What is the difference between ISO 10218-1 and ISO 10218-2?

ISO 10218-1 is for robot manufacturers. It defines the safety requirements the robot itself must meet. Universal Robots certifies all robots to this standard. A robot without an end-effector is considered partly completed machinery and is supplied with a Declaration of Incorporation.

ISO 10218-2 is for robot system integrators. It covers the complete robot application — including end-effectors, workpieces, guarding, and the overall installation. The integrator is responsible for the completed machine and its CE marking.

What is ISO/TS 15066?

ISO/TS 15066 is a Technical Specification (not a standard) published in February 2016 that provides additional guidance for collaborative robot applications. It includes guidance on risk assessment for collaborative applications and an informative annex with biomechanical pain thresholds for human-robot contact.

Much of the content in ISO/TS 15066 has been integrated into the new ISO 10218-1:2025 edition.

What other safety standard are relevant?

• ISO 13849-1 & -2: Defines how safety-related control systems must be designed and validated. UR robots are certified to PLd Category 3.
• IEC 62061: Roughly equivalent to ISO 13849-1, using SIL (Safety Integrity Level) instead of PL. UR's PLd Category 3 corresponds to SIL 2 in terms of safety performance, but the two are derived using different methodologies (ISO 13849-1 vs IEC 62061).
• ISO 12100: General principles for risk assessment and risk reduction for machinery.
• IEC 60204-1: Electrical equipment of machines — defines stop categories (Cat 0, 1, 2).
• IEC 62443: Cybersecurity for industrial automation and control systems.

Performance Level d (PLd) is the second-highest reliability classification under ISO 13849-1, meaning the safety function is extremely reliable. It is the level required for hazardous robot applications.

Category 3 refers to the dual-channel architecture: two independent safety channels monitor each other, so a single fault cannot lead to loss of the safety function. This dual redundancy is built into the hardware of every UR robot.

PLd Category 3 corresponds to SIL 2 per IEC 62061 in terms of safety performance, but the two are derived using different methodologies (ISO 13849-1 vs IEC 62061).

Can safety functions be disabled?

The fundamental collaborative safety of UR robots cannot be disabled. Certain safety functions can be configured, deactivated, or muted within the parameters permitted by the standards. All safety functions have been evaluated and certified to PLd Category 3 by TÜV Rheinland.

Key safety functions support two parameter sets — Normal and Reduced — selectable via the Reduced mode safety input. This enables flexible deployment: for example, full-speed operation with guarding in Normal mode, and close-proximity human-robot interaction in Reduced mode.

What are the stop categories?

Stop categories are defined by IEC 60204-1 and classify how robot motion is stopped safely:

When any safety limit is exceeded or a fault is detected, the robot transitions to a safe state via Stop Category 1 or 0.

What is the difference between emergency stop and safeguard stop?

Emergency stop is a Stop Category 1 stop, manually triggered by pressing the red emergency pushbutton. It is intended for emergencies only and should not be part of a daily routine. The robot makes a controlled stop, then drive power is removed.

Safeguard stop is a Stop Category 2 stop, typically triggered by external protective devices such as light curtains, safety scanners, or safety PLCs. The robot stops and maintains a monitored standstill with drive power retained. Resuming from a safeguard stop can be automatic or require a manual reset.

Both stop functions are certified at Performance Level d.

What safety Functions do UR robots have?

UR robots provide a comprehensive set of configurable safety functions, all evaluated and certified to PLd Category 3 by TÜV Rheinland:

When any safety limit is exceeded or a fault is detected, the robot transitions to a safe state via Stop Category 1 or 0.

For the complete and up-to-date specification, refer to the official UR product manuals.

What safety-rated I/Os are available?

UR robots provide 16 configurable safety-rated I/Os — 8 inputs and 8 outputs — all dual-channel. These include emergency stop, safeguard stop, reduced mode switching, operational mode selection, 3PE input, freedrive enable, and configurable safety outputs for system status monitoring.

Additionally, PROFIsafe (SIL 2 functional safety communication over PROFINET) is supported on all CB5 control boxes (CB5.0–CB5.6), with both PolyScope 5 and PolyScope X, enabling integration with safety PLCs.

What techniques for collaborative applications do UR robots support?

UR robots are certified for collaborative applications using two techniques defined in ISO 10218-1:

• Monitored Standstill — The robot holds position at standstill with safety monitoring active. A person can enter the workspace and interact with the robot while it is safely stopped.
• Power and Force Limiting (PFL) — The robot limits forces and pressures to levels safe for human contact, as defined in ISO/TS 15066. If any force/torque parameter is exceeded, a protective stop is triggered.

Combined with external protective devices (e.g., laser scanners, light curtains), UR robots also support Speed and Separation Monitoring (SSM) applications, where the robot adjusts speed based on distance to nearby humans.

The application risk assessment determines which mode(s) are appropriate for a given installation.

What is Hand-Guided Control (HGC)?

Hand-Guided Control is a new capability defined under ISO 10218-1:2025. It allows an operator to move the robot by hand with its own configurable speed limit, monitored standstill, and software-based limiting enforced by the safety system.

HGC requires a hold-to-run control device located near the mechanical interface. A 3PE may be used instead of hold-to-run if it addresses ergonomic risks of sustained actuation. When HGC is active, single point of control and direct control apply, and the robot must move smoothly without harmful vibration. Universal Robots is adding HGC support as part of our ISO 10218-1:2025 certification.

What is ISO 10218-1:2025?

ISO 10218-1:2025 (Edition 3) is the first major revision of the industrial robot safety standard since 2011. Published in February 2025, it was developed over nine years by experts from more than 20 countries — including Universal Robots' own Safety Officer, who is widely recognized in this field.

The new edition significantly raises the bar for robot safety, expanding from 4 named safety functions to 15 explicitly defined safety functions with testable criteria.

What are the major changes?

Do I need to replace my robot when ISO 10218-1:2025 takes effect?

No. Existing robots can continue to operate under their original certification. ISO 10218-1:2025 applies to newly placed-on-market products.

Existing installations certified under ISO 10218-1:2011 can upgrade to the new software and take advantage of new safety functions while continuing to use the standard teach pendant — but this does not make them ISO 10218-1:2025 compliant.

What does "single point of control" mean for my application?

ISO 10218-1:2025 replaces the current local/remote control paradigm with a new model:

• Direct Control (teach pendant): The teach pendant holder has full authority over programming, teaching, and manual motion. When active, external interfaces cannot initiate motion.
• External Control (Robot API & controller ports): Control actions can be executed via the Robot API and its controller ports (Dashboard Server, Primary/Secondary Client, RTDE). Explicit permission must be granted. The teach pendant can always reclaim control.

Only one source can command control actions at a time, enforced as a safety-rated function. Industrial communication interfaces (PROFINET, EtherNet/IP, Modbus TCP) are separate from External Control and remain available for data exchange and I/O integration. Mainly integrators will notice the structural change.

What happens to the mixed mode of operation?

Under ISO 10218-1:2025, the commonly used practice of combining manual and automatic operation without strict separation is no longer permitted. Robots will operate in either Automatic or Manual mode, with safety-rated mode switching between them.

In Manual mode, the 3PE must be active for motion. In Automatic mode, proper safeguarding must be in place per the risk assessment.

When will UR robots be certified to ISO 10218-1:2025?

ISO 10218-1:2025 TÜV Rheinland certification planned for January 2027 — for all products with PolyScope 5 and PolyScope X — aligned with the EU Machinery Regulation enforcement date.

The new ISO 10218-1:2025 compliant software will be provided as a free upgrade for both PolyScope 5 and PolyScope X on all compatible hardware (e-Series and UR Series).

Important distinction: While existing robots will receive the new software and can take advantage of new safety functions, this does not make them ISO 10218-1:2025 certified or compliant. ISO 10218-1:2025 certification applies to new products placed on the market from January 2027. Robots originally sold under ISO 10218-1:2011 continue to operate under their original certification — and they do not need to be re-certified.

What stays the same under ISO 10218-1:2025?

The core safety principles remain the foundation:

• Power and Force Limiting
• Monitored standstill
• Software-based axis and space limiting
• PLd Category 3 dual-channel architecture
• All existing communication interfaces remain available with current functionality

UR's safety architecture already aligns with the updated standard.

Why is a 3PE teach pendant now mandatory?

ISO 10218-1:2025 requires all robots to integrate a Three-Position Enabling Device (3PE) with the teach pendant. The 3PE is a proven safety mechanism used across industrial automation: any reflexive reaction — whether releasing in surprise or clenching in panic — triggers an immediate safety stop.

New products certified to ISO 10218-1:2025 will only work with the 3PE Teach Pendant. The standard teach pendant cannot be used with 2025-certified products.

How does the 3PE work?

Three positions, one safety principle:

• Position 1 (Released): Robot stopped — safety stop active.
• Position 2 (Center/Hold): Motion enabled — robot can move.
• Position 3 (Fully pressed): Robot stopped — safety stop active.

Freedrive: Double-click Position 2 (Center/Hold) enables Freedrive — the robot can be guided by hand while the 3PE is held in position 2.

The UR 3PE Teach Pendant features two 3PE switches for ergonomic support of both left-handed and right-handed operation — only one needs to be pressed. IP54 rated.

Is the 3PE Teach Pendant available today?

Yes. The 3PE Teach Pendant is already available for e-Series and UR Series robots running PolyScope 5.9.5+ or PolyScope X. It is a plug-and-play accessory — no additional wiring or URCap required.

Will the standard teach pendant still be available?

The standard teach pendant will be phased out by Q1 2027. New robots will ship with the 3PE Teach Pendant only. The standard TP will remain available only as a spare part for installations based on ISO 10218-1:2011 hardware.

The standard teach pendant will not function with new ISO 10218-1:2025 certified products.

Will both PolyScope 5 and PolyScope X be certified to ISO 10218-1:2025?

Yes. Universal Robots is targeting TÜV Rheinland certification to ISO 10218-1:2025 for all products with PolyScope 5 and PolyScope X by January 2027, aligned with the EU Machinery Regulation enforcement date.

Your current UR investment — whether you're running PolyScope 5 or PolyScope X — is on a clear path to the latest safety standard.

Which hardware is compliant with ISO 10218-1:2025?

• UR Series (UR8Long, UR15, UR18, UR20, UR30): Latest generation. Runs PolyScope X (with CB5.6) and PolyScope 5. On the full ISO 10218-1:2025 compliance path.
• e-Series (UR3e, UR5e, UR7e, UR12e, UR16e): Runs PolyScope X (with CB5.6) and PolyScope 5. On the full ISO 10218-1:2025 compliance path.

CB3 Series is not compliant — CB3 robots reached End of Life in 2022 and only run PolyScope 3. They are not on the ISO 10218-1:2025 certification path and will not receive the new software. CB3 robots continue to operate under their original ISO 10218-1:2011 certification.

What control boxes are available?

• CB5.6: Latest generation. Ships with PolyScope X. Supports both PolyScope 5 and PolyScope X. Required for PolyScope X. Includes PROFIsafe support.
• CB5.0–CB5.5: Fully supported with PolyScope 5. With the latest software, these controllers provide the same safety functionality as CB5.6. All CB5 control boxes can be upgraded to CB5.6 for PolyScope X compatibility.

Does ISO 10218-1:2025 include cybersecurity requirements?

Yes — this is a first. ISO 10218-1:2025 clause 5.1.16 mandates a security assessment of the robot. Where the assessment identifies that a cyber threat can result in safety risks, cybersecurity measures must be provided — including means to prevent unauthorized access to hardware, software, and configuration data. This makes it the first robot safety standard to integrate cybersecurity requirements. The standard references IEC 62443 and ISO/TR 22100-4 for further guidance.

The EU Machinery Regulation (EU 2023/1230) also includes cybersecurity requirements for safety-related functions. Security is now inseparable from safety.

What is UR's cybersecurity posture?

• Universal Robots has been investing in cybersecurity well ahead of the standard:

  • IEC 62443-4-1 ML2 certified by TÜV Rheinland (December 2025) — secure development lifecycle
  • IEC 62443-4-1 ML3 planned H2 2026
  • IEC 62443-4-2 SL1 planned for PolyScope X by 2027 — product security certification, ahead of the EU Cyber Resilience Act enforcement date

What is a risk assessment?

A risk assessment is the overall process of identifying all risks and judging whether they are reduced to an appropriate level. It includes:

• Risk analysis: Specification of limits, hazard identification, and risk estimation (defining likely severity of harm and probability of occurrence).
• Risk evaluation: Judgment of whether risk reduction objectives have been achieved.

A risk assessment must be documented. A residual risk is the risk remaining after protective measures have been implemented.

See ISO 12100 for general risk assessment principles, and ISO/TS 15066 for collaborative application guidance including biomechanical thresholds.

Who is responsible for the risk assessment?

• The integrator (or end-user, if they integrate the system themselves) is responsible for the risk assessment and the completed robot application per ISO 10218-2.

  Universal Robots provides the certified robot (per ISO 10218-1) with a Declaration of Incorporation. Once an end-effector or tooling is added, the robot becomes a complete machine, and the integrator must ensure the full installation is safe and CE-marked.