Introduction
The ABB IRB 6700 series stands as a testament to robust industrial robotics, offering significant payload and reach capabilities tailored for demanding applications. Whether you're involved in installing, operating, or maintaining models like the IRB 6700-235/2.65, -205/2.80, -175/3.05, or -150/3.20 with the IRC5 controller, understanding the practical nuances beyond the standard product manual is crucial for maximizing uptime, ensuring safety, and achieving optimal performance.
This guide dives into key aspects covered in the manual, translating complex details into actionable insights. We'll focus on installation prerequisites, critical safety considerations, essential maintenance tasks, and calibration fundamentals, highlighting areas where a deeper understanding can prevent costly errors and enhance operational efficiency. This isn't just a summary; it's a practical companion aimed at technicians, engineers, and maintenance personnel working hands-on with the IRB 6700.
IRB 6700 Key Components Overview
This diagram illustrates the main components of the ABB IRB 6700 robot system. Components highlighted in red require special attention for safety.
Guide Contents
1. Unboxing & Installation
Pre-installation checks, transportation methods, lifting instructions, and foundation requirements.
2. Workspace & Setup
Working range, constraints, restricting movement, and fitting equipment guidelines.
3. Critical Safety Insights
Core dangers, essential precautions, and specific safety warnings for operation and maintenance.
4. Maintenance Deep Dive
Key inspections, component lifespans, battery replacement, cleaning procedures and specific maintenance tasks.
5. Calibration Essentials
Understanding when to calibrate, calibration methods, and procedures for maintaining accuracy.
6. Key Reference Points
Screw torques, tools, weight specifications, safety standards and additional reference information.
1. Unboxing & Installation Essentials
Proper installation is the foundation of reliable robot operation. While the manual provides detailed steps, let's emphasize the critical points.
Pre-Installation Checks: More Than Just Ticking Boxes
Before the robot even arrives at its designated spot, ensure the environment is ready:
Operating Conditions
Verify ambient temperature (+5°C to +50°C) and humidity (max 95% at constant temp). Note that temperatures below 10°C may require a warm-up phase to prevent performance issues due to lubricant viscosity.
Foundation Requirements
This is non-negotiable:
- Levelness: Maximum deviation of 0.2 mm across anchor points is crucial.
- Tilt: The robot must be installed with 0° tilt. Any deviation reduces payload capacity.
- Resonance: Minimum foundation resonance frequency must be 22 Hz.
A perfectly flat foundation significantly improves the repeatability of calibration and overall robot accuracy.
Weight & Lifting
The base robot weighs around 1300 kg (excluding DressPack/tooling). Always verify your lifting equipment (forklift aids, slings) is rated appropriately.
Transportation: Method Matters
ABB strongly recommends Method 1 (robot secured to its transport fixture/pallet).
If Method 1 isn't feasible, Method 2 involves using a specific transport support (xx0800000037) bolted to the robot, typically when moving with tooling attached.
Critical Warning
The robot is inherently unstable if not secured to its foundation or transport fixture. Do not change the robot's shipping position before it's properly anchored! Tipping is a serious risk.
Lifting Safely
Forklift Method
Use the dedicated fork lift device set (4 pockets). Never lift with fewer than four pockets.
Roundslings Method
Follow the specific configuration shown in the manual (xx1300001574), ensuring slings are correctly positioned and not strained inappropriately.
Securing the Robot
- Use the specified M24, quality 8.8 bolts and washers, torqued to 625 Nm.
- Tighten in a criss-cross pattern.
- Utilize guide sleeves for precise positioning on the base plate or foundation.
Pro Tip
The precise torque value (625 Nm) for the foundation bolts is critical. Using an insufficient torque can lead to foundation movement during high-acceleration motions, while excessive torque can damage the threads or stretch the bolts, reducing their clamping force over time.
2. Mastering the Workspace & Setup
Once secured, understanding the robot's operational envelope and how to configure it is key.
Working Range & Constraints
| Axis | Standard Range | With LeanID Option (780-4) | Notes |
|---|---|---|---|
| Axis 1 | ±170° | ±170° | Can be restricted with mechanical stops |
| Axis 2 | -65°/+85° | -65°/+85° | Software restriction only |
| Axis 3 | -180°/+75° | -180°/+75° | Software restriction only |
| Axis 4 | ±300° | ±300° | - |
| Axis 5 | ±130° | ±120° | Note the reduction with LeanID option |
| Axis 6 | ±360° | ±220° | Can be extended to ±93.7 revolutions via software |
Axis 6 Extension
The default ±360° range can be significantly extended (up to ±93.7 revolutions) via software parameter changes, crucial for applications requiring continuous rotation.
Restricting the Working Range
Why Restrict the Range?
Essential for preventing collisions with peripheral equipment or structures within the cell.
How to Restrict
- Axis 1: Mechanical stops can be added in 15° increments. Corresponding software limits must be configured.
- Axes 2 & 3: Restricted via software parameters only.
Important
When adding mechanical stops to Axis 1, you must update the corresponding software parameters (Upper/Lower joint bound) in the system configuration. Failure to do so can result in the robot attempting to move beyond the physical stops, causing damage to the robot and potentially creating a safety hazard.
Fitting Equipment (Payloads & Tooling)
Accuracy is Key
Incorrectly defined loads (mass, center of gravity, inertia) are a primary cause of poor performance, operational stops, and potential damage. Define these meticulously in the IRC5 controller software.
Attachment Points
The manual shows permissible mounting holes on the frame, lower arm, and upper arm. Adhere strictly to these specifications.
Load Limits
- Frame: Max 250 kg, respecting inertia limit JH = 100 kgm²
- Upper Arm: Max 50 kg extra load, with CoG within 500 mm of the axis-3 extension
Tool Flange
Standard and LeanID versions have different interfaces. Ensure compatibility with your end-of-arm tooling (EOAT).
3. Critical Safety Insights
The manual dedicates significant space to safety for good reason. Industrial robots are powerful and potentially hazardous.
Core Dangers
Unexpected Movement
Even during programming or manual operation, the robot may move unexpectedly.
High Voltage
In the controller and robot cabling (up to 800 VDC).
Hot Surfaces
Motors and gearboxes can cause severe burns.
Stored Energy
Especially the balancing device spring and electrical capacitors in the controller.
Crushing/Entanglement
Particularly during manual operation or maintenance. Never position yourself between robot and fixed objects.
Essential Precautions
Lockout/Tagout (LOTO)
Always switch off and lock the main power before entering the workspace or performing maintenance/repair. Follow your facility's LOTO procedures without exception.
Safety Fencing/Barriers
Ensure they are properly installed, dimensioned to withstand potential impacts, and interlocked correctly. Safety barriers must prevent access to the hazardous area during automatic operation.
Emergency Stops
Know the location of all E-stops (FlexPendant, Controller) and understand if they trigger an uncontrolled (Category 0) or controlled (Category 1) stop. Never use E-stops for routine program interruption.
FlexPendant Safety
Never disable the 3-position enabling device. Always take the FlexPendant with you when entering the cell. Use reduced speed (max 250 mm/s) for programming and testing inside the cell unless full speed is absolutely necessary and performed by trained personnel aware of the risks.
Stay Clear
Never position yourself under the robot arm. Be mindful of all moving axes and tooling. Maintain awareness of your position relative to the robot at all times.
Specific Warnings Recap
ESD
Use wrist straps and grounded mats when handling sensitive electronics like the SMB.
Batteries
Handle with care (gloves, glasses). Do not short, crush, or incinerate. Dispose of correctly.
Lubricants
Use protective gear (gloves, goggles). Be aware of hot oil/grease (up to 90°C). Never overfill gearboxes. Use only specified lubricant types.
4. Maintenance Deep Dive
Regular maintenance is the key to longevity and reliability. The manual provides a schedule based on calendar time and operating hours (Duty Time Counter).
Key Inspections Simplified
Checking oil levels is a frequent task. Here's the essence:
1 Axis 1
Check via the vent hole plug. Correct level is 58 mm ± 5 mm below the sealing surface.
2 Axis 2
Check via the level plug. Correct level is 0 - 10 mm below the plug hole opening when the robot is in its calibration position.
3 Axis 3
Check via the level plug. Correct level is 0 - 10 mm below the plug hole opening (robot in calibration position).
4 Axis 4
Check via the fill/level plug. Correct level is 0 - 10 mm below the plug hole opening (robot in calibration position).
5 Axis 5
Check via the fill/level plug. Correct level is 0 - 10 mm below the plug hole opening (robot in calibration position).
6 Axis 6
Check via the fill plug. Correct level is 50 mm ± 5 mm below the sealing surface, OR 0 - 10 mm below the plug hole if Axis 5 is rotated to +77°.
Pro Tip
Always ensure the robot is in the correct position before checking oil levels. For axes 2-6, this is typically the calibration position (all axes at 0°). Checking levels in the wrong position will give inaccurate readings.
Component Lifespans & Considerations
The manual provides expected component life (e.g., 40,000 hours for gearboxes, balancing device under specific test cycles). Note that:
Cable Harness Life
Varies significantly (40,000 hrs "normal" vs. 20,000 hrs "extreme"). "Extreme" includes press tending or heavy Axis 1 usage. Harsh environments shorten life further. Inspect regularly.
Balancing Device
This critical component requires careful inspection for:
- Dissonance (tapping/squeaking sounds)
- Damage (piston rod scratches)
- Leaks (grease from front ear seals)
- Contamination/obstructions
Requires periodic lubrication of the front spherical roller bearing.
Critical Warning
Never attempt to disassemble the balancing device cylinder itself – it contains lethal stored energy.
Battery Replacement (SMB)
- The 'Battery charge low' alert (38213) signals replacement time.
- Location: Frame recess.
- Crucial Step: After replacing the battery, you must update the revolution counters (see Calibration section). Keep controller power ON until replacement to minimize risk of losing sync.
SMB Battery Location
Cleaning
Frequency
Depends on the environment. Dusty or contaminated environments require more frequent cleaning.
Allowed Methods
Vary by protection type (Standard vs. Foundry Plus). Foundry Plus allows high-pressure water/steam under specific conditions (pressure, distance, nozzle type).
Key Don'ts
- Never spray connectors/seals directly
- Never use unapproved solvents
- Never use compressed air
- Ensure covers are fitted before washing
5. Calibration Essentials
Calibration ensures the robot knows its exact position.
When to Calibrate
Full Standard Calibration
After replacing motors or transmission parts affecting joint position. This re-establishes the robot's zero position accurately.
Absolute Accuracy Calibration
Required to restore full Cartesian accuracy after major structural repairs or if highest TCP precision is mandated. Often, standard calibration suffices after simple motor/gearbox swaps.
Revolution Counter Update
Required whenever the connection between the resolver and the controller is lost. This includes:
- After battery replacement (if power was lost)
- After disconnecting robot cables
- After manually moving an axis with brakes released and power off
- After certain resolver-related errors
Methods Overview
Standard (Calibration Pendulum)
The most accurate method for defining the robot's zero position (all axes at 0°). Data stored on the SMB.
Absolute Accuracy (CalibWare)
Builds upon standard calibration, adding compensation for mechanical tolerances and load deflections for enhanced TCP accuracy. Data also on SMB. Robots with this option have an "ABSOLUTE ACCURACY" sticker.
Revolution Counter Update (Rough Calibration)
This synchronizes the controller with the robot's current position but does not establish the precise zero position like a full calibration.
- Carefully jog the robot so all calibration marks align.
- Critical for Axes 4 & 6: Ensure these axes are on the correct revolution. Being off by a full turn will cause errors, even if marks align. Check the calibration label values.
- Use the FlexPendant: ABB Menu > Calibration > Update Revolution Counters. Select axes and confirm.
Important Note
Revolution Counter Updates do not restore full positional accuracy. They only ensure the controller knows the approximate position of each axis. For full accuracy, a standard calibration using the pendulum method is required.
Checking Calibration
After updating counters or performing calibration, verify the zero position using:
MoveAbsJ Command
Use MoveAbsJ [[0,0,0,0,0,0],...] command in a test program.
Jogging Window
Manually jog each axis to 0° and visually inspect alignment marks.
6. Key Reference Points
The manual's reference section (Chapter 7) contains valuable data.
Screw Torques (7.4)
Provides standard tightening torques for different screw sizes and classes (e.g., 8.8, 10.9, 12.9). Crucially, it differentiates between dry, oil-lubricated, and Gleitmo-treated screws.
Always use specified torques; special torques in procedures override standard values. Gleitmo screws have limited reuse (3-4 times).
Tools (7.6, 7.7)
Defines the Standard Toolkit contents and lists all required Special Tools with article numbers. Essential for planning maintenance/repair.
Weight Specs (7.5)
Components over 22 kg are highlighted, mandating the use of lifting aids.
Safety Standards (7.2)
Lists applicable ISO, EN, ANSI standards the robot complies with.
Conclusion
The ABB IRB 6700 is a powerful and reliable industrial robot, but its performance and longevity hinge on correct installation, diligent safety practices, and proactive maintenance. While the official product manual is the definitive resource for detailed procedures, understanding the why behind the steps and focusing on the practical implications discussed here can significantly enhance your effectiveness when working with this machine.
Always prioritize safety, adhere to specified torques and procedures, and don't hesitate to consult the full manual or ABB support when undertaking complex repairs or encountering unfamiliar situations. Proper care ensures the IRB 6700 remains a productive asset for years to come.
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