The ABB IRB 6700 family represents a significant step forward in large industrial robot technology, prized for its robustness, improved performance, and lower total cost of ownership. Designed for demanding applications across various industries, successful integration starts with understanding its variants and mastering the critical steps of installation and commissioning. This guide goes beyond the standard manual, offering practical insights for engineers, installation personnel, and maintenance teams tasked with bringing this powerhouse online safely and efficiently.
We'll delve into the key differences between the IRB 6700 variants, navigate the essential pre-installation checks, and highlight crucial considerations during transport and physical setup, leveraging information directly from the product manual (Document ID: 3HAC044266-001, Revision: -).
Choosing Your IRB 6700 Variant
More Than Just Numbers
The manual introduces four primary variants of the IRB 6700, distinguished by their payload capacity and reach:
IRB 6700 - 235/2.65
Highest Payload- 235 kg payload capacity
- 2.65 m reach
- Ideal for heavy-duty applications
IRB 6700 - 205/2.80
Balanced- 205 kg payload capacity
- 2.80 m reach
- Good balance of payload and reach
IRB 6700 - 175/3.05
Extended Reach- 175 kg payload capacity
- 3.05 m reach
- Better reach with moderate payload
IRB 6700 - 150/3.20
Maximum Reach- 150 kg payload capacity
- 3.20 m reach
- Longest reach in the series
ABB IRB 6700 Robot Arm
Why It Matters
Selecting the right variant isn't just about meeting minimum payload and reach requirements.
Payload vs. Reach Trade-off
Notice the inverse relationship. Higher payloads generally come with shorter reaches, and vice-versa. This impacts cell design and potential cycle times.
Working Envelope & Cell Layout
Detailed working range diagrams and turning radius specifications are crucial for designing a collision-free and efficient workspace.
Dynamic Performance
Different variants might have subtle differences in dynamic performance or energy consumption based on their arm lengths and motor tuning.
Key Insight
Carefully analyze your application's specific needs, including End-of-Arm Tooling (EOAT) weight, part weight, required motion paths, and cell constraints, before selecting a variant. Consulting the full Product Specification is essential.
| Model | Payload | Reach | R1 (mm) | R2 (mm) |
|---|---|---|---|---|
| IRB 6700-235/2.65 | 235 kg | 2.65 m | 920 | 2650 |
| IRB 6700-205/2.80 | 205 kg | 2.80 m | 942 | 2800 |
| IRB 6700-175/3.05 | 175 kg | 3.05 m | 990 | 3050 |
| IRB 6700-150/3.20 | 150 kg | 3.20 m | 1067 | 3200 |
Turning Radius Diagram
Pre-Installation: Setting the Stage for Success
Before the IRB 6700 arrives at your facility, meticulous preparation is key
Visual Inspection
Check for any shipping damage immediately upon arrival. Document anything suspicious.
Environmental Conditions
- Storage: -25°C to +55°C (up to +70°C for <24hrs)
- Operation: +5°C to +50°C
- Max 95% humidity for both
- Protection: IP67 rated
Foundation Requirements
The foundation must withstand significant forces and meet precise specifications:
- Max 0.2 mm deviation across anchoring points
- 0° maximum allowed tilt
- Minimum resonance frequency of 22 Hz
- Concrete quality: C25/C30 reinforced
Foundation – The Unsung Hero
This is arguably the most critical physical aspect. The foundation must withstand significant static and dynamic forces. The manual specifies maximum forces (e.g., ±19.8 kN horizontal, 14.6 ±15.7 kN vertical during E-stop) and torques (±37.1 kNm bending in XY plane during E-stop).
Unevenness directly impacts the robot's base calibration and absolute accuracy. While recalibration can compensate to some extent, starting with a perfectly level base minimizes potential errors and ensures optimal performance.
Key Insight
Don't underestimate foundation preparation. Errors here are costly and difficult to fix later, directly impacting robot accuracy and reliability.
Safe Handling & Transportation On-Site
Moving a ~1300 kg robot requires careful planning and adherence to safety protocols
Stability Warning
The IRB 6700 is mechanically unstable if not secured to its foundation. Moving the arms before bolting it down can easily cause it to tip over, especially when deviating from the stable shipping position.
Robot Shipping Position
Transport Methods
Method 1 (Recommended)
Robot without tool, in shipping position. This is the safest and ABB-preferred method.
Method 2 (If Necessary)
Robot with tool, requires a specific transport support. Warning: Incorrect transport can void the warranty.
Forklift Option
- Requires the optional Fork Lift Device Set (3HAC047054-002) fitted to the base
- All four pockets must be used
- Lift slowly and ensure adequate capacity (Robot base weight ~1300 kg + attachments)
Fork Lift Device
Roundsling Option
- Requires specific robot positioning (Axis 2: -45°, Axis 3: +65°, etc.)
- Uses M20 lifting eyes in the base
- Pay close attention to the securing slings (B & C) which prevent tipping but should not be strained during the lift
Roundsling Attachment
Manual Brake Release
Buttons are located on the manipulator base (SMB recess). Releasing brakes is hazardous as axes can move unexpectedly due to gravity.
- Typically needed for specific positioning during installation or maintenance
- Requires 24VDC power supplied to R1.MP connector if the controller isn't connected
- Warning: Ensure personnel are clear before releasing brakes!
Brake Release Unit Location
Safety First
Always ensure lifting equipment is properly rated and personnel stay clear of suspended loads.
Installation & Securing: The Final Steps
Once positioned, securing the robot correctly is vital
Base Plate
Using an ABB base plate (3HAC12937-7) simplifies installation and ensures correct alignment. It includes guide sleeves for precise robot positioning.
Base Plate Dimensions
Securing the Robot
- Use the specified M24 x 100, quality 8.8 bolts (4 pcs) with 4mm flat washers
- Lightly lubricate screws before assembly
- Crucially, tighten bolts in a criss-cross pattern to the specified torque (625 Nm) to ensure even clamping and prevent base distortion
- Use the guide sleeves provided with the base plate (or ensure foundation guides) for accurate positioning
Robot Base Hole Configuration
Restricting Working Range
If the robot's full rotation could cause collisions, optional mechanical stops can be fitted to the base. These limit Axis 1 movement in 15° increments.
Important: Installing mechanical stops requires corresponding adjustments to software parameters (Upper/Lower Joint Bound) in the controller to prevent errors and ensure safety functions work correctly.
Axis 1 Mechanical Stop
Maintenance Workflow Visualization
Understanding the key maintenance processes and decision points
Key Insight
Regular, informed maintenance based on the manual's schedule and expected life data is the best investment to protect the IRB 6700 and ensure consistent production. Ignoring maintenance significantly increases the risk of costly unplanned downtime and repairs.
Beyond the Basics: Key Considerations
Installation doesn't end with bolting the robot down
Load Definition is Critical
Accurately defining the payload (EOAT + part weight), including its center of gravity and moments of inertia, in the robot controller software is paramount.
Incorrect load data leads to:
- Poor motion performance
- Increased component wear
- Potential overloads
- Inaccurate path following
Fitting Equipment
The manual specifies allowable locations and maximum masses for fitting extra equipment on the robot structure.
- Frame (hip): Max 250kg, with inertia considerations
- Upper arm: Max 50kg, specific CoG location
- Tool flange: Standard and LeanID options available
Adhere strictly to these limits to avoid performance issues or damage. Drilling new holes is restricted.
Attachment Hole Positions
Initial Checks
- Remove tools
- Ensure fixtures are secure
- Verify safety equipment
- Clear the area
- Run at reduced speed initially
Maintenance Access
During installation, be mindful of future maintenance access to:
- Lubrication points
- Oil level plugs
- SMB battery compartment
- Cable harness inspection points
Calibration Context
Upon initial setup, critical steps include:
- Updating revolution counters after jogging to calibration marks
- Failure to do this results in incorrect positioning
- Replacing motors or gearboxes later will necessitate recalibration
Operational Safety & Key Systems
Understanding safety features and critical components
Emergency Stops (E-Stops)
Purpose:
Intended only for genuine emergencies to immediately halt hazardous motion, overriding all other controls. Not for routine program stops, as this causes unnecessary wear.
Types:
- Uncontrolled stop (Category 0): Immediate power cut to motors
- Controlled stop (Category 1): Motors powered during braking to maintain path, then power cut
Controlled stops are generally preferred to minimize stress on the robot, but configuration depends on the specific cell risk assessment.
Locations:
Always be aware of all E-Stop button locations – on the FlexPendant, the controller cabinet, and potentially elsewhere within the safety cell.
Enabling Device ("Dead Man's Switch")
Located on the FlexPendant, this three-position switch is crucial for safety during manual operation (programming, testing).
- Robot motion is only permitted when the switch is held in the middle position
- Releasing it or pressing it fully activates MOTORS OFF state
- Never tamper with or bypass the enabling device
Reduced Speed Function
Limits robot TCP speed to 250 mm/s in manual mode, providing a safer speed for close-proximity tasks like teaching points.
Safety Note:
- Working inside the robot's range should always be done in Manual Reduced Speed mode
- Do not change core kinematic parameters like transmission gear ratios via software
Understanding the Balancing Device
Located prominently at the rear of the robot frame, the balancing device is a critical component, especially on larger robots like the IRB 6700.
Function:
Uses powerful internal springs to counteract the gravitational forces acting on the robot's lower and upper arms. This reduces the load on the axis motors, allowing for faster acceleration, lower energy consumption, and smoother motion.
Importance of Inspection:
Regular checks are vital for:
- Unusual noises like tapping or squeaking
- Damage to the piston rod
- Grease leakage from seals
- Contamination/obstruction
The Danger: Stored Energy
The internal springs store a massive amount of potential energy. The manual repeatedly warns that incorrect handling is potentially lethal.
- Replacement/repair requires specific tools and strict adherence to procedures
- Never attempt to open the main cylinder
- Decommissioning requires specialized procedures by trained personnel
Calibration: The Foundation of Accuracy
Calibration ensures the robot knows precisely where its joints are, translating this into accurate TCP (Tool Center Point) positioning in the workspace.
IRB 6700 Calibration Marks/Scales
Revolution Counter Update
Required if link between controller and absolute position is lost. Involves manually jogging to calibration marks.
Note: For axes with non-integer gear ratios, being off by a full revolution will result in an incorrect calibration.
Standard Calibration
Fine calibration performed after replacing components that affect the mechanical relationship between motor and zero position.
Uses specialized tools like the Calibration Pendulum.
When is Calibration Needed?
- Lost Revolution Counter Memory: Requires counter update
- Component Replacement (Motor/Gearbox/Transmission): Requires standard calibration
- Robot Rebuild/Crash: Requires standard calibration
Key Insight
By integrating a deep understanding of the IRB 6700's safety features into daily operations and appreciating the necessity and methods of calibration, users can operate the robot safely, maintain its precision, and maximize its contribution to the production environment.
Conclusion
Successfully installing an ABB IRB 6700 requires more than just following steps; it demands careful planning, adherence to safety protocols, and an understanding of why certain procedures are critical.
From selecting the right variant based on payload and reach trade-offs, meticulously preparing the foundation, handling the robot safely during transport, to accurately securing it and defining its load, each stage impacts the robot's final performance, accuracy, and longevity.
By leveraging the detailed instructions in the ABB manuals and incorporating the practical insights highlighted here, teams can ensure a smooth, safe, and successful commissioning of the powerful and versatile IRB 6700 robot system.