Understanding Your IRB 6700
The ABB IRB 6700 family represents a significant leap in heavy-payload industrial robotics, renowned for its robustness, reliability, and lower total cost of ownership. Designed for demanding applications, these robots (including variants like IRB 6700-235/2.65, -205/2.80, -175/3.05, and -150/3.20) are workhorses in industries requiring high performance and durability. However, unlocking their full potential requires meticulous attention to detail during installation, commissioning, maintenance, and operation.
Variants & Capabilities
The IRB 6700 line offers various payload capacities (150kg to 235kg) and reaches (2.65m to 3.20m), catering to diverse application needs. Understanding your specific model (e.g., IRB 6700 - 150/3.20) is crucial for load calculations and workspace planning.
Key Dimensions
Familiarize yourself with the robot's footprint and turning radius for accurate cell layout and interference checks.
Protection Ratings
The standard IRB 6700 boasts an IP67 rating, making it highly resistant to dust and water ingress. The Foundry Plus option maintains this rating while adding enhanced protection for harsh foundry environments. Knowing your protection level dictates acceptable cleaning methods.
Installation & Commissioning
A successful robot integration starts with a flawless installation. The manual emphasizes several critical stages that must be followed precisely to ensure optimal performance, safety, and longevity of your IRB 6700.
Installation Process Overview
flowchart TB
Start([Start Installation]) --> SitePrep[Site Preparation]
SitePrep --> Foundation[Foundation Preparation]
SitePrep --> Environment[Environment Check]
Foundation --> Transport[Safe Transportation]
Environment --> Transport
Transport --> Lifting[Lifting Methods]
Lifting --> Positioning[Positioning Robot]
Positioning --> Securing[Securing to Foundation]
Securing --> Electrical[Electrical Connections]
Electrical --> Range[Working Range Setup]
Range --> Equipment[Equipment Fitting]
Equipment --> LoadDef[Load Definition]
LoadDef --> Calibration[Calibration]
Calibration --> Testing[Test Operations]
Testing --> Complete([Installation Complete])
classDef critical fill:#f87171,stroke:#b91c1c,color:white
classDef important fill:#fcd34d,stroke:#d97706,color:#78350f
classDef normal fill:#93c5fd,stroke:#2563eb,color:#1e3a8a
class Foundation,Securing,LoadDef critical
class Lifting,Electrical,Calibration important
class SitePrep,Environment,Transport,Range,Equipment,Testing normal
Foundation
This is non-negotiable. The foundation must meet stringent levelness (max 0.2 mm deviation across anchor points) and rigidity (min. 22 Hz resonance frequency) requirements. An inadequate foundation compromises accuracy, repeatability, and potentially safety.
Environment
Ensure operating conditions (temperature +5°C to +50°C, humidity <95%) are within spec. Note the recommendation for a warm-up phase below 10°C to prevent sluggishness due to oil viscosity.
Personnel
Only ABB-trained personnel with mechanical/electrical expertise should perform installation.
Stability
CRITICAL! The IRB 6700 (weighing approx. 1300 kg base, without DressPack or tools) is inherently unstable until securely bolted down. Never attempt to move the robot arms from the shipping position before it's anchored.
Lifting Methods
Forklift
Requires the specific Fork Lift Device Set (3HAC047054-002) attached to all four base points.
Roundslings
Preferred method using specified M20 lifting eyes and sling lengths/configurations detailed in the manual. Pay close attention to sling placement to avoid interference and ensure stability.
Transportation with Tool
Discouraged, but if necessary, requires a specific transport support and procedure outlined in the manual to prevent damage.
Base Plate
If used, the base plate (353 kg) must be leveled and secured correctly first.
Robot to Foundation
Uses four M24, quality 8.8 bolts. The manual specifies a tightening torque of 625 Nm and stresses the importance of a criss-cross tightening pattern to avoid distorting the base. Guide sleeves ensure proper alignment.
Electrical Connections
Standard connections involve the Robot Power Cable (R1.MP) and Robot Signal Cable (R1.SMB) between the robot and the IRC5 controller. Length options vary (7m to 30m). Customer cabling for tools/signals is optional (DressPack).
Restricting the Working Range (Axis 1)
For safety or layout constraints, the Axis 1 working range (±170° default) can be mechanically limited using optional stop kits (3HAC044287-001). These provide 15° increments. Crucially, any mechanical restriction MUST be mirrored by adjusting software system parameters.
Fitting Equipment & Defining Loads
The manual specifies allowable mounting points and load limits for additional equipment on the frame (up to 250 kg, considering inertia JH ≤ 100 kgm²) and upper arm (up to 50 kg, specific CoG limits).
CRITICAL
All loads (tooling, fixtures, extra equipment) must be accurately defined in the robot's software (mass, center of gravity, moments of inertia). Incorrect load data leads to poor performance, premature wear, operational stops, and potentially catastrophic damage.
Tool flanges vary (standard vs. LeanID option 780-4).
Maintenance: Ensuring Peak Performance
Regular, proactive maintenance is key to maximizing the IRB 6700's uptime and lifespan. The manual provides a detailed schedule and procedures that should be strictly followed.
Maintenance Schedule Overview
| Component | Task | Frequency | Criticality |
|---|---|---|---|
| Gearbox (All Axes) | Check oil levels | Every 6 months | Critical |
| Gearbox (All Axes) | Oil change | Every 20,000 hours | High |
| Balancing Device | Visual inspection | Every 6 months | Critical |
| Balancing Device | Lubrication (front bearing) | Every 10,000 hours | High |
| Cable Harness | Inspect for wear | Every 6 months | Medium |
| SMB Battery | Replace | Every 10,000 hours or on alert | High |
| Mechanical Stops | Check integrity | Every 12 months | Medium |
Gearbox Oil Levels
Critical! Inspections typically involve checking the level relative to a specific plug hole or using a dipstick method (Axis 1). Correct levels vary by axis and sometimes orientation. Low oil leads to wear/failure; high oil can blow seals due to pressure build-up.
Balancing Device
Inspect for noise (tapping, squeaking), damage (scratches on piston rod), leaks (grease from front ear seal), and ensure free movement (no obstructions). This gas-spring unit counterbalances the arm weight and is crucial for performance and motor life.
Cable Harness
Visually inspect for wear, chafing, cracks, especially around axes 2 and 3. Check securing clamps/straps.
SMB Battery Replacement
Replace every 10,000 hours or upon "Battery charge low" (38213) alert. This battery maintains the revolution counter data when the controller is off. Replacing it requires updating the revolution counters.
Additional Maintenance Procedures
Lubrication
The balancing device's front spherical roller bearing requires greasing (Optimol PD0) every 10,000 hours.
Cleaning
Methods depend on protection type (Standard vs. Foundry Plus). Use specified detergents/pressures. Never spray directly at seals, connectors, or joints. Ensure protective covers are fitted.
| Protection Type | Cleaning Method |
|---|---|
| Standard | Mild detergents, low pressure |
| Foundry Plus | Higher pressure washing, specialized cleaners |
Safety: The Non-Negotiable Foundation
The manual dedicates extensive coverage to safety, reflecting its paramount importance. Understanding and respecting these safety procedures is critical for all personnel working with or around the IRB 6700.
Moving Robot
Potentially lethal. Unexpected movements can occur. Never stand under the arm.
Electrical
High voltages (up to 800 VDC for motors) are present. Always switch off and lock out main power before service. Be aware of stored energy (capacitors).
Hot Surfaces
Motors and gearboxes become very hot. Use caution to avoid burns.
Stored Energy (Balancing Device)
Contains high-pressure gas springs. Never attempt to dismantle or tamper with it beyond specified procedures. Decommissioning requires specialized handling.
Pneumatic/Hydraulic Systems
Residual pressure can exist even after shutdown. Depressurize before service.
ESD
Sensitive electronics (like the SMB) require proper grounding (wrist strap) during handling.
Lubricants/Chemicals
Use protective gear (gloves, goggles). Hot oil is a burn hazard. Dispose of waste oil correctly.
Brake System
Regularly test brake holding capability (Section 1.2.4.4). Use brake release buttons only when necessary and with extreme caution, ensuring the arm is supported if needed. Ensure buttons aren't jammed after service near the SMB recess.
Calibration Insights
Maintaining the robot's accuracy relies on proper calibration. Understanding when and how to calibrate is essential for optimal performance.
When Calibration is Needed
- After replacing motors, gearboxes, or other transmission components
- If the revolution counter memory is lost (e.g., dead SMB battery)
- After mechanical damage or collisions
- When position accuracy has degraded over time
Calibration Methods
Standard Calibration
The most accurate standard method, establishing the robot's zero position using a Calibration Pendulum.
Absolute Accuracy (Optional)
Compensates for mechanical tolerances and deflections for higher Cartesian accuracy. Requires CalibWare tool. A robot with this option has a specific label.
Updating Revolution Counters
Essential after battery loss or initial setup. Involves jogging each axis to its calibration mark and using the FlexPendant's calibration menu to store the correct turn count. Extreme care is needed for axes 4 & 6 on certain models to avoid calibrating on the wrong revolution.
Checking Calibration
Verify by jogging to zero using the FlexPendant or running a MoveAbsJ[[0,0,0,0,0,0],...] program and checking alignment marks.
Beyond the Basics: Repair and Decommissioning
The manual provides extensive repair procedures for various components and systems. These operations require specialized training and tools.
Complexity
Repairs often involve intricate disassembly, specialized tools (lifting accessories, press tools, guide pins), and careful reassembly (torque specs, seal/bearing mounting procedures).
Lifting
Specific lifting accessories and attachment points are mandatory for heavy components (arms, motors, gearboxes).
Leak-Down Test
Essential after replacing motor/gearbox seals to ensure integrity (prevents oil leaks).
Decommissioning
Follow environmental guidelines for disposing of materials (oil, batteries, electronics). The balancing device requires specialized, hazardous decommissioning due to stored energy.
Conclusion
The ABB IRB 6700 is a powerful and reliable industrial robot, but its performance and longevity hinge on adhering to the detailed procedures and safety protocols outlined in its product manual. Proper installation on a suitable foundation, diligent adherence to the maintenance schedule (especially oil checks and changes), correct load definition, and an unwavering commitment to safety are paramount.
By understanding the 'why' behind the procedures and respecting the potential hazards, users can ensure their IRB 6700 operates safely and efficiently for its entire service life, truly delivering on its promise of lower total cost of ownership and enhanced productivity.
Always refer to the specific manual (Document ID: 3HAC044266-001, Revision -) and associated documentation for definitive procedures and specifications for your robot variant and controller.
Related Articles
Foundation & Mounting: Ensuring Stability
Essential safety and performance requirements for proper foundation design.
Essential Maintenance Schedule
Comprehensive maintenance schedules and component lifespan information.
Safety Protocols Guide
Essential safety information consolidated for easy reference.