The arrival of a new ABB IRB 6700 robot is an exciting moment, signaling a significant step towards enhanced automation. However, before this powerful machine starts its work, a crucial phase of unboxing, inspection, and preparation is necessary. Simply tearing open the crate isn't enough; careful steps must be taken to ensure safety, verify the robot's condition, and confirm site readiness. This article guides installation and maintenance personnel through these vital initial steps, drawing from the IRB 6700 product manual, focusing on practicalities and safety beyond just the basic checklist.
Key Specifications at a Glance
Weight
Approximately 1300 kg (base model without DressPack or tooling)
Operating Temperature
+5°C to +50°C (Warm-up required below 10°C)
Protection Class
Standard IP67 or Foundry Plus IP67
Foundation Requirements
Levelness: max 0.2mm deviation
Min. resonance frequency: 22 Hz
ABB IRB 6700 Installation Phases
The complete installation pathway from unboxing to commissioning, highlighting critical decision points and safety checkpoints
1. Before You Begin: Essential Prerequisites & Safety Mindset
Before the crate is even opened, ensure the groundwork is laid for a smooth and safe process. This preparation extends beyond the physical setup to include personnel qualifications and safety measures.
Qualified Personnel
As outlined in the manual (page 52), installation must be performed by craftsmen trained by ABB. They need the required knowledge of mechanical and electrical installation/maintenance/repair work and must conform to all national and local codes. This isn't just red tape; the complexity and potential hazards demand expertise.
Safety First - Always
The manual dedicates Chapter 1 (page 15 onwards) entirely to safety, and this emphasis cannot be overstated. Before proceeding, personnel should be familiar with general and specific safety instructions, including electrical safety and general risks like crushing or impact hazards.
Critical Safety Warning
The ABB IRB 6700 weighs approximately 1300 kg excluding any optional DressPack or tooling. Using underrated lifting equipment is extremely dangerous. Verify that all lifting accessories are rated for at least this weight before attempting any movement.
Pro Tip: Environmental Controls
If storing the robot before installation, ensure the storage location meets the specified conditions: temperature between -25°C to +55°C (up to +70°C for less than 24 hours) and maximum 95% non-condensing humidity. Improper storage conditions can damage sensitive components.
2. The Initial Inspection: What to Check Immediately
Once the robot is accessible, perform these critical checks as outlined on page 52 of the manual. This crucial first look can identify issues that might compromise safety or operation later.
- Visual Inspection: Thoroughly examine the robot for any signs of damage that may have occurred during shipping. Document any dents, cracked casings, damaged cables, or connectors immediately.
- Shipping Position Verification: Confirm the robot is in its shipping position (as shown on page 60). This is the most stable configuration for the robot when not secured.
- Documentation Check: Ensure all accompanying documentation (manuals, calibration data, potentially on DVD - page 10, 565) is present and matches the specific robot serial number and model variant.
- Lifting Gear Confirmation: Re-confirm that the chosen lifting accessory is not only suitable for the weight (1300 kg+) but also compatible with the robot's designated lifting points.
Inspection Checklist
"Undetected shipping damage can lead to operational failures and safety hazards later. Take the time to thoroughly document the robot's condition upon arrival."
3. Site & Environmental Readiness Check
Is the robot's designated home truly ready? Verify these critical points derived from the pre-installation procedure (pages 52-54) before proceeding with the installation.
Storage vs. Installation Environment
Storage Temperature: -25°C to +55°C continuous, up to +70°C for <24hrs
Operating Temperature: +5°C to +50°C
Humidity: Max 95% non-condensing
Note: For environments below 10°C, warm-up procedures are required to prevent performance issues due to oil/grease viscosity.
Foundation Requirements
Levelness: Max deviation 0.2mm across anchoring points
Tilt: 0° recommended
Load-bearing: Must support robot weight (1300kg) plus operational forces
Resonance: Minimum frequency 22 Hz
Installation Path & Space
Clearance: Ensure sufficient height and width clearance along the entire transport path
Floor: Verify floor can support transport equipment with robot load
Working Space: Allow adequate space around installation site for personnel movement during setup
Service Access: Consider future maintenance access requirements
Power & Utilities Verification
| Utility | Requirement | Notes |
|---|---|---|
| Electrical Power | 200-600V, 3-phase (controller dependent) | Verify voltage and grounding meet local requirements |
| Compressed Air | If pneumatic tools used | Clean, dry air with appropriate pressure |
| Network | Ethernet connection (if integrated with other systems) | Coordinate with IT department for configuration |
| Safety Systems | E-stops, light curtains, safety gates | Verify all safety systems are ready for integration |
4. Handling the Heavyweight: Understanding Weight & Stability
This section deserves special attention due to the inherent risks associated with the robot's significant mass. The IRB 6700 weighs approximately 1300 kg in its base configuration (page 52), and all handling must account for this substantial weight.
Critical Tipping Hazard
Until the robot is securely fastened to its foundation, it is inherently unstable. Moving the arms will shift the center of gravity and can easily cause the robot to tip over, leading to severe injury or damage. The manual explicitly states the shipping position (shown on page 60) is the most stable. Do not change the robot's configuration or move its arms before it is securely bolted down.
Even when moving the robot before final installation, take precautions. The manual includes a specific warning symbol related to tipping risk when loosening bolts, highlighting the importance of secure fastening at all stages.
Stability Facts
- Robot is only stable when secured to foundation
- Shipping position provides best balance when unsecured
- Center of gravity shifts dramatically with arm movement
- Never release brakes before securing the robot
- Always maintain full control during transport
Technical Note: Center of Gravity
The robot's center of gravity varies significantly based on arm position. In the shipping position (page 60), the center of gravity is deliberately positioned for maximum stability. Any unauthorized position change before securing can create a dangerous imbalance.
For this reason, the base plate and foundation mounting procedures (pages 72-77, 84-85) should be completed as a priority, before any other configuration changes.
5. Moving the Robot: Approved Transportation
Once initial checks are complete and the site is ready, the robot needs to be moved. The manual outlines precautions (pages 62-63) for safe transportation.
Method 1: Without Tool (Recommended)
- Transport with the robot in its recommended shipping position (page 60)
- Remove any attached tools or end-effectors before transport
- Choose appropriate lifting method based on available equipment
- Simpler and safer than Method 2
Method 2: With Tool (If Method 1 Impossible)
- Transport with a tool requires a specific recommended transport support (details/diagrams on pages 65-66)
- Requires specific securing procedures (page 67)
- Carries higher risks than Method 1
- Requires strict adherence to instructions
Pre-Movement Preparation
Required Equipment
- Appropriate lifting equipment (forklift or crane)
- Fork Lift Device Set (3HAC047054-002) for forklift option
- Rated roundslings (2.5m, 2000kg) for crane option
- Transport support if using Method 2
Safety Precautions
- Clear transportation path of obstacles and personnel
- Never position personnel under suspended robot
- Move slowly and avoid sudden starts/stops
- Maintain control at all times during movement
Pro Tip: Transport Planning
Before attempting to move the robot, have a detailed transportation plan including the exact route, required clearances, and contingency procedures. If possible, perform a "dry run" with similar dimensions but without the actual robot to identify potential obstacles or challenges.
6. Lifting the Robot: Precision Handling Required
Whether using a forklift or overhead crane with roundslings, lifting the 1300+ kg robot demands adherence to specific procedures outlined in the manual.
Forklift Lifting (Manual Section 2.4.1, Pages 69-71)
Required Equipment
This method mandates the use of the dedicated Fork Lift Device Set (3HAC047054-002), consisting of four specially designed pockets that must be securely bolted to the robot base using M20x60 screws with 280 Nm torque.
Crucially, all four pockets must be fitted and used. Lifting with fewer pockets creates an unstable and dangerous situation.
Procedure
- The robot should be in its shipping position (page 60) without any payload
- Bolt all four pockets securely to the robot base
- Position forklift forks through the pockets
- Lift and move slowly and carefully, ensuring the robot remains level
- Avoid sudden starts or stops
Roundsling Lifting (Manual Section 2.4.4, Pages 78-81)
Required Equipment
Requires specific lifting eyes (M20, page 78) fitted to the base corners, correctly rated roundslings (e.g., 2.5m, 2000kg capacity), and potentially securing slings to prevent tipping.
Robot Position
The robot must be placed in the specific lifting position shown on page 79:
- Axis 2: -45°
- Axis 3: +65°
- Axis 5: +70° approximately
This differs from the shipping position and is optimized for balance during the lift.
Attachment
- Slings must be correctly routed through the lifting eyes (diagrams on page 78)
- Ensure slings are not rubbing against sharp edges
- Additional slings are used fore and aft (page 80-81) purely for stability
- Front sling must be clear of the brake release unit plate (page 81)
Personnel must never be under the suspended load. Lift smoothly and avoid jerky movements.
Common Lifting Errors to Avoid
Using Underrated Equipment
Never use lifting equipment rated below the robot's weight (1300+ kg). Include a safety margin in your calculations.
Incorrect Robot Position
Using a position other than specified for the lift method chosen can destabilize the robot during lifting.
Improper Sling Routing
Failure to route slings exactly as shown in the diagrams can cause uneven loading or sling damage.
Missing Stabilizing Slings
Omitting the fore and aft stabilizing slings when using the roundsling method can result in robot tipping during the lift.
Rapid Movement
Quick acceleration or deceleration during lifting/transport can cause dangerous swinging or shifting of the heavy load.
Insufficient Clearance
Failing to account for the full dimensions of the robot during transport, resulting in collisions with the environment.
7. The Foundation Interface: Base Plate & Installation
The connection between the robot and the floor is critical for accuracy and stability. This step mitigates the tipping risk by securely anchoring the robot.
Base Plate Option (Manual Sections 2.4.2 & 2.4.3, Pages 72-77)
Purpose
Provides a stable, precisely machined interface, especially useful if the foundation isn't perfectly level. Improves repeatability.
Handling
The base plate itself is heavy (353 kg, page 72) and requires proper lifting eyes and slings for placement.
Installation Steps
- Level using leveling bolts and potentially shims
- Secure to the foundation using appropriate anchor bolts (recommendations like Hilti HDA-P M20 on page 76)
- Follow the supplier's guidelines for anchor bolt installation depth and concrete quality (e.g., C25/C30)
- Confirm levelness after securing
Securing the Robot (Manual Section 2.4.6, Pages 84-85)
Positioning
Carefully lower the robot onto the base plate or foundation, using guide pins (page 85) to ensure correct alignment with the mounting holes. If using a base plate, align with the orienting grooves and guide sleeve holes (page 75).
Bolt Preparation & Installation
- Lightly lubricate the attachment bolts (M24 x 100, quality 8.8 specified on page 84) before insertion
- Tighten the M24 bolts in a criss-cross pattern (page 85) to ensure the base is evenly secured
Critical Torque Value
Apply the correct final tightening torque: 625 Nm (page 85). Use a calibrated torque wrench. Incorrect torque can lead to instability or damage.
Pro Tip: Foundation Verification
If installing directly to the foundation (without a base plate), confirm the surface meets the stringent levelness requirement of 0.2mm deviation across anchoring points (page 54) using precision measurement tools. For concrete foundations, ensure proper curing time has elapsed before robot installation.
Fitting Additional Equipment (Manual Section 2.4.8, Pages 87-92)
Attachment Points
The manual details specific mounting holes and permissible load locations on the frame (hip load), lower arm, and upper arm (pages 87-90). Adhere strictly to these locations and weight/inertia limits:
- JH = 100 kgm² for frame load
- M1 ≤ 50 kg for upper arm load
Critically important: Any added equipment must have its mass, center of gravity, and moments of inertia accurately defined in the robot controller's software (page 86). Failure to do so will result in poor performance, potential motor/gearbox overload, inaccurate movements, and possible safety stops or even collisions.
Tool Flange
Ensure the correct tool flange is used (standard or LeanID, pages 91-92) and that the tool is mounted securely according to specifications.
8. Electrical Connections (Manual Section 2.6, Page 96)
Once mechanically secured, connect the robot to the controller. This step requires attention to detail to ensure proper electrical function and safety.
Cable Connections
Main Cable Types
- Robot Power (R1.MP): Connects between the robot base and the controller cabinet (XS1 on controller)
- Robot Signal (R1.SMB): Connects between the robot base and the controller cabinet (XS2 on controller)
Customer Cabling
If optional equipment or user I/O is used, route these cables according to plan, often alongside the main robot cables or through designated DressPack channels.
Critical Safety Requirement: Ensure protective earth connections are correctly made at both the robot and controller ends before applying power. This is a fundamental safety requirement (page 51).
Safety During Connection
Power Off State
Ensure main power is off during all electrical connections. Use proper lockout/tagout procedures following local regulations and guidelines.
ESD Protection
When handling sensitive electronic components, observe ESD precautions using wrist straps connected to the designated point (often on the controller).
Cable Routing
Route cables to avoid pinch points, moving parts, and sharp edges. Properly secure cables to prevent strain on connectors.
Pro Tip: Cable Inspection
Before connecting cables, carefully inspect all connectors for damage, contamination, or bent pins. Damaged connectors can cause intermittent issues that are difficult to diagnose later. Also, capture photos of the properly connected cables for future reference during maintenance.
9. Powering Up & Initial Checks: Commissioning Your IRB 6700
With the IRB 6700 securely bolted down and primary electrical connections made, the commissioning phase begins. This isn't just flipping a switch; it involves crucial checks and configurations to ensure the robot operates safely and accurately within its intended environment.
Pre-Power-Up Final Checks
Connection Verification
- Verify all robot-to-controller cables (R1.MP, R1.SMB, any customer/DressPack cables) are securely seated
- Confirm protective earth continuity between the robot chassis, controller cabinet, and facility ground
Environmental Check
- Perform a final visual sweep of the robot's entire potential working envelope
- Ensure no tools, equipment, or personnel are obstructing its path
Safety System Integration
Confirm that external safety devices (light curtains, gates, E-stops - see Section 1.2.2, Page 17) are correctly wired into the controller's safety interface according to the overall system design and local regulations.
First Power-Up & Revolution Counter Update
Initial Boot Sequence
- Turn on the main power switch at the controller (Manual Section 1.3.6, Page 46)
- Observe the FlexPendant for normal boot sequence
- Monitor for any immediate error messages
Revolution Counter Check/Update (Manual Section 5.5, Pages 542-543)
Why it's Critical: The robot needs to know the exact turn number for each axis motor relative to its calibration position. This data can be lost if the SMB battery was discharged or disconnected.
Powering up with incorrect revolution counts leads to incorrect positioning, which can cause damage to the robot or surroundings.
Procedure:
- Navigate to 'ABB Menu -> Calibration -> Rev. Counters'
- If the robot's physical position matches its calibration marks (zero position), update the counters
- Tick the relevant axes or 'Select all', then tap 'Update'
- After updating, verify the calibration marks align visually (Section 5.6, Page 544)
Restricting the Working Range (If Necessary)
Why Restrict?
To prevent collisions with fixed structures, other equipment, or designated no-go zones (Manual Section 2.5.1, Page 93).
Methods
- Software Limits: Configured via system parameters in the controller software (referenced on page 93). This is the most common method for axes 2 and 3.
- Hardware Limits (Axis 1): Physical mechanical stops can be added to the base to limit axis 1 rotation (Section 2.5.2, Pages 94-95). This involves installing specific hardware (Movable mechanical stop set, 3HAC044287-001) onto the robot base.
- Safety Configuration: More advanced safety options might involve SafeMove (if purchased/configured) for defining complex safety zones.
If hardware stops are installed, the corresponding software limits must also be updated to match. Incorrectly set limits can cause unexpected stops or fail to prevent collisions.
Initial System Checks & Safety Tests
Critical Safety Tests
- Brake Test (Manual Section 1.2.4.4, Page 30): Perform a static brake test on each axis. Move each axis to a position of maximum static load, switch the controller to 'MOTORS OFF' mode, and verify that the axis holds its position.
- E-Stop Functionality: Test all Emergency Stop buttons (FlexPendant, controller cabinet, external E-stops) to ensure they function correctly, stopping robot motion and requiring a defined reset procedure (Section 1.2.5.1, Page 34).
- Enabling Device Check: Verify the FlexPendant enabling device ('dead man's switch') functions correctly in manual mode – motion should only occur when held in the halfway position and stop immediately upon release or full press (Section 1.2.4.6, Page 32).
Pro Tip: Revolution Counter Special Case
As noted on page 542, axes 4 and 6 have specific gear ratios where being off by a full rotation might still align the visual calibration marks. It's vital to ensure these axes haven't been rotated excessively during handling before updating counters. If unsure, consult calibration procedures or ABB support.
10. Complete IRB 6700 Installation Checklist
Use this comprehensive checklist to ensure all steps of the installation process have been completed correctly. This serves as both a verification tool and documentation of the installation.
Pre-Installation
Mechanical Installation
Electrical & Commissioning
Final Documentation
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