Few alerts stop production lines faster than a critical system warning. If your ABB IRB 6700 robot is displaying the alert "38213 Battery charge low", it's a sign that requires prompt attention. This alert indicates that the battery backing up the Serial Measurement Board (SMB) is nearing the end of its life. While the robot might continue operating for a short time, ignoring this alert can lead to significant downtime and recalibration efforts.
The SMB battery is crucial. It provides power to maintain the robot's axis calibration data (specifically, the revolution counters) when the main controller power is turned off. If this battery fails completely, the robot loses its synchronization, essentially forgetting the exact position of its axes. This necessitates a full recalibration procedure.
This guide provides practical, step-by-step instructions for maintenance personnel on how to safely replace the SMB battery in your IRB 6700, and crucially, how to perform the necessary post-replacement steps to avoid losing synchronization.
Why This Alert Matters: Understanding the Consequences
The "38213 Battery charge low" alert isn't just a suggestion; it's a warning of impending data loss. Here's why immediate action is recommended:
Synchronization Loss
Once the battery is fully depleted, the robot will lose its revolution counter data upon the next power cycle of the controller. This means it won't know the exact position of each axis relative to its home position.
Production Halt
An unsynchronized robot cannot run production programs safely or accurately. This directly impacts your manufacturing output and schedule.
Recalibration Required
Recovering from lost synchronization requires updating the revolution counters, which often involves manually moving the robot to its calibration (sync) marks – a potentially time-consuming process.
Replacing the battery before it fails completely and following the correct procedure can prevent these issues.
Safety First: Essential Precautions
Working inside the robot involves electrical components and potentially sensitive electronics. Always prioritize safety.
Electrical Safety
- Power OFF: Before opening any covers or attempting replacement, completely shut down the robot controller. Follow your facility's Lockout/Tagout (LOTO) procedures.
- Confirm that all power sources (electrical, hydraulic, pneumatic) are turned off and de-energized.
Electrical Cabinet Main Power Switch Diagram
ESD Protection
- The SMB unit and potentially the battery itself are sensitive to static electricity.
- Always wear a grounded ESD wrist strap before touching any internal components.
- Handle the new battery and SMB components only in an ESD-safe manner.
Electrostatic Discharge (ESD) Protection Diagram
Battery Handling
- Adhere to safe battery handling practices as outlined on page 48 of the manual.
- Do NOT: short circuit, attempt to recharge, puncture, incinerate, crush, immerse, or expose the battery to excessive heat.
- Use safety glasses during handling.
- Dispose of the old battery according to local environmental regulations. It should not be disposed of with general waste.
Tools and Parts Needed
New SMB Battery
Use only the correct, ABB-approved spare part for the IRB 6700. (Refer to Spare parts on page 565 for the specific article number).
Standard Toolkit
Including screwdrivers/tools appropriate for removing the SMB cover screws. (See Standard toolkit on page 559).
ESD Wrist Strap
Mandatory for protecting components from electrostatic discharge during the procedure.
Safety Glasses
For eye protection during the battery handling and replacement procedure.
Battery Replacement Process Overview
Step-by-Step SMB Battery Replacement Procedure
Reference: Manual Pages 165-167
Recommendation:
To minimize the risk of losing revolution counter data if the battery hasn't failed completely yet, it's advisable to keep the controller powered ON until the very last moment before physically removing the old battery. However, SAFETY OVERRIDES THIS. You must power down completely and use LOTO before opening the cover. The ideal scenario is to have the new battery ready and perform the swap quickly after powering down.
Position the Robot (Optional but Recommended)
Move the robot to its calibration/synchronization position (all axes at 0°). While not strictly necessary for the battery swap itself, it simplifies the post-replacement check.
Power Down & LOTO
Safely shut down the robot controller and apply Lockout/Tagout procedures to ensure power cannot be accidentally restored during maintenance.
SAFETY CRITICAL: Never skip this step, regardless of time pressure.
Apply ESD Protection
Put on your grounded ESD wrist strap and connect it to a designated ESD connection point or an unpainted metal surface on the robot frame or controller cabinet.
Locate and Access the SMB Unit
The SMB unit is located on the left-hand side of the robot frame. Identify the SMB cover (it may have a small secondary cover for battery access).
Robot Exterior Diagram showing general component locations
Remove Cover(s)
Unscrew and remove the small battery cover first (if present), then the main SMB cover if necessary to access the battery connector and battery holder. Keep screws safe.
Symbol for SMB Cover / Access Point
Disconnect the Old Battery
Carefully disconnect the battery cable connector from the SMB board. Note its orientation for reconnection later.
Remove the Old Battery
Gently pull the old battery out of its holder/recess. Handle it with care and set aside for proper disposal.
Install the New Battery
Place the new, ABB-approved battery into the holder/recess. Ensure it sits firmly in position.
Connect the New Battery
Connect the new battery cable to the SMB board, ensuring it's correctly oriented and securely seated in the connector.
Refit Cover(s)
Securely refit the SMB cover(s) using the original screws. Ensure a proper seal to maintain the robot's environmental protection.
Remove LOTO & Power ON
Remove Lockout/Tagout devices and power the controller back on to prepare for the critical post-replacement steps.
The CRITICAL Post-Replacement Step: Updating Revolution Counters
This step is MANDATORY after changing the SMB battery.
Failure to update the counters will likely result in synchronization errors (e.g., "Revolution counter not updated") the next time the robot tries to move after a power cycle, even if you replaced the battery before it completely failed.
Reference: Manual Pages 542-543
-
1
Access Calibration Menu
On the FlexPendant, navigate the menus:
ABB Menu→Calibration. -
2
Select Mechanical Unit
A list of mechanical units connected to the controller will appear. Tap the entry corresponding to your IRB 6700 robot arm (usually
ROB_1). -
3
Access Revolution Counters
On the screen for the selected mechanical unit, tap
Rev. Counters.
FlexPendant interface example - representing menu navigation
-
4
Select Axes
A list of axes will be displayed. You need to update all axes. You can either tick the box for each axis individually or tap
Select all. -
5
Update Counters
Tap the
Updatebutton. -
6
Confirm Warning
A warning dialog will appear, stating that updating counters may change programmed positions and that the operation cannot be undone. Tap
Updateto confirm and proceed.The system will now store the current physical position of the robot (which should ideally be close to the 0° calibration position if you positioned it earlier) as the correct value associated with the revolution counters.
Verification
Check Calibration Marks
If you initially moved the robot to its calibration position, visually verify that the calibration marks on each axis still align correctly after updating the counters. (See Calibration scale and correct axis position on page 540).
Test Movement
Carefully jog each axis individually in manual mode at low speed to ensure smooth and expected movement. Watch for any unusual behavior or resistance.
Run Test Program
Execute a simple test program to confirm the robot follows the path accurately. Start with slower speeds and work up to normal operational speeds.
Conclusion
The "38213 Battery charge low" alert on your IRB 6700 is a critical maintenance prompt. By following this guide – emphasizing safety precautions (especially ESD protection), using the correct replacement battery, and crucially, updating the revolution counters via the FlexPendant immediately after replacement – you can successfully replace the SMB battery and prevent costly downtime associated with lost robot synchronization.
Regular preventive checks of battery status during scheduled maintenance can help anticipate this replacement need before it becomes an urgent production issue. If you encounter persistent issues after following these steps, consult the detailed manuals or contact ABB support.
Related Articles
Your Essential IRB 6700 Maintenance Schedule & Component Life Guide
Actionable schedule to help with planning and preventative maintenance.
Repair Guide: Replacing the IRB 6700 SMB (Serial Measurement Board) Unit
A complete guide to replacing the entire SMB unit when it fails.
Maximizing Precision & Uptime: IRB 6700 Calibration Guide
Covers standard vs. Absolute Accuracy, when/how to update revolution counters.