The ABB IRB 6700 family represents a significant generation of large, heavy-payload industrial robots, renowned for their robustness, reduced total cost of ownership, and enhanced performance. Designed for demanding applications across various industries, understanding the nuances of its installation, safety protocols, and maintenance is crucial for maximizing uptime and ensuring operational safety. This guide delves into the practical aspects outlined in the product manual, offering insights beyond a simple feature list.
Whether you are an installation technician, maintenance personnel, or a plant manager considering the IRB 6700, this guide provides essential, actionable knowledge based on the official documentation for variants like the 235/2.65, 205/2.80, 175/3.05, and 150/3.20 paired with the IRC5 controller.
Understanding Your IRB 6700 Variant
The IRB 6700 comes in several variants, primarily differing in payload capacity and reach. These robots typically weigh around 1300 kg (excluding DressPack and tooling) and are available with IP67 protection as standard or the enhanced Foundry Plus option (also IP67) for harsher environments.
Refer to manual pages 56-58 for detailed working range diagrams
IRB 6700 Variants
Safety First: Non-Negotiables for the IRB 6700
Working with a powerful robot like the IRB 6700 demands rigorous adherence to safety procedures. The manual emphasizes several critical points:
Lockout/Tagout is Paramount
Before any installation, maintenance, or repair, always switch off the main power at the controller and lock the main switch. This prevents accidental power-up, which could be lethal.
Respect the Working Range
Moving manipulators are potentially lethal. Ensure safety fences, light curtains, and other interlocks are correctly installed and functional. Fence dimensions must withstand potential impacts.
Emergency Stops
Familiarize yourself with all emergency stop buttons (FlexPendant, Controller). Understand whether your system uses an uncontrolled (Category 0) or controlled (Category 1) stop. E-stops are for emergencies only, not routine program halts.
Enabling Device ("Dead Man's Switch")
When working in manual mode inside the cell, the FlexPendant's enabling device must be held correctly (half-pressed). Releasing or fully pressing it triggers MOTORS OFF. Never tamper with this device.
Hot Surfaces
Motors and gearboxes become very hot during operation. Always test for heat before touching and allow components to cool before handling.
ESD Precautions
The robot's electronics, particularly the Serial Measurement Board (SMB), are sensitive to Electrostatic Discharge. Always use a grounded wrist strap connected to the controller's ESD connection point when handling these components.
Balancing Device Danger
This device contains stored energy under high tension. Never attempt to dismantle or service it beyond the specific procedures detailed in the manual. Incorrect handling is potentially lethal.
Brake Release
Use the brake release buttons only when absolutely necessary and with extreme caution. Releasing brakes can cause axes to move rapidly due to gravity. Ensure the arm is supported or blocked if necessary.
Lifting & Stability
The robot is unstable until secured to its foundation. Keep it in the stable shipping position until bolted down. Never allow personnel under a suspended load.
Installation & Commissioning Deep Dive
Proper installation is foundational to the robot's performance and longevity.
1 Pre-Installation Checks
Foundation
Must be level (max deviation 0.2mm across attachment points) and meet minimum resonance frequency (22 Hz). Tilting the robot reduces maximum payload capability.
Environment
Ensure operating conditions (temperature +5°C to +50°C, humidity <95%) are met. Low temps may require a warm-up routine.
Weight
The robot base is ~1300 kg. Account for tooling and DressPack when planning installation and foundation requirements.
2 Transportation & Unpacking
SAFETY ALERT: Tipping Risk
The robot is unstable until secured to its foundation. Improper handling can cause serious injury or damage.
- Prioritize Method 1: Use ABB's recommended transport fixtures/positions whenever possible. Remove tools before transport.
- Method 2 (With Tool): If Method 1 isn't feasible, use the specified transport support and secure the robot correctly. This involves jogging close, releasing brakes (Axis 3), and then tightening.
3 Lifting
Forklift Method
Use the dedicated fork lift device set (3HAC047054-002) attached to the base. Use all four pockets.
SAFETY TIP
Ensure lifting gear capacity exceeds the robot's weight (~1300 kg + extras).
Roundslings Method
Follow the specific configuration shown. Ensure correct sling lengths and placement, especially the non-strained securing slings. The robot needs to be jogged to a specific lifting pose first.
DANGER
Never allow personnel under a suspended load during lifting operations.
4 Securing the Robot
Base hole configuration for mounting
- Use the correct base plate (optional, 3HAC12937-7) or ensure the foundation meets specifications.
- Level the base plate meticulously (max 0.2mm deviation).
- Use M24, quality 8.8 screws (4 pcs) with washers, tightened to 625 Nm in a criss-cross pattern. Use guide sleeves for positioning.
IMPORTANT
Correct foundation and anchoring are critical for robot performance and safety. Inadequate mounting can lead to vibration, reduced accuracy, and potential failure.
5 Fitting Equipment & Loads
CRITICAL STEP
Incorrectly defined loads (mass, center of gravity, moments of inertia) can cause poor performance, operational stops, or severe damage.
Define in Software: Loads must be defined accurately in the IRC5 controller (Ref: Operating manual - IRC5 with FlexPendant).
Standard Tool Flange
LeanID Flange
Upper Arm Load
Max 50kg, CoG within 500mm of axis 3 extension
Maintaining Peak Performance
Regular maintenance based on the schedule is vital for ensuring optimal robot performance and longevity. Here are the key maintenance activities:
Oil Level Inspections (All Axes)
Crucial for gearbox longevity. Check levels at specified intervals (e.g., 12 months for axis 1-6). The manual details specific positions and levels:
- Axis 1: 58±5mm below plug surface
- Axis 2: 0-10mm below plug hole
Insight:
Low oil leads to overheating and wear; overfilling causes pressure build-up and seal damage. Use the correct oil type (Ref: Technical reference manual - Lubrication in gearboxes).
Oil Changes (All Axes)
Performed less frequently (e.g., 20,000 hours / 5 years). Follow procedures carefully, using an oil dispenser if possible, and ensure proper ventilation.
Pro Tip:
Warm oil drains faster; run the robot briefly before changing. Dispose of used oil responsibly.
SAFETY NOTE
Always open fill/drain plugs carefully to release pressure safely before fully removing them. Ensure vent plugs are open during filling/draining operations.
Balancing Device Inspection
Regularly check for:
- Noise (tapping, squeaking)
- Damage (scratches on piston rod)
- Leaks (grease around front ear seals)
Lubricate the front spherical bearing as scheduled.
WARNING
Issues with the balancing device can affect performance and safety. Never attempt to dismantle the balancing device without proper training and tools.
Cable Harness Inspection
Check for wear, chafing, or damage, especially around moving axes (Axis 2/3 bends).
Ensure brackets and straps are secure. Expected life varies with usage:
- Normal usage: 40,000 hours
- Extreme usage: 20,000 hours
SMB Battery Replacement
Replace every 7 years or when the "Battery charge low" alert (38213) appears.
Crucial Tip:
Keep controller powered ON after the alert until the battery is replaced to avoid losing revolution counter values.
Access the battery via the SMB cover. Update revolution counters immediately after replacement.
Cleaning
Regularly clean the robot according to its protection type (Standard/Foundry Plus). Use approved methods:
- Vacuum
- Cloth
- Low-pressure water/steam with rust inhibitor
WARNING
Never spray high pressure directly at seals, connectors, or joints.
Calibration Essentials
Calibration ensures the robot knows its exact position. Recalibration is needed if motors, gearboxes, or structural parts are replaced, or if revolution counter memory is lost.
Key Calibration Concepts
Standard Calibration
Uses the Calibration Pendulum method to set the robot's zero position accurately. This is the baseline.
Absolute Accuracy (Optional)
Builds upon standard calibration to compensate for mechanical tolerances and deflections, improving accuracy in the Cartesian coordinate system. Requires CalibWare software. A robot with this option has an "ABSOLUTE ACCURACY" sticker.
Revolution Counter Update
A rough calibration needed after memory loss or first installation. Manually jog each axis to align its calibration marks and use the FlexPendant's Calibration menu to update the counters.
Critical:
For axes 4 & 6, ensure they are on the correct turn, not just visually aligned marks, to avoid significant errors. Always verify position after updating using MoveAbsJ [[0,0,0,0,0,0],...]
Calibration Process
Identify when recalibration is needed (after parts replacement or counter memory loss)
Select the appropriate calibration method based on your needs
For counter updates, carefully align each axis with its calibration marks
Update counters via the FlexPendant interface
Verify calibration by moving to known positions
Maintenance & Calibration Decision Flow
Decommissioning Considerations
IMPORTANT SAFETY INFORMATION
Improper decommissioning can lead to serious hazards. Follow these guidelines carefully.
Safety First
ALWAYS remove batteries (explosion risk with heat) and drain all oils/grease (fire risk) before applying heat or cutting.
Balancing Device
Must be handled by a specialized decommissioning company following the specific cutting procedure to safely release stored spring energy.
Environment
Dispose of hazardous materials (batteries, oils, electronics) according to local regulations.
Key Repair Considerations
Component Weight
Many components are extremely heavy:
- Axis-1 gearbox: ~92kg
- Upper arm: ~200kg
- Complete arm system: ~1100kg
WARNING
Never attempt repairs involving heavy components without the exact ABB-specified lifting accessories and procedures.
Special Tools
The manual frequently references specific ABB special tools. These are not optional recommendations; they are often required for safe and correct execution of repairs.
Examples Include:
- Lifting Accessories for motors, gearboxes, arm structures
- Guide Pins for aligning heavy components
- Balancing Device Tools for safely handling the high-tension spring system
Insight:
While attempting repairs without these tools might seem cost-saving initially, it dramatically increases the risk of personnel injury, component damage, extended downtime, and voiding warranties.
Post-Repair Testing
Going beyond just starting the robot, a cautious test run after repair involves:
Pre-Check:
- Ensure all tools, spare bolts, rags, etc., are removed
- Verify all components are properly secured with correctly torqued bolts
Movement & Observation:
- Start in Manual Reduced Speed mode (250 mm/s)
- Jog affected axes slowly, listening for unusual noises
Related Resources
Foundation & Mounting Guide
Detailed specifications for creating stable foundations that meet resonance and levelness requirements.
Read moreMaintenance Schedule
Comprehensive maintenance timeline and component life expectancy guide for optimal robot performance.
Read moreSafety Protocols
Comprehensive safety guidelines for operating and maintaining the IRB 6700 robot safely.
Read moreConclusion
The ABB IRB 6700 is a powerful and reliable industrial robot, but its optimal performance and safe operation hinge on correct installation, adherence to stringent safety protocols, and diligent maintenance. By understanding the procedures and why they matter—from meticulous foundation preparation and accurate load definition to timely oil checks and crucial revolution counter updates—users can ensure they harness the full potential of this advanced robotic platform.
Always refer to the specific product manuals and safety documentation provided by ABB for detailed instructions and the latest information.