Unlock Peak Performance: Your Practical Guide to the ABB IRB 6700 Lifecycle

The ABB IRB 6700 series represents a significant step forward in large industrial robot technology, known for its robustness, payload capacity, and reach. Models like the IRB 6700-235/2.65, 205/2.80, 175/3.05, and 150/3.20 are workhorses in demanding applications. However, unlocking their full potential and ensuring longevity requires more than just understanding the spec sheet. It demands meticulous attention to safety, installation, maintenance, and proper handling throughout the robot's lifecycle.

This guide delves into the practical aspects covered in the IRB 6700 product manual (3HAC044266-001, Rev -), translating complex procedures into actionable insights for installation personnel, maintenance technicians, and repair specialists. We'll go beyond simply listing steps to explore the "why" behind them, helping you manage your IRB 6700 effectively and safely.

Safety First: Non-Negotiables for the IRB 6700

Working with powerful industrial robots like the IRB 6700 necessitates an unwavering commitment to safety. The manual dedicates significant space to this, and for good reason. Here are some critical takeaways:

The Lethal Potential

Never underestimate the power and speed of the robot. Unexpected movements can occur. Ensure safety fences, light curtains, emergency stops, and interlocks are correctly installed and functional before power-up.

Ref: 1.2.4.1, 1.2.5.1

Electrical Hazards

High voltages are present in the controller and manipulator (up to 800 VDC for motors). Always switch off and lock out the main power before performing any maintenance or repair, unless a procedure explicitly requires power for diagnostics. Remember stored energy in capacitors!

Ref: 1.3.6

Mechanical Energy & Gravity

Brake Release: Releasing brakes is hazardous. The arm can fall unexpectedly due to gravity. Ensure the arm is supported or in a safe position. Crucially, check that brake release buttons aren't jammed after service near the SMB recess.
Balancing Device: This unit contains high-tension springs. Never attempt to open or tamper with it outside of specified procedures using correct tools. Incorrect handling is potentially lethal.
Lifting & Tipping: The IRB 6700 is heavy (approx. 1300 kg base weight). Use only approved lifting methods and correctly rated accessories. The robot is unstable until securely bolted to the foundation.

Ref: 1.2.4.3, 2.4.5, 1.3.5, 1.3.2, 4.6.2, 2.2.1, 2.4.1, 2.4.4, 2.2.3

Other Hazards

Hot Surfaces: Motors and gearboxes become hot during operation. Allow cooling time before handling.
ESD Sensitivity: Internal electronics, especially the Serial Measurement Board (SMB), are sensitive to Electrostatic Discharge. Always use a properly grounded wrist strap when working near these components.
Chemicals: Handle gearbox lubricants (oil/grease) and batteries with care, using appropriate PPE (gloves, safety glasses) and following disposal regulations. Hot oil presents a burn risk.

Ref: 1.2.3.2, 1.3.7, 1.3.9, 3.4.1, 1.3.8

Always refer to Chapter 1 (Safety) in the manual for comprehensive details and specific warnings related to each task.

Installation & Commissioning: Getting Started Right

A successful installation lays the groundwork for reliable operation. Key considerations include:

Pre-Installation Checks

Before moving the robot, verify the site conditions:

Environment: Ensure temperature (+5°C to +50°C operating) and humidity (<95%) are within spec.
Foundation: Must be level (max deviation 0.2mm), flat, and rigid (min resonance frequency 22 Hz) to support the robot's weight and operational forces. Deviations impact accuracy.
Protection: Confirm the robot's protection class (e.g., IP67 Standard or Foundry Plus) matches the operating environment.

Ref: 2.2.1

Transportation & Lifting

Proper handling prevents damage and ensures safety:

Use the recommended shipping position for maximum stability.
Employ only the specified lifting methods: Forklift with the 4-point device set or the designated roundsling configuration.
Warning Never lift with fewer than four forklift pockets.
Personnel must never be under a suspended load.

Example of proper industrial robot lifting configuration. Always follow ABB-specific instructions.

Ref: 2.2.3, 2.4.1, 2.4.4

Securing the Robot

Properly anchoring the robot ensures stability and accuracy:

Position the robot using the base plate guide sleeves.
Use the specified M24, quality 8.8 bolts and tightening sequence (625 Nm, criss-cross pattern) to secure the robot to the foundation. Lubricate threads lightly.

Pro Tip: The 0.2mm flatness requirement seems strict, but deviations directly translate to positioning errors at the Tool Center Point (TCP), especially at full reach. Use shims if necessary during base plate installation.

Ref: 2.4.3, 2.4.6

Connections & Load Definition

Setting up the robot for optimal performance:

Connect the robot power and signal cables (R1.MP, R1.SMB) between the robot base and the IRC5 controller. Ensure correct lengths are used.
Crucial Accurately define any additional loads (end-effectors, tooling, dress packs) in the robot's software, including mass, center of gravity, and moments of inertia. Incorrect load data leads to poor performance, increased wear, and potential damage.

Ref: 2.6.1, 2.4.7, 2.4.8

Working Range Restriction

If necessary, mechanically restrict Axis 1 using optional stops and adjust software limits accordingly.

Ref: 2.5.2

Maintaining Peak Performance: The IRB 6700 Maintenance Regimen

Regular maintenance is essential for maximizing uptime and the lifespan of your IRB 6700. The manual provides a detailed schedule.

Maintenance Schedule Overview

graph TD A[Maintenance Schedule] --> B[Daily] A --> C[Monthly] A --> D[Quarterly] A --> E[Yearly] A --> F[Based on Operating Hours] B --> B1[Visual Inspection] B --> B2[Check for Unusual Noises] C --> C1[Check Gearbox Oil Levels] C --> C2[Cable Harness Inspection] D --> D1[Balancing Device Inspection] D --> D2[Mech. Stops/Dampers Check] E --> E1[Safety Label Verification] E --> E2[Battery Check] F --> F1[Oil Change: 20,000 hrs] F --> F2[Balancing Device Lubrication] F --> F3[Harness Replacement] click C1 callback "Check oil levels in all six axes gearboxes using designated level plugs." click F1 callback "Follow specific procedures for each axis (Ref: 3.4.2-3.4.7)" click E2 callback "Replace SMB battery proactively per schedule or immediately upon low battery alert (38213)"

Click on elements for more details. Maintenance intervals are based on calendar time (months) or operating hours (Duty Time Counter).

Key Inspection Points

Gearbox Oil Levels

Regularly check oil levels in all six axes gearboxes using the designated level plugs. Follow the specific procedures for each axis, as positions may vary for correct readings.

Ref: 3.3.1-3.3.6, 3.4.1

Balancing Device

Inspect for unusual noises (tapping, squeaking), damage (scratches on piston rod), leaks (grease from front ear seals), and ensure free movement without obstructions.

A "tapping" sound might indicate internal spring issues requiring device replacement. A "squeaking" sound could point to worn internal bearings or lack of lubrication.

Ref: 3.3.7

Cable Harness

Visually inspect the entire harness for wear, chafing, or damage, paying close attention to flexing areas near axes 2 and 3. Ensure brackets and clamps are secure.

Pro Tip: Feel for any unusual stiffness, kinks, or potential chafing points, especially inside protective conduits. Robots in high-cycle, complex-motion applications will require more frequent harness inspection.

Ref: 3.3.8

Mechanical Stops/Dampers

Check for deformation or damage, especially after a collision. Damaged stops/dampers must be replaced.

Ref: 3.3.10, 3.3.13

Essential Replacement & Lubrication

Gearbox Oil Changes

Follow the schedule for complete oil changes (e.g., every 20,000 hours). Use the correct procedure and only the specified oil type.

Never mix oil types unless specified.

SMB Battery

Replace the SMB battery proactively per the schedule or immediately upon a "Battery charge low" (38213) alert to prevent loss of revolution counter data.

Remember to update revolution counters after replacement.

Balancing Device Lubrication

Lubricate the front spherical roller bearing via grease nipples as scheduled. Use only the specified grease type.

Ref: 3.2.2, 3.4.2-3.4.7, 3.4.8, 3.5.1

Cleaning

Regular cleaning prevents buildup and allows for better inspection. Use only approved methods based on the robot's protection type (Standard or Foundry Plus).

Avoid high-pressure jets on seals, connectors, or joints.
Never use unapproved solvents.

Ref: 3.6.1

Repair & Calibration: Addressing Issues

Even with proper maintenance, repairs may be necessary. Chapter 4 of the manual details complex procedures like motor, gearbox, arm, and balancing device replacements.

Complexity

These are advanced tasks requiring trained personnel and specialized tools (listed in Chapter 7 and specific procedures). Procedures like replacing the Axis 1 gearbox or the Balancing Device involve significant disassembly and heavy components.

Attempting repairs without specialized tools can lead to component damage, inaccurate results, or safety incidents. They are designed to apply force correctly and ensure proper alignment.

Ref: Chapter 4, 4.8.1, 4.6.2

Post-Repair Checks

Always perform leak-down tests after gearbox/motor work and carefully check calibration.

Ref: 4.2.1

Calibration Essentials

Recalibration is critical after replacing components like motors or gearboxes, or if the SMB battery is depleted.

Updating Revolution Counters

If synchronization is lost, manually move the robot to its calibration marks and use the FlexPendant function to update the counters. Crucially, ensure axes 4 and 6 are on the correct turn.

Ref: 5.3, 5.5

Standard Calibration

This is the standard, accurate method required after component replacement affecting axis positioning.

Ref: 5.2

Absolute Accuracy (Optional)

If the robot has this option, standard calibration is often sufficient after component replacement, but a full CalibWare routine may be needed to restore 100% absolute positioning accuracy.

Ref: 5.2

Axis 4/6 Calibration Warning

Pay extreme attention to ensuring Axes 4 and 6 are on the correct revolution before updating counters. Due to their gear ratios, getting this wrong by even one turn makes correct calibration impossible without potentially rotating the axis manually to find the true zero position relative to the marks.

End-of-Life: Responsible Decommissioning

When the IRB 6700 reaches the end of its service life, responsible decommissioning is crucial.

Hazardous Materials

Be aware of materials requiring special disposal: batteries (Lithium/NiCad), oils/greases, electronics.

Ref: 6.1

Safety During Scrapping

Before cutting or applying heat:

REMOVE ALL BATTERIES: They can explode if heated.
DRAIN ALL OILS/GREASE: They are flammable.
SUPPORT THE ROBOT: Arms will collapse when motors are removed.

Ref: 6.2

Balancing Device Decommissioning

This requires a specialized procedure due to the high stored energy. The unit should be sent to a qualified decommissioning company. If handled internally, extreme caution and the specified cutting torch procedure must be followed to safely release spring tension.

Ref: 6.3

Conclusion

The ABB IRB 6700 is a powerful and reliable industrial robot, but its performance and lifespan depend heavily on proper handling, installation, and maintenance. By understanding the critical safety procedures, following the recommended maintenance schedule, using correct tools and techniques for repair, and ensuring proper calibration, you can maximize the value and operational life of this significant asset. Always treat the official product manual as the definitive source for detailed step-by-step instructions.

Pro Tips for IRB 6700 Management

The Criticality of Correct Lubrication

Gearboxes and bearings are designed with specific tolerances and operating temperatures. Using incorrect lubricants can cause:

Overheating due to wrong viscosity.
Increased wear due to inadequate film strength or additive incompatibility.
Seal degradation if the lubricant attacks the seal material.
Voiding the warranty.

Cable Harness Care is Proactive Maintenance

While visual inspection is key, pay extra attention to areas where the harness flexes most. Feel for any unusual stiffness, kinks, or potential chafing points, especially inside protective conduits.

If your application fits the "Extreme Usage" profile (high frequency, large-angle bends, constant twisting, high acceleration cycles), plan for more frequent inspections and potentially budget for earlier harness replacement than the standard expected life.

Calibration: Precision Matters

Losing power (dead SMB battery) or disconnecting resolver cables will require updating revolution counters. Why? The system loses track of which "turn" each axis is on. Skipping this step leads to incorrect positioning and potential collisions. Always move the robot precisely to its calibration marks before updating.

Getting Started: IRB 6700 Unboxing & Initial Installation

Practical first steps for new users and installers.

Essential IRB 6700 Maintenance Schedule & Component Life Guide

Detailed maintenance schedules and component lifespan information.

Diagnosing and Fixing Common IRB 6700 Problems

Solutions for known issues including SMB communication errors.