Universal Robots UR5e User Manual

Universal Robots e-Series

User Manual

UR5e

Original instructions (en)

Universal Robots e-Series

User Manual

UR5e

Version 5.0.2

Original instructions (en)

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.

The Universal Robots logo is a registered trademark of Universal Robots A/S.

UR5e/CB5 ii Version 5.0.2

Contents

Preface ix

What Do the Boxes Contain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

How to Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Where to Find More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

I Hardware Installation Manual I-1

1 Safety I-3

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3

1.2 Validity and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3

1.3 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4

1.4 Warning Symbols in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4

1.5 General Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5

1.6 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-8

1.7 Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-8

1.8 Pre-Use Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-10

1.9 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-10

1.10 Movement Without Drive Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-10

2 Safety-related Functions and Interfaces I-13

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-13

2.2 Stop Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-14

2.3 Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-14

2.4 Safety Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-15

2.5 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-17

3 Transportation I-19

4 Mechanical Interface I-21

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-21

4.2 Workspace of the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-21

4.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-21

4.4 Maximum Payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-25

5 Electrical Interface I-27

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-27

5.1.1 Control Box Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-27

5.2 Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-27

5.3 Electrical Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-28

5.4 Controller I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-30

5.4.1 Common speciﬁcations for all digital I/O . . . . . . . . . . . . . . . . . . . . . . I-30

Version 5.0.2

iii UR5e/CB5

5.4.2 Safety I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-31

5.4.3 General purpose digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-35

5.4.4 Digital Inputs from a button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-36

5.4.5 Communication with other machines or PLCs . . . . . . . . . . . . . . . . . . . I-36

5.4.6 General purpose analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-36

5.4.7 Remote ON/OFF control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-38

5.5 Mains Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-39

5.6 Robot Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-40

5.7 Tool I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-41

5.7.1 Tool Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-42

5.7.2 Tool Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-42

5.7.3 Tool Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-43

5.7.4 Tool Communication I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-44

6 Maintenance and Repair I-45

6.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-45

7 Disposal and Environment I-47

8 Certiﬁcations I-49

8.1 Third Party Certiﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-49

8.2 Supplier Third Party Certiﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-49

8.3 Manufacturer Test Certiﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-49

8.4 Declarations According to EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . I-50

9 Warranties I-51

9.1 Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-51

9.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-51

A Stopping Time and Stopping Distance I-53

B Declarations and Certiﬁcates I-57

B.1 CE/EU Declaration of Incorporation (original) . . . . . . . . . . . . . . . . . . . . . . . . I-57

B.2 Safety System Certiﬁcate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-58

B.3 Environmental Test Certiﬁcate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-60

B.4 EMC Test Certiﬁcate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-61

C Applied Standards I-63

D Technical Speciﬁcations I-69

II PolyScope Manual II-1

10 Introduction II-3

10.1 PolyScope Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3

10.1.1 Header Icons/Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-3

10.1.2 Footer Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-4

10.2 Getting Started Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-5

UR5e/CB5 iv Version 5.0.2

11 Quick Start II-7

11.1 Robot Arm Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-7

11.1.1 Installing the Robot Arm and Control Box . . . . . . . . . . . . . . . . . . . . . . II-7

11.1.2 Turning Control Box On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-8

11.1.3 Turning Robot Arm On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-8

11.2 Quick System Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-8

12 Operational Mode Selection II-11

12.1 Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-11

12.2 3-Position Enabling Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-12

12.2.1 Manual High Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-13

13 Safety Conﬁguration II-15

13.1 Safety Settings Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-15

13.1.1 Accessing Safety Conﬁguration . . . . . . . . . . . . . . . . . . . . . . . . . . . II-15

13.1.2 Setting a Safety Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-16

13.1.3 Changing the Safety Conﬁguration . . . . . . . . . . . . . . . . . . . . . . . . . . II-16

13.1.4 Applying New Safety Conﬁguration . . . . . . . . . . . . . . . . . . . . . . . . . II-17

13.1.5 Safety Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-17

13.2 Safety Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-17

13.2.1 Robot Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-17

13.2.2 Safety Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-19

13.2.3 Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-20

13.2.4 Joint Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-20

13.2.5 Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-21

13.2.6 Tool Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-23

13.2.7 Tool Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-24

13.2.8 I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-26

13.2.9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-27

14 Run Tab II-29

14.1 Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-29

14.2 Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-29

14.3 Robot Age . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-30

14.4 Move Robot into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-30

15 Initialize Tab II-33

15.1 Robot Arm State Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-33

15.2 Active Payload and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-33

15.3 Initializing the Robot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-34

15.4 Installation File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-34

16 Program Tab II-37

16.1 Program Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-37

16.1.1 Program Execution Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-38

16.1.2 Search Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-38

16.1.3 Program Tree Toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-38

16.1.4 Empty Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-39

Version 5.0.2

v UR5e/CB5

16.2 Command Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-39

16.3 Graphics Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-41

16.4 Variables Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-42

16.5 Basic program nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-42

16.5.1 Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-42

16.5.2 Wait . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-51

16.5.3 Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-52

16.5.4 Popup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-52

16.5.5 Halt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-53

16.5.6 Comment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-53

16.5.7 Folder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-54

16.6 Advanced program nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-54

16.6.1 Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-54

16.6.2 SubProgram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-55

16.6.3 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-56

16.6.4 If . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-56

16.6.5 Script . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-57

16.6.6 Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-58

16.6.7 Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-58

16.6.8 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-59

16.7 Wizards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-59

16.7.1 Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-59

16.7.2 Seek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-61

16.7.3 Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-64

16.8 URCaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-66

16.8.1 Conveyor Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-66

16.9 The First Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-67

17 Installation Tab II-69

17.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-69

17.1.1 TCP Conﬁguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-69

17.1.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-72

17.1.3 I/O Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-73

17.1.4 I/O Signal Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-74

17.1.5 Assigning User-deﬁned Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-74

17.1.6 I/O Actions and I/O Tab Control . . . . . . . . . . . . . . . . . . . . . . . . . . . II-74

17.1.7 Conveyor Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-75

17.1.8 Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-76

17.1.9 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-77

17.1.10 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-78

17.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-78

17.3 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-79

17.3.1 Using a feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-80

17.3.2 Adding a Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-80

17.3.3 Addine a Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-81

17.3.4 Plane Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-82

17.3.5 Example: Manually Updating a Feature to Adjust a Program . . . . . . . . . . . II-83

UR5e/CB5 vi Version 5.0.2

17.3.6 Example: Dynamically Updating a Feature Pose . . . . . . . . . . . . . . . . . . II-84

17.4 Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-84

17.4.1 MODBUS client I/O Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-85

17.4.2 Ethernet/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-88

18 Move Tab II-89

18.1 Move Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-89

18.2 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-89

18.3 Tool Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-90

18.3.1 Pose Editor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-90

18.4 Joint Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-92

18.5 Home . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-92

18.6 Freedrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-92

19 I/O Tab II-95

19.1 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-95

19.2 MODBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-96

19.2.1 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-96

19.2.2 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-96

20 Log Tab II-97

20.1 Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-97

20.2 Joint Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-97

20.3 Date Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-97

20.4 Saving Error Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-97

21 File manager II-99

21.1 Open... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-99

21.2 New... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-100

21.3 Save... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-101

22 Hamburger menu II-103

22.1 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-103

22.2 About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-103

22.3 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-103

22.3.1 Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-103

22.3.2 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-104

22.3.3 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-104

Glossary II-107

Index II-109

Version 5.0.2

vii UR5e/CB5

UR5e/CB5 viii Version 5.0.2

Preface

Congratulations on the purchase of your new Universal Robots e-Series robot, UR5e.

The robot can be programmed to move a tool, and communicate with other machines using electrical signals. It is an arm composed of extruded aluminium tubes and joints. Using our patented programming interface, PolyScope, it is easy to program the robot to move the tool along a desired trajectory.

With six joints and a wide scope of ﬂexibility, Universal Robots e-Series collaborative robot arms are designed to mimic the range of motion of a human arm. Using our patented programming interface, PolyScope, it is easy to program the robot to move tools and communicate with other machines using electrical signals. Figure 1 illustrates the main components of the robot arm and can be used as a reference throughout the manual.

What Do the Boxes Contain

When you order a complete robot, you receive two boxes. One contains the robot arm, the other contains:

• Control Box with Teach Pendant

• Mounting bracket for the Control Box

• Mounting bracket for the Teach Pendant

• Key for opening the Control Box

• Mains cable or Power cable compatible to your region

Version 5.0.2

ix UR5e/CB5

Where to Find More Information

Figure 1: Klouby, základna a příruba nástroje ramene robota.

• Stylus pen with laser

• This manual

Important Safety Notice

The robot is partly completed machinery (see 8.4) and as such a risk assessment is required for each installation of the robot. Note: You must follow all of the safety instructions in chapter 1.

How to Read This Manual

This manual contains instructions for installing and programming the robot. The manual is separated into two parts:

Hardware Installation Manual: The mechanical and electrical installation of the robot.

PolyScope Manual: Programming of the robot.

This manual is intended for the robot integrator who must have a basic level of mechanical and electrical training, as well as be familiar with elementary programming concepts.

Where to Find More Information

The support website (http://www.universal-robots.com/support) available to all UR distributors, contains additional information such as:

• Other language versions of this manual

• The PolyScope Manual updates after the PolyScope is upgraded to a new version

UR5e/CB5 x Version 5.0.2

Where to Find More Information

• The Service Manual with instructions for troubleshooting, maintenance and repair of the

robot

• The Script Manual for advanced users

• The URCAPS an online platform for purchasing Universal Robots accessories and peripherals

Version 5.0.2

xi UR5e/CB5

Where to Find More Information

UR5e/CB5 xii Version 5.0.2

Part I

Hardware Installation Manual

1.1 Introduction

This chapter contains important safety information, which must be read and understood by the integrator of Universal Robots e-Series robots before the robot is powered on for the ﬁrst time.

In this chapter, the ﬁrst subsections are general. The later subsections contain speciﬁc engineering data relevant to enable setting up and programming the robot. Chapter 2 describes and deﬁnes safety-related functions particularly relevant for collaborative applications. Instructions and guidance provided in chapter 2 as well as in section 1.7 are particularly important.

It is essential to observe and follow all assembly instructions and guidance provided in other chapters and parts of this manual.

Special attention shall be paid to text associated with warning symbols.

1 Safety

NOTE:

Universal Robots disclaims any and all liability if the robot (arm control box and/or teach pendant) is damaged, changed or modiﬁed in any way. Universal Robots cannot be held responsible for any damages caused to the robot or any other equipment due to programming errors or malfunctioning of the robot.

1.2 Validity and Responsibility

The information in this manual does not cover designing, installing and operating a complete robot application, nor does it cover all peripheral equipment that can inﬂuence the safety of the complete system. The complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.

The integrators of UR robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that any signiﬁcant hazards in the complete robot application are eliminated.

This includes, but is not limited to:

• Performing a risk assessment for the complete robot system

• Interfacing other machines and additional safety devices if deﬁned by the risk assessment

• Setting up the appropriate safety settings in the software

• Ensuring that the user will not modify any safety measures

• Validating that the total robot system is designed and installed correctly

• Specifying instructions for use

• Marking the robot installation with relevant signs and contact information of the integrator

Version 5.0.2

I-3 UR5e/CB5

• Collecting all documentation in a technical ﬁle; including the risk assessment and this manual

Guidance on howto ﬁnd and read applicablestandards and laws is providedon http://universal-robots.

com/support/

1.3 Limitation of Liability

Any safety information provided in this manual must not be construed as a warranty, by UR, that the industrial manipulator will not cause injury or damage, even if industrial manipulator complies with all safety instructions.

1.4 Warning Symbols in this Manual

The symbols below deﬁne the captions specifying the danger levels used throughout this manual. The same warning signs are used on the product.

DANGER:

This indicates an imminently hazardous electrical situation which, if not avoided, could result in death or serious injury.

1.4 Warning Symbols in this Manual

DANGER:

This indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.

WARNING:

This indicates a potentially hazardous electrical situation which, if not avoided, could result in injury or major damage to the equipment.

WARNING:

This indicates a potentially hazardous situation which, if not avoided, could result in injury or major damage to the equipment.

WARNING:

This indicates a potentially hazardous hot surface which, if touched, could result in injury.

CAUTION:

This indicates a situation which, if not avoided, could result in damage to the equipment.

UR5e/CB5 I-4 Version 5.0.2

1.5 General Warnings and Cautions

This section contains some general warnings and cautions that can be repeated or explained in different parts of this manual. Other warnings and cautions are present throughout this manual.

DANGER:

Make sure to install the robot and all electrical equipment according to the speciﬁcations and warnings found in chapters 4 and

Version 5.0.2

I-5 UR5e/CB5

1.5 General Warnings and Cautions

WARNING:

1. Make sure the robot arm and tool/end effector are properly and securely bolted in place.

2. Make sure the robot arm has ample space to operate freely.

3. Make sure that safety measures and/or robot safety conﬁguration parameters have been set up to protect both programmers, operators and bystanders, as deﬁned in the risk assessment.

4. Do not wear loose clothing or jewellery when working with the robot. Make sure long hair is tied back when working with the robot.

5. Never use the robot if it is damaged, for example if joint caps are loose, broken or removed.

6. If the software prompts an error, immediately press emergency stop, write down the conditions that led to the error, ﬁnd the corresponding error codes on the log screen, and contact your supplier.

7. Do not connect any safety equipment to standard I/O. Use safety-related I/O only.

8. Make sure to use the correct installation settings (e.g. Robot mounting angle, mass in TCP, TCP offset, safety conﬁguration). Save and load the installations ﬁle along with the program.

9. The freedrive function (Impedance/Backdrive) shall only be used in installations where the risk assessment allows it. Tool/end effectors and obstacles shall not have sharp edges or pinch points.

10. Make sure to warn people to keep their heads and faces outside the reach of the operating robot or robot about to start operating.

11. Be aware of robot movement when using the teach pendant.

12. If determined by the risk assessment, do not enter the safety range of the robot or touch the robot when the system is in operation.

UR5e/CB5 I-6 Version 5.0.2

1.5 General Warnings and Cautions

13. Collisions can release high levels of kinetic energy, which are

14. Combining different machines can increase hazards or cre-

15. Never modify the robot. A modiﬁcation might create hazards

16. If the robot is purchased with an extra module (e.g. eu-

signiﬁcantly higher at high speeds and with high payloads. (Kinetic Energy =

Mass · Speed2)

ate new hazards. Always make an overall risk assessment for the complete installation. Depending on the assessed risk, different levels of functional safety can apply; as such, when different safety and emergency stop performance levels are needed, always choose the highest performance level. Always read and understandthe manuals for all equipment used in the installation.

that are unforeseen by the integrator. All authorized reassembling shall be done according to the newest version of all relevant service manuals.

romap67 interface) then look up that module in the respective manual.

17. Make sure the users of the robot are informed of the location of the emergency stop button(s) and are instructed to activate the emergency stop in case of emergency or abnormal situations.

WARNING:

1. The robot and its controller box generate heat during operation. Do not handle or touch the robot while in operation or immediately after operation as prolonged contact can cause discomfort. To cool the robot down, power off the robot and wait one hour.

2. Never stick ﬁngers behind the internal cover of the controller box.

Version 5.0.2

I-7 UR5e/CB5

CAUTION:

1.6 Intended Use

UR robots are industrial robots intended to handle tools/end effectors and ﬁxtures, or to process or transfer components or products. For details about the environmental conditions under which the robot should operate, see appendices B and D.

UR robots are equipped with special safety-related features, which are purposely designed to enable collaborative operation, where the robot system operates without fences and/or together with a human.

1.7 Risk Assessment

1. When the robot is combined, or working, with machines capable of damaging the robot, it is highly recommended to test all functions and the robot program separately. It is also recommended to test the robot program using temporary waypoints outside the workspace of other machines.

2. Do not expose the robot to permanent magnetic ﬁelds. Very strong magnetic ﬁelds can damage the robot.

Collaborative operation is only intended for non-hazardous applications, where the complete application, including tool/end effector, work piece, obstacles and other machines, is without any signiﬁcant hazards according to the risk assessment of the speciﬁc application.

Any use or application deviating from intended use is deemed to be impermissible misuse. This includes, but is not limited to:

• Use in potentially explosive environments

• Use in medical and life critical applications

• Use before performing a risk assessment

• Use outside of stated speciﬁcations

• Use as a climbing aid

• Operation outside the permissible operating parameters

1.7 Risk Assessment

One of the most important things that an integrator needs to do is to perform a risk assessment. In many countries this is required by law. The robot itself is partly completed machinery, as the safety of the robot installation depends on how the robot is integrated (E.g. tool/end effector, obstacles and other machines).

It is recommended that the integrator uses ISO 12100 and ISO 10218-2 to conduct the risk assessment. Additionally the integrator can choose to use the Technical Speciﬁcation ISO/TS 15066 as additional guidance.

The risk assessment that the integrator conducts shall consider all work tasks throughout the lifetime of the robot application, including but not limited to:

UR5e/CB5 I-8 Version 5.0.2

1.7 Risk Assessment

• Teaching the robot during set-up and development of the robot installation

• Troubleshooting and maintenance

• Normal operation of the robot installation

A risk assessment must be conducted before the robot arm is powered on for the ﬁrst time. A part of the risk assessment conducted by the integrator is to identify the proper safety conﬁguration settings, as well as the need for additional emergency stop buttons and/or other protective measures required for the speciﬁc robot application.

Identifying the correct safety conﬁguration settings is a particularly important part of developing collaborative robot applications. See chapter 2 and part II for detailed information.

Some safety-related features are purposely designed for collaborative robot applications. These features are conﬁgurable through the safety conﬁguration settings and are particularly relevant when addressing speciﬁc risks in the risk assessment conducted by the integrator:

• Force and power limiting: Used to reduce clamping forces and pressures exerted by the

robot in the direction of movement in case of collisions between the robot and the operator.

• Momentum limiting: Used to reduce high transient energy and impact forces in case of

collisions between robot and operator by reducing the speed of the robot.

• Joint, elbow and tool/end effector position limiting: Particularly used to reduce risks as-

sociated with certain body parts. E.g. to avoid movement towards head and neck.

• Tool/end effector orientation limiting: Particularly used to reduce risks associated with

certain areas and features of the tool/end effector and work-piece. E.g. to avoid sharp edges to be pointed towards the operator.

• Speed limitation: Particularly used to ensure a low speed of the robot arm.

The integrator must prevent unauthorized access to the safety conﬁguration by using password protection. A collaborative robot application risk assessment for contacts that are intentional and/or due to reasonably foreseeable misuse is required and must address:

• Severity of individual potential collisions

• Likeliness of occurrence of individual potential collisions

• Possibility to avoid individual potential collisions

If the robot is installed in a non-collaborative robot application where hazards cannot be reasonably eliminated or risks cannot be sufﬁciently reduced by use of the built-in safety-related functions (e.g. when using a hazardous tool/end effector), then the risk assessment conducted by the integrator must conclude the need for additional protective measures (e.g. an enabling device to protect the operator during set-up and programming).

Universal Robots identiﬁes the potential signiﬁcant hazards listed below as hazards that must be considered by the integrator. Note: Other signiﬁcant hazards can be present in a speciﬁc robot installation.

1. Penetration of skin by sharp edges and sharp points on tool/end effector or tool/end effec-

2. Penetration of skin by sharp edges and sharp points on obstacles near the robot track.

Version 5.0.2

tor connector.

I-9 UR5e/CB5

3. Bruising due to contact with the robot.

4. Sprain or bone fracture due to strokes between a heavy payload and a hard surface.

5. Consequences due to loose bolts that hold the robot arm or tool/end effector.

6. Items falling out of tool/end effector, e.g. due to a poor grip or power interruption.

7. Mistakes due to different emergency stop buttons for different machines.

8. Mistakes due to unauthorized changes to the safety conﬁguration parameters.

Information on stopping times and stopping distances are found in chapter 2 and appendix A.

1.8 Pre-Use Assessment

The following tests must be conducted before using the robot for the ﬁrst time or after any modiﬁcations are made. Verify that all safety input and output are appropriately and correctly connected. Test that all connected safety input and output, including devices common to multiple machines or robots, are functioning. As such you must:

• Test that emergency stop buttons and input stop the robot and engage brakes.

• Test that safeguard input stop the robot motion. If safeguard reset is conﬁgured, check that it needs to be activated before motion can be resumed.

1.10 Movement Without Drive Power

• Examine the initialization screen to test that reduced mode can switch the safety mode to reduced mode.

• Test that the operational mode switches the operational mode, see icon in top right corner of user interface.

• Test that the 3-position enabling device must be pressed to enable motion in manual mode and that the robot is under reduced speed control.

• Test that System Emergency Stop outputs are actually capable of bringing the whole system to a safe state.

• Test that the system connected to Robot Moving output, Robot Not Stopping output, Reduced Mode output, or Not Reduced Mode output can actually detect the output changes

1.9 Emergency Stop

Activate the emergency stop push-button to immediately stop all robot motion.

Note: According to IEC 60204-1 and ISO 13850, emergency devices are not safeguards. They are complimentary protective measures and are not intended to prevent injury.

The risk assessment of the robot application shall conclude if additional emergency stop buttons are need. Emergency stop push-buttons must comply with IEC 60947-5-5 (see section 5.4.2).

1.10 Movement Without Drive Power

In the unlikely event of an emergency, you can use forced back-driving where you must move robot joint/s, but robot power is either impossible or unwanted. To perform forced back-driving you must push, or pull, the robot arm hard to move the joint. Each joint brake has a friction clutch that enables movement during high forced torque. Note: In a service situation, the brake on the joints can be released without connected power.

UR5e/CB5 I-10 Version 5.0.2

1.10 Movement Without Drive Power

WARNING:

• Moving the robot arm manually is intended for urgent emergency purposes only and might damage the robot joints.

Version 5.0.2

I-11 UR5e/CB5

1.10 Movement Without Drive Power

UR5e/CB5 I-12 Version 5.0.2

2 Safety-related Functions and Interfaces

2.1 Introduction

Universal Robots e-Series robots are equipped with a range of built-in safety functions as well as safety I/O, digital and analog control signals to or from the electrical interface, to connect to other machines and additional protective devices. Each safety function and I/O is constructed according to EN ISO13849-1:2008 (see chapter 8 for certifications) with Performance Level d (PLd) using a category 3 architecture.

See chapter 13 in part II for conﬁguration of the safety functions, inputs and outputs in the user interface. See chapter 5 for descriptions on how to connect safety devices to I/O.

NOTE:

1. The use and conﬁguration of safety functions and interfaces must follow the risk assessment procedures for each robot application. (see chapter 1 section 1.7)

2. If the robot discovers a fault or violation in the safety system (e.g. if one of the wires in the Emergency Stop circuit is cut or a safety limit is violated) then a Stop Category 0 is initiated.

3. The stopping time should be taken into account as part of the application risk assessment

DANGER:

1. The use of safety conﬁguration parameters different from those determined by the risk assessment can result in hazards that are not reasonably eliminated or risks that are not sufﬁciently reduced

2. Ensure tools and grippers are connected appropriately so if there is an interruption of power, no hazards occurl

3. Use caution with 12V, since an error made by the programmer can cause the voltage to change to 24V, which might damage the equipment and cause a ﬁre

4. The end effectoris not protected by the UR safety system. The functioning of the end effector and/or connection cable is not monitored

Version 5.0.2

I-13 UR5e/CB5

2.2 Stop Categories

Depending on the circumstances, the robot can initiate three types of stop categories deﬁned according to IEC 60204-1). These categories are deﬁned in the following table.

Stop Category Description 0 Stop the robot by immediate removal of power. 1 Stop the robot in an orderly, controlled manner. Power is

2 *Stop the robot with power available to the drives, while

Note: *Universal Robots robots’ Category 2 stops are further described as SS1 or as SS2 type stops according to IEC 61800-5-2.

2.3 Safety Functions

Universal Robots robot safety functions, as listed in the table below, are in the robot but are meant to control the robot system i.e. the robot with its attached tool/end effector. The robot safety functions are used to reduce robot system risks determined by the risk assessment. Positions and speeds are relative to the base of the robot.

2.3 Safety Functions

removed once the robot is stopped.

maintaining the trajectory. Drive power is maintained after the robot is stopped.

Safety Function Description Joint Position Limit Sets upper and lower limits for the allowed joint positions. Joint Speed Limit Sets an upper limit for joint speed. Safety Planes Deﬁnes planes, in space, that limit robot position. Safety

planes limit either the tool/end effector alone or both the

tool/end effector and the elbow. Tool Orientation Deﬁnes allowable orientation limits for the tool. Speed Limit Limits maximum robot speed. The speed is limited at the

elbow, at the tool/end effector ﬂange, and at the center of

the user-deﬁned tool/end effector positions. Force Limit Limits maximum force exerted by the robot tool/end ef-

fector and elbow in clamping situations. The force is lim-

ited at the tool/end effector, elbow ﬂange and center of the

user-deﬁned tool/end effector positions. Momentum Limit Limits maximum momentum of the robot. Power Limit Limits mechanical work performed by the robot. Stopping Time Limit Stopping Distance Limit

Limits maximum time the robot uses for stopping after a

protective stop is initiated.

Limits maximum distance travelledby the robot after a pro-

tective stop is initiated.

The robot also has the following safety inputs:

UR5e/CB5 I-14 Version 5.0.2

2.4 Safety Function

Safety Input Description Emergency Stop Button

Robot Emergency Stop

System Emergency Stop Safeguard Stop Performs a Stop Category 2. Safeguard Reset Returns from the Safeguard Stop state, when an edge on

Reduced Mode Transitions the safety system to use the Reduced mode

3-Position Enabling Device

Operational Mode Mode to switch, when needed. NOTE: required when a 3-

Performs a Stop Category 1 informing other machines using the System Emergency Stop output, if that output is deﬁned. Performs a Stop Category 1 via Control Box input, informing other machines using the System Emergency Stop output, if that output is deﬁned. Performs a Stop Category 1 on robot only.

the Safeguard Reset input occurs.

limits. Initiates a Safeguard Stop when the enabling device is fully compressed or fully released. When this happens, the enabling device inputs are high.

Position Enabling Device is used.

For interfacing with other machines, the robot is equipped with the following safety outputs:

Safety Output Description System Emergency Stop Robot Moving While this signal is logic high, no single joint of the robot

Robot Not Stopping Logic high when the robot is stopped or in the process

Reduced Mode Logic low when the safety system is in Reduced Mode. Not Reduced Mode Logic low when the system is not in Reduced Mode.

All safety I/O are dual channel, meaning they are safe when low (e.g., the Emergency Stop is active when the signals are low).

2.4 Safety Function

The safety system acts by monitoring if any of the safety limits are violated or if an Emergency Stop or a Safeguard Stop is initiated. The reactions of the safety system are:

While this signal is logic low, the Robot Emergency Stop input is logic low or the Emergency Stop button is pressed.

moves more than 0.1 rad.

of stopping due to an Emergency Stop or Safeguard Stop. Otherwise it will be logic low.

Version 5.0.2

Trigger Reaction Emergency Stop Stop Category 1. Safeguard Stop Stop Category 2. Limit Violation Stop Category 0. Fault Detection Stop Category 0.

I-15 UR5e/CB5

2.4 Safety Function

When performing the application risk assessment, it is necessary to take into account the motion of the robot after a stop has been initiated. In order to ease this process, the safety functions Stopping Time Limit and Stopping Distance Limit can be used. These safety functions dynamically reduces the speed of the robot motion such that it can always be stopped within the limits. It is important to note that the joint position limits, the safety planes and the tool/end effector orientation limits take the expected stopping distance travel into account i.e. the robot motion will slow down before the limit is reached.

The functional safety can be summarized as:

Safety Function Tolerance Performance

Level Emergency Stop – d 3 Safeguard Stop – d 3 Joint Position Limit 5

◦

d 3 Joint Speed Limit 1.15◦/s d 3 Safety Planes 40 mm d 3 Tool Orientation 3

◦

d 3 Speed Limit 50mm/s d 3 Force Limit 25 N d 3 Momentum Limit 3

kg m

/s d 3 Power Limit 10W d 3 Stopping Time Limit 50 ms d 3 Stopping Distance Limit 40mm d 3

WARNING:

There are two exceptions to the force limiting function that are important when designing an application (Figure 2.1). As the robot stretches out, the knee-joint effect can give high forces in the radial direction (away from the base) at low speeds. Similarly, the short leverage arm, when the tool/end effector is close to the base and moving around the base, can cause high forces at low speeds. Pinching hazards can be avoided by removing obstacles in these areas, placing the robot differently, or by using a combination of safety planes and joint limits to eliminate the hazard by preventing the robot moving into this region of its workspace.

Universal Robots UR5e User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Where to Find More Information

Important Safety Notice

How to Read This Manual

1.1 Introduction

1 Safety

1.2 Validity and Responsibility

1.3 Limitation of Liability

1.4 Warning Symbols in this Manual

1.6 Intended Use

1.7 Risk Assessment

1.8 Pre-Use Assessment

1.9 Emergency Stop

1.10 Movement Without Drive Power

2 Safety-related Functions and Interfaces

2.1 Introduction

2.3 Safety Functions

2.4 Safety Function