How to Resolve ABB IRB 6700 Robot Alert 38213: Complete SMB Battery Replacement Guide

Overview

The SMB (Serial Measurement Board) battery in your ABB IRB 6700 robot plays a critical role in maintaining axis position data when the controller power is off. When you receive the "38213 Battery charge low" alert, it indicates the battery needs replacement to avoid losing synchronization data. This guide provides a step-by-step process to safely replace the battery while preserving the robot's calibration.

The Problem

Alert 38213 indicates your SMB battery is running low and requires replacement to avoid losing axis position data.

The Solution

Replace the SMB battery while maintaining power or updating revolution counters to preserve calibration.

Time Required

15-30 minutes for battery replacement plus 5-10 minutes for counter updates if needed.

Critical Warning

Do not ignore the low battery alert. Complete failure of the SMB battery will result in lost synchronization, requiring a full manual calibration procedure.

The SMB Battery's Critical Function

What Does The SMB Battery Do?

The Serial Measurement Board (SMB) battery serves a crucial purpose in your IRB 6700 robot:

Maintains revolution counter data when the robot controller is powered off
Preserves the robot's calibration/synchronization information
Ensures the robot can accurately know its position when powered back on
Prevents the need for manual recalibration procedures

Consequences of Battery Failure

If the SMB battery fails completely:

Loss of axis position information
Robot will require full manual calibration
Increased downtime and production losses
Potential for positioning errors if not properly recalibrated

Why Battery Replacement Is Critical

Replacing the SMB battery is considered a preventative maintenance task that should be performed immediately after receiving alert 38213. Delaying replacement carries significant risks:

Production Interruption: Unplanned downtime if battery fails during operation

Additional Labor: Manual recalibration requires skilled personnel

Precision Loss: Potential impact on positioning accuracy

Safety Concerns: Incorrect positions may affect safety functions

Battery Type Information

Always use the ABB-specified spare part battery for the IRB 6700. The battery includes specialized protection circuits and must match the specifications for your robot model.

Replacement Process Overview

The diagram below illustrates the complete SMB battery replacement procedure, highlighting key decision points and safety considerations:

flowchart TB A[Alert 38213 Detected] --> B{Prepare for replacement} B -->|Gather materials| C[Obtain ABB-approved battery] B -->|Safety preparation| D[Apply LOTO procedures] B -->|Optional but recommended| E[Move robot to calibration position] C & D & E --> F[Power down robot controller] F --> G[Apply ESD protection] G --> H[Locate & access SMB unit] H --> I[Remove covers] I --> J[Locate battery on SMB board] J --> K[Replace battery quickly] K --> L[Refit covers] L --> M[Power up controller] M --> N{Update revolution counters} N -->|Yes, via FlexPendant| O[Calibration → Rev. Counters → Update] N -->|No, if quick replacement| P[Verify robot operation] O --> P P -->|Success| Q[Record maintenance in log] P -->|Issues persist| R[Troubleshoot with ABB support] style A fill:#ff7900,stroke:#ff7900,color:white style N fill:#0056a4,stroke:#0056a4,color:white style O fill:#0056a4,stroke:#0056a4,color:white style R fill:#f87171,stroke:#f87171,color:white style Q fill:#10b981,stroke:#10b981,color:white

The critical step is updating the revolution counters after battery replacement to maintain synchronization.

Step-by-Step Replacement Procedure

1

Prepare for Replacement

Obtain the correct ABB-approved SMB battery spare part for your IRB 6700 model
Gather required tools: screwdrivers, ESD wrist strap, safety glasses
Optional but recommended: Move robot to a known position (preferably the calibration position)
Schedule maintenance during a non-production period

Important Safety Note

Only qualified personnel trained in robot maintenance and electrical safety should perform this procedure.

2

Apply Safety Procedures

Shut down the robot controller following the proper procedure
Apply Lockout/Tagout (LOTO) procedures to ensure all power sources are isolated
Put on safety glasses and attach ESD wrist strap to prevent electrostatic damage

DANGER

Always ensure ALL power sources (electrical, hydraulic, pneumatic) are off and Lockout/Tagout procedures are followed before opening any covers. Accidental startup while working is extremely hazardous.

3

Access the SMB Unit

Locate the SMB unit on the robot arm (refer to IRB 6700 Product Manual for exact location)
Remove cover screws carefully, keeping them in a safe place
Take note of cover orientation for proper reassembly

Tip

If screw heads are damaged or difficult to remove, use the correct size tool and apply steady pressure. Avoid excessive force which could strip the screw heads.

4

Replace the Battery

Locate the battery on the SMB board
Carefully disconnect and remove the old battery without damaging connectors
Install the new ABB-approved battery, ensuring correct orientation and secure connection
Perform a visual check to ensure proper installation

WARNING

The SMB unit is highly sensitive to electrostatic discharge. Failure to use proper ESD precautions (grounded wrist strap) can permanently damage the board.

5

Reassemble and Power Up

Refit the SMB cover in the correct orientation
Secure all screws to the proper torque
Remove LOTO devices and power up the robot controller

6

Update Revolution Counters (CRITICAL)

This step is mandatory after battery replacement to ensure the robot maintains correct position data.

On the FlexPendant, navigate to Calibration menu
Select Rev. Counters
Select each axis individually
Press Update for each axis
Confirm the update when prompted

If you replaced the battery quickly (within a few minutes of powering down), the revolution counters should retain their values. However, updating them is still necessary to ensure reliable operation.

CRITICAL

Skipping this step will result in the robot losing synchronization. The robot would then require a full manual calibration procedure, which is significantly more time-consuming.

7

Verify and Document

Verify the "38213 Battery charge low" alert has cleared
Test robot movement to ensure proper operation
Document the battery replacement in your maintenance log, including:
- Date of replacement
- Robot serial number
- Technician name
- Battery part number used
- Confirmation that revolution counters were updated

Maintenance Planning

Consider implementing a calendar-based preventive maintenance schedule for SMB battery replacement to avoid unexpected alerts and potential downtime.

Troubleshooting & FAQs

What if synchronization was lost before replacement?

If the battery failed completely before replacement or the revolution counters weren't updated correctly, you'll need to perform a standard calibration procedure:

Carefully jog each robot axis until its physical calibration marks align perfectly
Use the FlexPendant (Calibration → Rev. Counters → Select Axis → Update) to store the counter value for each axis individually once aligned
For precise standard calibration, you might need specific calibration tools (like the Calibration Pendulum)
If your robot has the Absolute Accuracy option, a full Absolute Accuracy calibration might be required

Alert 38213 persists after battery replacement

If the low battery alert reappears shortly after replacement, consider these possibilities:

Faulty New Battery: Though rare, the replacement battery itself could be defective. Try another new, approved battery if available.
Connection Issue: Double-check that the battery cable is securely and correctly plugged into the SMB board.
SMB Unit Fault: The Serial Measurement Board itself might have a fault affecting its ability to utilize or monitor the battery.
Charging Circuit Issue: Issues within the board's power management could potentially cause premature drain.

How often should the SMB battery be replaced?

Several factors influence SMB battery life:

Time: Regular degradation over time, even if the robot isn't heavily used
Temperature: Operating in consistently high ambient temperatures can shorten battery life
Controller Power Cycles: Frequency of power transitions might have minor impacts
Battery Batch Quality: Manufacturing variations can lead to differences in lifespan

Consider implementing a preventive maintenance schedule to replace the battery every few years, based on ABB recommendations for your specific model.

When to escalate to ABB Service?

Certain symptoms indicate a potentially deeper issue requiring professional diagnosis:

Alert 38213 persists immediately after replacing with multiple new batteries
Frequent premature battery failure across multiple replacements
Inability to update revolution counters despite following the procedure
Simultaneous SMB communication errors with battery alerts
Visible damage to the SMB board, connectors, or battery housing

Environmental responsibility: Battery disposal

Lithium batteries require proper disposal and should never be thrown into general waste:

Follow all local, regional, and national regulations regarding hazardous waste disposal
Use designated battery recycling programs or collection points
When storing old batteries before disposal, keep them in a non-conductive container
Prevent terminals from touching each other or conductive surfaces (tape over terminals)
Store in a cool, dry place away from flammable materials

Troubleshooting Alert 38213:
SMB Battery Replacement Guide