on
PCB
C50A100 Cable not connected Robot Problem: Robot Cable Check cable and
is not detected connections between robot
and control box
C50A101 Short circuit in robot Robot Problem: 48V power Check robot type. Look for
detected or wrong supply or wrong robot type short circuit in cable and in
robot connected to robot arm.
control box
C50A102 Voltage rising too Robot Problem: 48V power
slowly supply

7. Troubleshooting
C50A103 Voltage failed to Robot Problem: 48V power

reach acceptable supply
level
C51 CRC check failure on
secondary bus
C51A0 Processor B
C51A1 Primary screen CRC check failure on Safety
processor processor 1 in Teach
pendant
C51A2 Secondary screen CRC check failure on Safety
processor processor 2 in Teach
pendant
C51A3 Primary E67
C51A4 Secondary E67
C53 IO overcurrent Safety Control Board error Remove all external

detected connections to I/O’s. Check
for short circuit
C53A1 IO overcurrent Safety Control Board error Remove all external
detected, max is connections to I/O’s. Check
800mA for short circuit
C53A2 IO overcurrent Tool error Remove all external
detected, max is connections to I/O’s. Check
600mA for short circuit
C55 Safety system error Safety system malfunction a) Check Motherboard,
Safety Control Board,
Screenboard, Current
distributor (Euromap, if
installed).
b) Check safety devices
and cables/connections to
these devices.
c) Do a Complete rebooting
5.3.7
C55A23 Safety relay error Current distributor error a) Check cable from Safety
(minus connection) Control Board to Current
distributor or 48V Power
supply and Current
distributor for issues
5.3.7

7. Troubleshooting
(plus connection) Control Board to Current
supply and Current
5.3.7
C55A33 Safety relay error (a Current distributor error a) Check cable from Safety
relay is stuck) Control Board to Current
supply and Current

5.3.7
(relays are not on) Control Board to Current
supply and Current
5.3.7
C55A50 Voltage present at Safety Control Board a) Do a Complete rebooting
unpowered robot hardware fault sequence as per section
5.3.7
replace Safety Control
Board
C55A51 Voltage will not Safety Control Board a) Do a Complete rebooting
disappear from robot hardware fault sequence as per section
5.3.7
Board

7. Troubleshooting
C55A52 5V, 3V3 or ADC error Safety Control Board a) Do a Complete rebooting
(5V too low) hardware fault sequence as per section
5.3.7
Board
C55A53 5V, 3V3 or ADC error Safety Control Board a) Do a Complete rebooting
(5V too high) hardware fault sequence as per section
5.3.7
Board
C55A90 Bootloader error,
robot voltage too low

or current too high
C55A91 Bootloader error,
robot voltage too high
C55A100 Safety violation
C55A101 Safety Channel Error
in Safety Control
Board
in Screen
in Euromap67
Interface
C55A109 Received fault
message from PC
C55A110 Safety State is
changing too often
C55A111 On/Off State is
changing too often
C55A112 Robot current sensors
readings differ
C55A120 Robot current is too
high while emergency
stopped
C55A121 Robot current is too
high while safeguard
stopped

7. Troubleshooting
C56 Overvoltage shutdown Voltage exceeded 55V a) Check Energy Eaters

cable and connections.
b) Check Energy
c) Replace Energy Eater
C57 Brake release failure a) Check Brake, solenoid
b) Check TCP
configuration, payload and
mounting settings
C57A1 Joint did not move or a) Check Brake, solenoid
motor encoder is not b) Check TCP
functioning configuration, payload and
mounting settings
C57A2 Large movement a) Check Brake, solenoid
detected during brake b) Check TCP
release configuration, payload and

mounting settings
C57A3 Robot was not able to a) Check Brake, solenoid
brake release, see log b) Check TCP
for details configuration, payload and
mounting settings
C58 Motor encoder not
calibrated
C59 Overcurrent shutdown Overcurrent in joint. a) Check for short circuit.
Argument = Current in Amps. b) Do a Complete rebooting
5.3.7
replace joint
C61 Idle power The system is drawing more Try the following actions to
consumption to high power than expected while see which resolves the
idle. issue:
Argument = Watt. a) Check Energy Eaters
cable and connections
b) Check Energy Eater
c) Replace Energy Eater
C62A1 Thermal issue: Joint Warning a) Check nothing is
temperature: High (80 hindering free movement of
C)" the joints
b) Check TCP
mounting settings

7. Troubleshooting
C62A3 Thermal issue: Warning a) Check nothing is

Warning: Static load hindering free movement of
to high the joints
b) Check TCP
mounting settings
C62A11 Thermal issue: Joint Stop a) Check nothing is
temperature: Shut hindering free movement of
down (85 C)" the joints
b) Check TCP
mounting settings
C62A13 Thermal issue: Stop a) Check nothing is
Shutdown: Static load hindering free movement of
to high the joints
b) Check TCP
mounting settings
C63 Motor test failed in
step {unsigned}.
C65 PSU voltage to high The power supply output Try the following actions to
voltage is above 49V. see which resolves the
Argument = Volt. issue
a) Ensure supply is not
delivering more than 49V
b) Check Energy Eaters
cable and connections
c) Check Energy Eater
d) Replace power supply
C68 SPI error Joint: Absolut encoder on a) Check for short circuit.
joint communication error b) Do a Complete rebooting
5.3.7
than several times in a row,
replace joint
C70 Close to gearbox Acceleration / deceleration a) Reduce acceleration in
shear limit too high. Mechanical user program.
problem in gear related to b) Do a Complete rebooting
encoder mounting sequence as per section
5.3.7
than several times in a row,
replace joint

7. Troubleshooting
C71 Startup check error Fault: Firmware in joint Update firmware

C71A0 Hardware is size0, Fault: Firmware in joint Update firmware
wrong firmware at the
joint
joint
joint
joint

joint
C71A5 Invalid hardware size
read
C71A6 ADC calibration failed Only in joint
C71A7 Unknown error result The motor wires are a) Check joint for damaged
damaged, bad connection in or loose connections
screw terminals or defect b) Replace the joint
PCB
C71A8 Motor short circuit to The motor wires are a) Check joint for damaged
ground or H-bridge damaged, bad connection in or loose connections
problems screw terminals or defect b) Replace the joint
PCB
C71A9 Motor indication The motor wires are a) Check joint for damaged
signal does not work damaged, bad connection in or loose connections
screw terminals or defect b) Replace the joint
PCB
C71A10 Phase 1 is The motor wires are a) Check joint for damaged
unconnected or not damaged, bad connection in or loose connections
working screw terminals or defect b) Replace the joint
PCB
C71A11 Phase 2 is The motor wires are a) Check joint for damaged
unconnected or not damaged, bad connection in or loose connections
working screw terminals or defect b) Replace the joint
PCB

7. Troubleshooting
C71A12 Phase 3 or multiple The wire is (1) damaged or a) Check joint for damaged
phases is (2) has been disconnected or loose connections
unconnected or not from the PCB (not likely) or b) Replace the joint
working (3) defect PCB
C71A50 Current sensor test Sensor reported wrong a) Check joint for damaged
failed current when probed or loose connections
b) Replace the joint
C71A51 Current sensor test Sensor reported wrong a) Check joint for damaged
failed current when probed or loose connections
C71A52 Current sensor test Sensors reported different a) Check joint for damaged
failed currents when probed or loose connections
C72 Power Supply Unit 48 V Power problem
failure
C72A1 0 Power supplies are Power supply was not able to Check power connection
active deliver 48V between Power supply and
C72A2 1 Power supply Power supply was not able to Check power connection
active, but we expect deliver 48V or UR10 flash between Power supply and
2 (UR10) card in UR5 robot Safety Control Board and
check that the
flashcard/USB and robot
match
C72A3 2 Power supplys UR5 flash card in UR10 robot Check that the
active, but we expect flashcard/USB and robot
1 (UR5) match
C73 Brake test failed
during selftest, check
brakepin
C74 Joint encoder warning Magnetic encoder error
(Absolut encoder)
C74A1 Invalid decode: Check grounding and
Readhead shielding for EMC
misalignment, ring problems
damaged or external
magnetic field
present.
C74A2 Speed reading is not
valid

7. Troubleshooting
C74A4 System
error=malfunction or
inconsistent
calibration detected
C74A8 Supply voltage is out
of range
C74A16 Temperature is out of
range
C74A64 Signal low =Too far
from magnetic ring
C74A128 Signal saturation
=Too close to
magnetic ring
C74A207 Joint encoder error Example: Argument 207 is the sum of 128,64,8,4,2,1 which

means that all the errors in connection to argument 1, 2, 4,
8, 64 and 128 have been reported.
C75 Joint encoder error Magnetic encoder error
(Absolut encoder)
C75A1 Invalid decode: a) Do a Complete rebooting
Readhead sequence as per section
misalignment, ring 5.3.7
damaged or external b) Check grounding and
magnetic field shielding for EMC
present. problems
replace joint
C75A2 Speed reading is not a) Do a Complete rebooting
valid sequence as per section
5.3.7
replace joint
C75A4 System a) Do a Complete rebooting
error=malfunction or sequence as per section
inconsistent 5.3.7
calibration detected b) If this happens more
replace joint
C75A8 Supply voltage is out Check previous error
of range

7. Troubleshooting
C75A16 Temperature is out of Check previous error

range
C75A32 Signal lost a) Do a Complete rebooting
=Misaligned readhead sequence as per section
or damaged ring 5.3.7
replace joint
C75A64 Signal low =Too far a) Do a Complete rebooting
from magnetic ring sequence as per section
5.3.7
replace joint
C75A128 Signal saturation a) Do a Complete rebooting
=Too close to sequence as per section

magnetic ring 5.3.7
replace joint
C75A207 Joint encoder error Example: Argument 207 is the sum of 128,64,8,4,2,1 which
means that all the errors in connection to argument 1, 2, 4,
8, 64 and 128 have been reported.
C76 Joint encoder Error between sensor and Check connections or very
communication CRC joint circuit heavy electrical noise
error
C77 Sudden position The position reading from
change detected on the encoder was different
the joint-encoder than expected.
C78 Large sudden position The position reading from
change detected on the encoder was severely
the joint-encoder different than expected, the
latest measurement was
discarded
C78A255 Large sudden position Example: The argument 255 is a number that relates to the
change detected on size of the position change. In other words, this can be
the joint-encoder treated as a C78 error.
C80A51 Window watchdog
reset
C100 Robot changed mode Status warning, general Check preceding errors in
modus change log history
C101 Real Robot Connected

7. Troubleshooting
C102 Real Robot not

connected –
Simulating Robot
C103 UR Ethernet Error Communication problem a) Check that the Ethernet
between Motherboard and cable between
Safety Control Board Motherboard and Safety
Control Board is connected
5.3.7
C103A1 Connection to Safety Motherboard did not receive a) Check that the Ethernet
Control Board lost 3 packets in a row cable between
Motherboard and Safety

5.3.7
C103A2 Package lost from
C103A3 Ethernet connection
initialization with
failed
C104 Error=Empty
command sent to
robot
C111 Something is pulling Check TCP configuration,
the robot payload and mounting
settings
C115 Unknown robot type The robot type specified in
the configuration is unknown
C116 Realtime part warning Possible CPU-overload due Restructure user program
to structure of user program
C117 Restart Safety Control The Safety Control Board Do a Complete rebooting
Board failed couldn’t be rebooted from sequence as per section
the controller. 5.3.7
C150 Protective Stop:
Position close to joint
limits
C151 Protective Stop: Tool
orientation close to
limits

7. Troubleshooting

Position close to
safety plane limits
C153 Protective Stop: Check TCP configuration,
Position deviates payload and mounting
from path settings
C154 Protective Stop: Robot cannot move linear Use MoveJ or change the
Position in singularity near a singularity motion
Robot cannot
maintain its position,
check if payload is
correct
C156 Protective Stop: The robot may move Verify that the TCP
Wrong payload or unexpected due to wrong configuration and mounting

mounting detected, or settings in the used installation is
something is pushing correct
the robot when
entering Freedrive
mode
C157 Protective Stop: Make sure no objects are
Collision detected by in the path of the robot and
joint resume the program
C160 Protective stop: The a) Verify that the robot position in the 3D graphics
robot was powered matches the real robot, to ensure that the encoders
off last time due to a function before releasing the brakes. Stand back and
joint position monitor the robot performing its first program cycle as
disagreement expected.
b) If the position is not correct, the robot must be repaired.
In this case, click “Power Off Robot”.
c) If the position is correct, please tick the check box
below the 3D graphics and click “Robot Position Verified”
C161 Protective stop: Large a) Verify that the robot position in the 3D graphics
movement of the matches the real robot, to ensure that the encoders
robot detected while function before releasing the brakes. Stand back and
it was powered off. monitor the robot performing its first program cycle as
The joints were expected.
moved while it was b) If the position is not correct, the robot must be repaired.
powered off, or the In this case, click “Power Off Robot”.
encoders do not c) If the position is correct, please tick the check box
function. below the 3D graphics and click “Robot Position Verified”
C171 Issue with blends

7. Troubleshooting
C171A0 A MoveC-waypoint The value for the blend Decrease the blend radius
were skipped due to a radius is too large compared or choose waypoints that
blend. to the distance between the are further apart.
waypoints.
C171A1 Blend radius too Increase blend in MoveC
small in a MoveC
C171A3 A ServoC-waypoint The value for the blend Decrease the blend radius
waypoints.
C171A4 Overlapping Blends in Decrease the blend radius
a MoveJ, a waypoint or choose waypoints that
was skipped are further apart.

C171A9 A MoveP-waypoint The value for the blend Decrease the blend radius
waypoints.
C171A10 Blend radius too
small error in a
MoveP
a MoveL, a waypoint or choose waypoints that
C172 Illegal control mode

7. Troubleshooting
C184 Joint self test not

received by controller
C185A1 START_NORMAL_
OPERATION is not
allowed on selftest
firmware
C185A2 GOTO_BACKDRIVE_
COMMAND is not
allowed on selftest
firmware
C186A1 joint_mode == JOINT_
RUNNING_MODE is
not allowed on
selftest firmware
C190 Joint failed during

selftest
C190A0 Motor encoder index
mark not found
C190A1 Phases not mounted
correctly
C190A2 Motor encoder
counting the wrong
way
C190A3 Joint encoder
counting the wrong
way
C190A4 No movement
detected while trying
to move the motor
C190A11 Temperature
alignment did not
warm up to 45
degrees C within 30
minutes
C190A12 Temperature
alignment did not
cool down to 45
degrees C within 60
minutes
C191 Safety system
violation

7. Troubleshooting
C191A1 Joint position limit

violated
C191A2 Joint speed limit
violated
C191A3 TCP speed limit
violated
C191A4 TCP position limit
violated
C191A5 TCP orientation limit
violated
C191A6 Power limit violated
C191A7 Joint torque window
violated

too large
C191A9 Reduced mode output
violation
C191A10 Safeguard stop output
violation
C191A11 Emergency stop
output violation
C191A12 Momentum limit
violation
C191A13 Robot moving output
violation
C191A14 Robot is not braking During the braking process, Check TCP configuration,
in stop mode the safety system monitors payload and mounting
if the robot brakes as settings
expected. If this is not the
case, this error is generated
C191A15 Robot is moving in When the robot is stopped a) Check if the robot is
stop mode due to a safety violation or a physically pushed while
safeguard stop, the safety safeguard stopped
system generates this error, b) Check TCP
if the robot moves while in configuration, payload and
this mode mounting settings
C191A16 Robot did not stop in
time
C191A17 Received a null vector Fault in config file, when no
for TCP orientation GUI is used

7. Troubleshooting
C191A18 Robot not stopping

output violation
C191A19 Invalid safety IO Fault in config file, when no
configuration GUI is used
C191A20 Configuration
information or limit
sets not received
C191A21 The other safety
processor detected a
violation
C191A22 Received unknown
command from
controller
C191A23 Invalid setup of safety a) Check Firmware/update
limits firmware
5.3.7
C191A24 Reduced Mode Output a) Check Firmware/update
set, while it should firmware
not be b) Do a Complete rebooting
5.3.7
C191A25 Reduced Mode Output a) Check Firmware/update
not set, while it firmware
should be b) Do a Complete rebooting
5.3.7
C191A26 Not Reduced Mode a) Check Firmware/update
Output set, while it firmware
should not be b) Do a Complete rebooting
5.3.7
C191A27 Not Reduced Mode a) Check Firmware/update
Output not set, while firmware
it should be b) Do a Complete rebooting
5.3.7

7. Troubleshooting
C191A28 Robot Emergency Too high payload a) Check that max payload
Stop exceeded of the robot has not been
maximum stop time exceeded.
b) Check TCP
mounting settings
C191A29 System Emergency Too high payload a) Check that max. payload
Stop exceeded of the robot has not been
maximum stop time exceeded.
b) Check TCP
mounting settings
C191A30 Safeguard Stop Too high payload a) Check that max. payload
exceeded maximum of the robot has not been
stop time exceeded.

b) Check TCP
mounting settings
C191A31 Operation mode
switch is present
while the three
position switch is
missing
violated - Joint 0
(Base)
violated - Joint 1
(Shoulder)
violated - Joint 2
(Elbow)
violated - Joint 3
(Wrist 1)
violated - Joint 4
(Wrist 2)
violated - Joint 5
(Wrist 3)
C192 Safety system fault

7. Troubleshooting
C192A1 Robot still powered in When emergency stop is

emergency stop active, the robot arm powers
off. The controller is
responsible for sending the
power off command. This
error is generated, if the
safety system detects that
the robot arm still has
power.
C192A2 Robot emergency E-stop in teach pendant or in Check safety devices and
stop disagreement Robot E-stop circuit problem cables/connections to
these devices.
C192A3 System emergency System E-stop circuit Check safety devices and
stop disagreement problem cables/connections to
these devices.
C192A4 Safeguard stop Safeguard circuit problem Check safety devices and
disagreement cables/connections to
these devices.
C192A5 Euromap safeguard Euromap circuit problem Check cables from Safety
stop disagreement Control Board to Euromap
and to external machine
C192A6 Joint position a) Check TCP
disagreement configuration, payload and
mounting settings
b) Check that safety
settings respected.
C192A7 Joint speed a) Check TCP
mounting settings
settings respected.
C192A8 Joint torque a) Check TCP
mounting settings
settings respected.
C192A9 TCP speed a) Check TCP
mounting settings
settings respected.

7. Troubleshooting
C192A10 TCP position a) Check TCP

mounting settings
settings respected.
C192A11 TCP orientation a) Check TCP
mounting settings
settings respected.
C192A12 Power disagreement Power calculation: uP-A and Joint error: Check previous
uP-B disagreement error codes from the same
joint and evaluate
disagreement

C192A14 Reduced mode input Safety I/O uP-A and uP-B Check safety devices and
disagreement disagreement cables/connections to
these devices.
C192A15 Reduced mode output Safety I/O uP-A and uP-B Check safety devices and
these devices.
C192A16 Safety output failed The safety output did not Check for short circuit on
reach the correct value in the I/O or for wrong connection
expected time to output.
C192A17 Safeguard stop output Safety I/O uP-A and uP-B Check safety devices and
these devices.
C192A18 The other safety
processor is in fault
C192A19 Emergency stop Safety I/O uP-A and uP-B Check safety devices and
output disagreement disagreement cables/connections to
these devices.
C192A20 SPI output error Power supply for the I/O is Check if the connection to
detected not detected the internal Power supply
is correct. If an external
power supply is being used,
check if it is powered on
and correct voltage.
C192A21 Momentum
disagreement

7. Troubleshooting
C192A22 Robot moving output Safety I/O uP-A and uP-B Check safety devices and
these devices.
C192A23 Wrong processor ID
C192A24 Wrong processor
revision
C192A25 Potential brownout Voltage drop on Safety
detected Control Board or defect
C192A26 Emergency stop Safety I/O uP-A and uP-B Check safety devices and
these devices.
C192A27 Safeguard stop output Safety I/O uP-A and uP-B Check safety devices and
these devices.
C192A28 Robot not stopping Safety I/O uP-A and uP-B Check safety devices and
these devices.
C192A29 Safeguard reset input Safety I/O uP-A and uP-B Check safety devices and
these devices.
C192A30 Safety processor
booted up in fault
mode
C192A31 Reduced Mode Output Safety I/O uP-A and uP-B Check safety devices and
these devices.
C192A32 Not Reduced Mode Safety I/O uP-A and uP-B Check safety devices and
Output disagreement disagreement cables/connections to
these devices.
C192A33 A timing issue Checksum disagreement
occurred during between safety processors
startup. Please uA and uB
restart to proceed
C192A34 User safety config
checksum
disagreement
between uA and GUI
C192A35 Robot config
checksum
disagreement
between uA and GUI

7. Troubleshooting
C192A36 Online RAM test

failed
C192A37 Not all safety related
functionalities are
running
C192A38 Package too short for
CRC calculation
C192A39 Three position switch
input disagreement
C192A40 Operation mode
switch input
disagreement
C193 One of the nodes is in Safety Control Board has a) See previous error
fault mode detected an error b) Do a Complete rebooting

5.3.7
C193A0 Joint 0 is in fault Safety Control Board has a) See previous error
mode detected an error b) Update the firmware on
the joint
5.3.7
the joint
5.3.7
the joint
5.3.7
the joint
5.3.7

7. Troubleshooting
the joint
5.3.7
the joint
5.3.7
C193A6 Tool is in fault mode Safety Control Board has a) See previous error
detected an error b) Do a Complete rebooting
5.3.7
C193A7 Screen 1 is in fault Safety Control Board has a) See previous error
mode detected an error on Safety b) Do a Complete rebooting
processor 1 in Teach sequence as per section
pendant 5.3.7
C193A8 Screen 2 is in fault Safety Control Board has a) See previous error
mode detected an error on Safety b) Do a Complete rebooting
processor 2 in Teach sequence as per section
pendant 5.3.7
C193A9 Euromap 1 is in fault Safety Control Board has a) See previous error
mode detected an error b) Do a Complete rebooting
5.3.7
C193A10 Euromap 2 is in fault Safety Control Board has a) See previous error
mode detected an error b) Do a Complete rebooting
5.3.7
C194 One of the nodes is
not booted or not
present
C194A0 Joint 0 is not booted Safety Control Board has
or not present detected an error

7. Troubleshooting

C194A6 Tool is not booted or Safety Control Board has
not present detected an error
C194A7 Screen 1 is not Safety Control Board has
booted or not present detected an error on Safety
processor 1 in Teach
pendant
C194A8 Screen 2 is not Safety Control Board has
booted or not present detected an error on Safety

processor 2 in Teach
pendant
C194A9 Euromap 1 is not Safety Control Board has
booted or not present detected an error
C194A10 Euromap 2 is not Safety Control Board has
booted or not present detected an error
C194A128 Joint 0 not ready Must be at least in IDLE Check for loose
while brake release mode when the brake communication cable.
requested release is requested
C194A134 Tool not ready while Must be at least in IDLE Check for loose
brake release mode when the brake communication cable.

7. Troubleshooting
C195 Conveyor speed too Conveyor speed higher than Make sure that conveyor
high robot is able to run tracking is set correctly
C195A1 Conveyor speed too Make sure that conveyor
high for joint speed tracking is set correctly
safety limit
high for TCP speed tracking is set correctly
safety limit
high for momentum tracking is set correctly
safety limit
C196 MoveP speed too high Too high speed in relation to Reduce speed or increase
blend radius blend radius in user
program
C197 Blend overlap warning

C200 Safety Control Board Safety Control Board: uP-A a) Do a Complete rebooting
hardware error has detected an error sequence as per section
5.3.7
Board
C200A1 Hardware ID is wrong Safety Control Board: uP-A a) Do a Complete rebooting
has detected an error: Wrong sequence as per section
Safety Control Board 5.3.7
Board
C200A2 MCU type is wrong Safety Control Board: uP-A a) Do a Complete rebooting
has detected an error sequence as per section
5.3.7
Board
C200A3 Part ID is wrong Safety Control Board: uP-A a) Do a Complete rebooting
5.3.7
Board

7. Troubleshooting
C200A4 RAM test failed Safety Control Board: uP-A a) Do a Complete rebooting
5.3.7
Board
C200A5 Register test failed Safety Control Board: uP-A a) Do a Complete rebooting
5.3.7
Board
C200A6 pRom Crc test failed Safety Control Board: uP-A a) Do a Complete rebooting

has detected an error: sequence as per section
firmware error 5.3.7
Board
C200A7 Watchdog reset the Safety Control Board: uP-A
processor has detected an error
C200A8 OVG signal test not Safety Control Board: uP-A a) Do a Complete rebooting
passed has detected an error: over sequence as per section
voltage generator 5.3.7
Board
C200A9 3V3A power good pin Safety Control Board: uP-A a) Do a Complete rebooting
is low has detected an error sequence as per section
5.3.7
Board
C200A10 3V3B power good pin Safety Control Board: uP-A a) Do a Complete rebooting
is low has detected an error sequence as per section
5.3.7
Board

7. Troubleshooting
C200A11 5V power good is low Safety Control Board: uP-A a) Do a Complete rebooting
5.3.7
Board
C200A12 3V3 voltage too low Safety Control Board: uP-A a) Do a Complete rebooting
5.3.7
Board
C200A13 3v3 voltage too high Safety Control Board: uP-A a) Do a Complete rebooting

5.3.7
Board
C200A14 48V input is too low a) Do a Complete rebooting
5.3.7
b) Check 48 V Power
supply, current distributer,
energy eater and Safety
Control Board for issues
C200A15 48V input is too high a) Do a Complete rebooting
5.3.7
b) Check 48 V Power
C200A16 24V IO short circuited Too high current a) Do a Complete rebooting
5.3.7
b) Disconnect external I/O
connections and check
external power supply if
connected

7. Troubleshooting
C200A17 PC current is too high Motherboard takes too high a) Do a Complete rebooting
current sequence as per section
5.3.7
b) Check cable between
Safety Control Board and
Motherboard and check all
connections to
Motherboard. Also check
for short circuit.
C200A18 Robot voltage is too a) Do a Complete rebooting
low sequence as per section
5.3.7
b) Check for short circuit in
robot arm.
c) Check 48 V Power

C200A19 Robot voltage is too a) Do a Complete rebooting
high sequence as per section
5.3.7
b) Check 48 V Power
C200A20 24V IO voltage is too a) Do a Complete rebooting
low sequence as per section
5.3.7
b) Disconnect I/O, check
external power supply if
connected and check
Safety Control Board for
issues
C200A21 12V voltage is too a) Do a Complete rebooting
high sequence as per section
5.3.7
b) Check 12 V Power
supply, cables and Safety

7. Troubleshooting
C200A22 12V voltage is too low a) Do a Complete rebooting

5.3.7
b) Check 12 V Power
supply, cables and Safety
C200A23 It took too long to Safety Control Board error a) Do a Complete rebooting
stabilize 24V sequence as per section
5.3.7
b) Check external 24 V and
issues
C200A24 It took too long to Safety Control Board error a) Do a Complete rebooting
stabilize 24V IO sequence as per section
5.3.7
b) Check external 24 V and

issues
C200A25 24V voltage is too Safety Control Board error a) Check external 24 V and
high Safety Control Board for
issues
5.3.7
C) If this happens more
Board
C200A26 24V IO voltage is too a) Disconnect I/O’s
high b) Do a Complete rebooting
5.3.7
c) Check external 24 V and
issues

7. Troubleshooting
C201A0 Setup of safety board No data was received from a) Do a Complete rebooting
failed the Safety Control Board at sequence as per section
initialization or invalid safety 5.3.7
parameters have been b) Check that the ethernet
received. cable between
Motherboard and Safety
and verify that the setup of
the Safety Configuration is
valid.
C202 SCE configuration
was illegal, after
applying tolerances
C203A0 PolyScope detected a The PolyScope continuously a) Check that the software
mismatch between verifies that the shown version is the same or

the shown and (to be) safety parameters are equal newer than the firmware on
applied safety to the running parameters the Safety Control Board.
parameters b) Reload the installation
5.3.7
C204A0 Protective Stop: Path
sanity check failed
C204A1 Sudden change in
target position
C204A2 Inconsistency
between target
position and speed
C204A3 Sudden stop The program contains To abort a motion, use
motions that are not ramped "stopj" or "stopl" script
correctly down commands to generate a
smooth deceleration before
using "wait". Avoid aborting
motions between
waypoints with blend
C204A4 Robot has not
stopped in the
allowed reaction and
braking time
C204A5 Robot program
resulted in invalid
setpoint

7. Troubleshooting
C204A6 Blending failed and Try changing the blend

resulted in an invalid radius or contact technical
setpoint support
C205 Target speed does
not match target
position
C205A0 Inconsistency
between target
position and speed
C206 Sanity check failed The software version on the
robot must be the same or
later than the version the
robot had from the factory.
C206A0 Target joint speed
does not match target

joint position – Joint
0 (Base)
1 (Shoulder)
2 (Elbow)
3 (Wrist 1)
4 (Wrist 2)
5 (Wrist 3)

7. Troubleshooting
C207 Fieldbus input Check fieldbus

disconnected connections (RTDE,
ModBus, EtherNet/IP and
Profinet) or disable the
fieldbus in the installation.
Check RTDE “watch dog”
feature. Check if a URCaps
is using this feature as
well.
7.2. LED indicators and Fuses on Safety Control Board

Safety Control Board (SCB)
1. Fuse 48 V:
The 5A fuse (F801) “48V” protects all 48V in the system inclusive of Euromap from over

current.
This information is only for troubleshooting. Do NOT replace the fuse under any
circumstances.
In case of failure, ONLY replace the SCB with a new tested board.
2. Fuse 24 V:
2 x 5A fuses (F1001 and F1002) in parallel protect the DI/DO 24 V supply on the Safety
Control Board, whether the 24 V is from the controller or external power supply. Do NOT
replace the fuses under any circumstances. In case of failure ONLY replace the SCB with a
new tested board.
3. LED indicators:
• 12V-PSU On when the power plug is connected.

• 12V System: On when the main controller power has been activated.
• 5V On when “12V System” is on and indicates that 5V is present.
• -4V On when “12V System” is on and indicates that – 4V to analog I/O is present.
• 3V3A On when 5V is on and indicates 3.3V for logic Safety circuit A is present.
• 3V3B On when 5V is on and indicates 3.3V for logic Safety circuit B is present.
• 48V Indicates 48 V is present on the Safety Control Board
• 24V 48V is detected and ok, indicates that internal 24 V is present for I/Os
• R 48 V present on robot arm
• A Indicates Status for Logic A: a blink sequence
• B Indicates status for Logic B: a blink sequence

7. Troubleshooting
7.2.1. Normal startup sequence for a CB3.x UR10

1. The 12V-PSU LED is on when the power plug is connected to a working power supply.
2. When the power button on the teach pendant is pressed, all LED indicators are turned on
except for the 48V, 24V and R LEDs. The A and B LEDs also exhibit a special behavior by
intermittently turning off and on ("blinking") once triggered.
3. The final phase of the startup sequence occurs (immediately) after the Polyscope software
is done loading. At this stage, the 48V and 24V LED indicators become active (are switched
on).
If the 48V LED indicator is off all the time in the startup sequence you should measure the
voltage:
See the E-Plan diagram: Schematic Overview
1. Measure the 48V on the Safety Control Board (SCB) where the 48V comes from the Current
distributor. And check this 1 second pulse.
1. The voltage is measured on the Safety Control Board. That means the Safety Control
Board is defect.
2. No voltage is measured on the Safety Control Board. Then measure the 230 V on the
input side of the 48V power supply. If the voltage pulse of 1 second is present, the
Power supply is defect.
3. No voltage is measured on the input of the power supply. Then measure the 230 V on
the input side of the Current distributor. If the voltage is present, the current
distributor is defect.

7. Troubleshooting
7.3. Error Phenomena

7.3.1. Control Box: NO CONTROLLER displayed in Initializing

7. Troubleshooting
7.3.2. NO CABLE displayed during power up

7.3.3. Protective Stop

Read also article 18939 on the support site www.universal-robots.com/support

7. Troubleshooting
Ignoring protective stops is considered abuse of the robot which voids the warranty.
These faults can be hidden from view under the following two circumstances:

7. Troubleshooting
1. Personnel simply resetting a fault without review of why the fault has happened.
WARNING
Ignoring protective stops masks fault detection!
Pay careful attention to protective stops.
Learn why they happen to improve your programs and preserve fault detection!
Protective stops must never be acknowledged and reset automatically, it must always be a
deliberate action by a user to resume after a protective stop.
In general, protective stops are designed to inform the user that the robot has stopped due to an
external event such as hitting an obstacle or similar. In case the robots are pushed close to the
limits, the robots can generate protective stops to indicate that they are not capable of following
the desired trajectory. After a protective stop, the following must be done before resuming
operation:
i. If there has been a collision or similar:

Remove the obstacle and ensure that operators are out of the way before resuming
operation. See Section 2 of Service Manual (see link below).
ii. If there has been NO collision or similar:
The robot is operating too close to the limits, the application should be adjusted to reduce
the load on the robot, for instance by reducing accelerations, by correct use of blends or
similar measures.
Protective stops are indications of issues, including program or production issues – not only
safety issues. An application which results in daily protective stops is not designed correctly
and needs to be modified.
2. If an automatic acknowledgment and reset of a protective stop has been programmed – no
one will see the protective stop.
WARNING
Automatic acknowledgment and reset of protective stops masks faults that will
lead to a failure condition.
When there is a protective stop, verify the cause.

If there has been no collision, then adjust the program
If an integrator has set-up the application program to do automatic acknowledgement and reset
of protective stops, the customer should contact the integrator change the program immediately,
as such override voids the product warranty and masks fault detection.
7.3.4. Power on failure in Initializing

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

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

7. Troubleshooting
7.3.5. Checklist After a Collision


7. Troubleshooting
7.3.6. Communication to joints and tool

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7. Troubleshooting
7. Troubleshooting
7.3.7. Complete Rebooting Sequence

7. Troubleshooting
7.4. Electrical Documentation

7.4.1. Schematic Overview
Diagrams in PDF or in E-plan format, can be found on the Support site: www.universal-
robots.com/support

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7. Troubleshooting
7.4.2. E-Plan diagrams

Diagrams in PDF or in E-plan format, can be found on the Support site: www.universal-
robots.com/support/

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8. Spare parts
8. Spare parts
NOTICE
The Spare Parts list incl. parts for other types of Robots. Please take extra notice
when looking up part numbers and descriptions.
Robot arm
CB3 part no. CB2 Part no. Product Name UR3 UR5 UR10 All
103303 Flat-ring sealing set UR3, external *
103413 Lid set complete UR3 incl. seal *
122020 Tool Mounting Bracket UR3 *

122030 Base Mounting Bracket Incl. Cable 6m *
UR3
124120 Joint Size 0 Wrist 1 UR3 *
124321 Joint Size 1 Elbow UR3 *
124122 Joint Size 2 Base UR3 *
124222 Joint Size 2 Shoulder UR3 *
104003 Elbow counterpart and lower arm kit UR3 *
103305 103305 Flat-ring sealing set UR5, external *
103405 103405 Lid set complete UR5 incl. seal *
122041 Tool Mounting Bracket UR5 CB3 *
122039 Tool Mounting Bracket UR5 CB2+ *
122050 122050 Base Mounting Bracket Incl. Cable 6m *
UR5
122121 Joint Size 1 Wrist 1 UR5 CB3 *
122011 Joint Size 1 Wrist 1 UR5 CB2+ *
122123 Joint Size 3 Base UR5 CB3 *
122031 Joint Size 3 Base UR5 CB2+ *
122223 Joint Size 3 Shoulder UR5 CB3 *

8. Spare parts
122032 Joint Size 3 Shoulder UR5 CB2+ *

122323 Joint Size 3 Elbow UR5 CB3 *
122033 Joint Size 3 Elbow UR5 CB2+ *
123100 123100 Elbow counterpart and lower arm UR5 *
103310 103310 Flat-ring sealing set UR10, external *
103410 103410 Lid set complete UR10 incl. seal *
122061 Tool Mounting Bracket UR10 CB3 *
122059 Tool Mounting Bracket UR10 CB2+ *
122071 122071 Base Mounting Bracket UR10 *
106424 106424 UR10 Base plug w/wire *

122324 Joint Size 3 Elbow UR10 CB3 *
122034 Joint Size 3 Elbow UR10 CB2+ *
122124 Joint Size 4 Base UR10 CB3 *
122042 Joint Size 4 Base UR10 CB2+ *
122224 Joint Size 4 Shoulder UR10 CB3 *
122043 Joint Size 4 Shoulder UR10 CB2+ *
104001 104001 Elbow counterpart and lower arm kit UR10 *
103500 Wire bundle kit for size 0 *
103501 Wire bundle kit for size 1 * *
103504 Wire bundle kit for size 4 *
103508 Wire bundle kit for lower arm *
103509 Wire bundle kit for upper arm *
Controller
CB3 part CB2 Part Product Name UR3 UR5 UR10 All
no no
122973 Controller excl. Teach Pendant UR3 *
122900 Controller excl. Teach Pendant UR5 CB3.1 *

8. Spare parts
122950 Controller excl. Teach Pendant UR10 CB3.1 *

122091 Teach Pendant complete CB3/CB3.1 *
122092 Teach Pendant complete CB2/CB2.1 * *
122673 Euromap E67 module *
106700 Euromap E67 kit CB2 (incl. Bypass plug and * *
cable)
106800 Euromap E67 kit CB3 (incl. Bypass plug and *
cable)
123670 123670 Euromap E67 cable 6m *
122671 122671 Euromap E67 Bypass Plug *
122650 Motherboard kit CB2.1 and CB3.1 (incl. RAM) *
122700 Masterboard kit CB2 * *
122420 CB2.0 to CB2.1 Motherboard Upgrade Kit * *

122430 CB3.0 to CB3.1 Motherboard Upgrade Kit * *
171030 171030 RAM module CB2.0 and CB3.0 * *
171031 RAM module CB2.1 and CB3.1 *
171022 171022 Flash card CB2 and CB3 * *
122421 122421 Flashcard for Robot incl. SW and Serial no. CB2 * *
and CB3
177002 177002 Power Supply Unit 12V *
177003 177003 Power Supply Unit 48V *
122431 122431 USB for Robot incl. SW and Serial no. CB2.1 and *
CB3.1
172080 172080 Current Distributor PCB *
172290 Safety Control Board *
107000 Safety Control Board Terminal Kit (12 terminals *
and jumper)
122745 122745 Energy-eater incl. fan *
177503 177503 Filter kit for controller (incl. two filters) *
139033 139033 Bracket for mounting Teach Pendant *
132407 132407 Bracket for mounting controller *
164231 164231 Cable Base to controller UR10 *
Tools
CB3 part CB2 Part Product Name UR3 UR5 UR10 All
no no

8. Spare parts
109010 109010 Tool kit UR3/5/10 (kit includes all below marked *
with * )
109101 109101 * Spanner hex 5,5mm *
109102 109102 * Spanner hex 7,0mm *
109110 109110 * Spanner hex 10,0mm *
109103 109103 * Screwdriver torx T10 *
109104 109104 * Torque screwdriver torx T8 + T10 *
109111 * Torque screwdriver torx T10 *
109112 * Torque screwdriver torx T20 *
109105 109105 * Torque wrench hex 5,5mm Size 1 and Size 2
109106 109106 * Torque wrench hex 7,0mm Size 3 *
109107 109107 * Torque wrench hex 10,0mm Size 4 *
109180 109180 * ESD Wrist strap *

164084 164084 * Bypass cable (for setting joint-ID) *
185500 Dual calibration tool *
131501 131501 Bracket for mounting robotarm UR5 (Item *
profile)
131502 131502 Bracket for mounting robotarm UR5 (BOSCH *
profile)
131503 Bracket for mounting robotarm UR3 (Item & *
BOSCH profile)
131510 131510 Bracket for mounting robotarm UR10 (Item & *
BOSCH profile)
131099 Lid tool protective cap alu. for tool connector *
173100 173100 Cable for tool external with angle connector *

9. Packing of robot
9. Packing of robot
Packing of robot and controller box for shipment
NOTICE
Remove any external tooling and external electrical connections before shipment.
Universal Robots may reject the shipment if 3rd party products cannot be
unmounted safely or they prohibit to the execution of required post repair tests.
Universal Robots assume no responsibility for 3rd party goods return shipment.
Please ensure the robot, controller and teach pendant is packed responsibly.
Universal Robots will always return Universal Robots products in original
Universal Robots packaging.
• Download correct put_in_box program regarding robot type and packing material from

www.universal-robots.com/support/
• Upload the program to the robot. See Using Magic files on how this can be done.
• Load the program and follow instructions given when running the program.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 Brake Release
• Power down, disconnect power and disconnect robot arm from controller.
• Pack robot arm and controller box in designated boxes. Make sure the robot arm is
orientated correct in the box.

10. Change log
10. Change log
Date Revision Action Changes
3. May UR10_ Added First revision 3.0 released
2014 en_3.0
19. June UR10_ Changed Pictures and illustrations changed to match 3. gen. robot
2014 en_3.0.1
11. July UR10_ Changed Error codes, Spareparts changed to match 3. Gen robot and
2014 en_3.0.2 ESD handling added
20. Octo. UR10_ Changed Electrical doc., E-plan, Spare parts update and error code
2014 en_3.1.1 update. New structure for disassemble/assemble guide.
ESD handling modified.
January UR10_ Changed Update of electrical drawings, Joint spare part adaption,
2016 en_3.1.2 error codes. Dual robot calibration. Added Motherboard 3.1
October UR10_ Added 3.1.19 Wire bundle installation
2016 en_3.2.0
December Added 3.1.4 Bolt length for joints
2016
Added Error code C71A12
Added 3.1.5 Added tolerance to Size 3 torque
Corrected 5.2 LED startup sequence
Added 3.2.4 Motherboard 3.1 upgrade instructions
Added 4.4 Backup of data
Corrected Various spellings, word, setup
February Changed 7 Packing robot
2017
Added 1.4 Warning signs
Added Tolerance description to C50A5 and C50A6
October Added Troubleshooting 5.3.6
2017
Added Error code C103A3
Corrected Error code C20A1 description
Added Steps when replacing 48V power supply
January Added Troubleshooting 5.3.7
2018
Corrected “how to fix” text corrected on many error codes
September UR10_ Updated Inspection plan to chapter 2
2018 en_3.2.1

10. Change log
Updated 1.4 Warning signs

August UR10_ Added More guidance to section 3.1.4
2019 en_3.2.3
August UR10_ Added Merge control box details
2019 en_3.2.4
September UR10_ Added More info in section 5.3.3 Protective stop
2019 en_3.2.5
Added 3.1.9.1 Special assembly instructions for Elbow joint –
upper arm
October UR10_ Changed Title and wording in section 2
2019 en_3.2.6

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CB3.0 valid from robot s/n 2014300001 to 2016301178

Valid from robot s/n: 2014330001

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

4.2. Robot Arm 10

5. Service and Replacement of Parts 12

5.2. Robot Arm 16

User Manual UR10

5.3.7. Replacement of 12V power supply 76

7.3. Error Phenomena 149

7.4. Electrical Documentation 158

UR10 User Manual

8. Spare parts 173

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

User Manual UR10

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

3.2. Company Details

User Manual 1 UR10

3.4. Warning Symbols in this Manual

death or serious injury.

UR10 2 User Manual

4. Recommended Inspection Activities

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

4.1.1. Inspection Plan

User Manual 3 UR10

Use the following sections as guide:

V = Visual inspection F = Functional inspection

4.1.2. Safety Functions

UR10 4 User Manual

4.1.3. Visual Inspection

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

4.1.4. Cleaning and Replacement of Filters

Original control box

User Manual 5 UR10

UR10 6 User Manual

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

Merge Control Box

User Manual 7 UR10

UR10 8 User Manual

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

Cleaning the Robot in Relation to COVID

User Manual 9 UR10

DO NOT USE BLEACH. Do not use bleach in any diluted cleaning solution.

4.2. Robot Arm

4.2.1. Inspection Plan

Use the following sections as guide: Monthly Bi-annually Annually

4.2.2. Functional Inspection

UR10 10 User Manual

4.2.3. Visual Inspection

• Move robot arm to HOME position (if possible).

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

User Manual 11 UR10

5. Service and Replacement of Parts

UR10 12 User Manual

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

User Manual 13 UR10

UR10 14 User Manual

Copyright © 2009–2020 by Universal Robots A/S. All rights reserved.

5.1.1. Recommended Tools