September 24, 2019, Safety Notice

FAQs

Please note the below is submitted for informational purposes only and does not constitute legal guidance.

1. Initial responses and questions by customers…
   • Do all affected robots have to be have PLUGkits installed and joints tightened?
     

     Universal Robots recommends the installation of PLUGkits and tightening the joints of all effected robots.

     Foremost, robots used in collaborative application are to be addressed.  Operation should be stopped until the completion of the steps described in the  .  For the affected robots that are used in applications where the robot system will NOT contact the person – the operation stop should happen as soon as practicable.

     For purpose of this Safety Notice, a “collaborative application” is an application where a person can be within reach of the robot system while the robot system is moving/operating. This can be the situation when there are NO safeguards and this can also be true when using safety scanners in a way that the robot moves SLOWER when a person is close to/near/ within reach of the robot system.

     Collaborative applications:
     Robots used in collaborative applications must be stopped and the instructions a) through e) set forth in the Safety Notice need to be applied prior to continued use of the robot.

     Non-collaborative applications:
     Robots in non-collaborative applications also need to be stopped as soon as practicable and the instructions a) through e) set forth in the Safety Notice need be applied prior to being returned to operation.
     
     
   • Is there guidance about how to prioritize the implementation of the PLUGkit and joint tightening, e.g.collaborative application, high number of protective stops?

     As stated in the Safety Notice, collaborative applications are the top priority, then non-collaborative applications. Within each group, sub-prioritization can be done – for example by using the incidence rate of protective stops.

     Our recommendation is that safety is the top priority. We cannot provide more specific guidance in terms of prioritization, as we are not familiar with customer applications and end-products. 

     As one possible indicator of impending failure is the occurrence of excessive protective stops, we encourage our customers to pay careful attention to the issue of protective stops which may be hidden from view under the following two (2) circumstances which are detailed in the Safety Notice.

     • Personnel simply resetting a fault without review of why the fault has happened.
     • If an automatic acknowledgement and reset of a protective stop has been programmed – no one will see the protective stop.
       
       
2. Is there a written procedure of how to get information on the number of protective stops from UR robots?
   Please follow steps to collect and read log files:
   
   1. Download the Support Log Reader (SLR)[1]
      https://www.universal-robots.com/download/?option=16450#section16447
   2. Install the SLR on a Windows PC.
   3. Download “Magic files[2]” for extracting the log file from a robot
      https://www.universal-robots.com/download/?option=16579#section16578
      • Save it in root folder on USB stick.
      • Insert USB stick into the robot.
      • A red "! USB !" warning sign will appear on the screen. 
        Warning: do not remove the USB stick when in progress.
      • The file will do it's magic.
        When a green "<- USB" sign appears on the screen, it is ok to remove the USB stick.
      • Remove USB stick.

   *) folder will be generated on USB stick named after the robot’s serial number and files will be copied to this location

   1. Start the SLR program
   2. Turn on all filters
   3. Drag the log file(named log_history.txt) from the folder with the robot’s serial number into the SLR
   4. Use the search bar to search for “protective stop”[3]
   5. All protective stop will be shown in the bottom.

    

   [1]  SLR information can be found in the Service Manual (e-Series) and in the SLR download link (link is shown above).

   [2]  Magic File information can be found in the Service Manual and the Magic File download link (link is shown above).

   [3]  Small screenshot video of how to “Search_protective_stop_in_SLR”

   For an “easy” count of protective stops:

   Write the error codes shown in the bottom when doing a search in SLR, open the log_history.txt in Notepad++ and do a search (CTRL+f), type in the error code in “find what” window and select Count.

   To see a video of this “easy count” of “Count_protective_stops_in_notepadPlusPlus”
   
   
3. What tools and parts are needed to install the PLUGkit and tighten the UR10 elbow joint?
   

   Part #	Description	Where to get this?	Comment
   103810	UR CB3 PLUGkit	Your UR distributor or your integrator will provide it.  If you do not get the kit(s), contact your distributor or integrator.	Includes mounting instructions. For the service manual: CB3 Service Manual If more kits are needed, contact your UR distributor or the local UR sales office.
   109106	Torque wrench Hex 7,0mm Size 3 - 2,6 Nm	Available for purchase from Universal Robots through our distributors.	This is used to tighten the elbow joint for the PLUGkit installation and for annual inspection and tightening. For the service manual: CB3 Service Manual This torque wrench should be available from other sources –get a calibrated tool.

   
   
   • You will need the Elbow lock kit from Universal Robots – UR part #103810. This will be provided by your distributor/integrator. The kit comes with instructions for mounting. Should you need more kits at any point in time during or after the upgrade, please contact distributor/local Universal Robot sales office.
   • For checking/tightening the screws of the elbow in connection with implementing the Elbow lock kit as well as for general maintenance checks you need a Torque wrench Hex 7,0mm Size 3 - 2,6 Nm. This can be purchased from Universal Robots – UR part # 109106 but similar tools are available locally from other sources as well. Important to use a calibrated tool.
   • Please note that the Elbow lock parts are constructed to ensure that it is always installed correctly if instructions are followed.
     
     
4. Do I need to recalibrate the robot after installing the PLUGkit and tightening ALL joints?
   • No calibration is needed since there is no robot disassembly. 
     
     
5. What do I do if my robot fails before installing the PLUGkit and tightening the joints?
   
   • Make sure you notify your distributor and regional Universal Robots support service. We will need the robot back for repair and re-calibration.
   • If Elbow lock kits were supplied within last 3 months but not installed at time of incident a service fee will be charged.
     
     
6. I just bought a new UR10 but did not unpack yet. Can I return it in exchange for a robot with Elbow lock installed? If I unpack to update myself, will I lose my Out of Box rights?
   • Universal Robots expect their partners to be able to install the Elbow lock kit without harming the robot in any way. We do not accept return of un-opened boxes for exchange.
   • It is still an option for Universal Robots to accept a claim as Out-of-box – even after opening the box and adding the Elbow lock. Each case is evaluated separately, and the installation of the Elbow lock will not affect that evaluation.
     
     
7. How will this affect how I run my applications? Will I have to re-teach the programs after installing the PLUGkits and tightening the joints?
   • Updating with the Elbow lock will not affect the functionality of the robot. This is only installed for safety and has no impact on the operation or function of the robot arm.
8. What if I need to exchange the elbow joint later? Can the PLUGkit be re-used?
   • Please do not attempt to re-use. If you order an elbow joint from Universal Robots a new kit will be supplied with the part. If you have parts sitting in your own inventory, pls. let your Universal Robots sales office know and kits will be supplied for these.
   • All robots and joints returned to Universal Robots service hubs for repair after 1st October 2019 will be returned with the Elbow lock installed.
     
     
9. There is a flat ring in the kit. Do I need to replace the flat ring – it will require that I un-install the entire application?
   • The flat ring supplied with the kit is part of the safety solution that holds the lock collars in place. If the flat ring is loose or tender from exposure to chemicals, it must be replaced when updating. If it is still in good condition you can re-use.
     
     
10. My customer wants to be compensated for down time in production – will UR pay?
    • Universal Robots cannot be held accountable for any cost related to loss of production or revenue in connection with the upgrade. Universal Robots have provided the Elbow lock kit free of charge.