Setting the Foundation for Success
The ABB IRB 6700 series represents a significant step forward in payload, performance, and reliability for industrial robots. Whether you're integrating the IRB 6700-235/2.65, -205/2.80, -175/3.05, or -150/3.20 model, a successful installation is the bedrock of its long-term operational success.
This guide dives deep into the practical aspects of installation and commissioning, offering insights beyond the standard manual to help installation personnel ensure a smooth, safe, and efficient setup.
We'll move beyond a simple checklist, focusing on the why behind the procedures.
IRB 6700 Installation Process Overview
Complete Installation Guide
Pre-Installation
Before You Begin: Pre-Installation Groundwork is Crucial
Skipping the pre-installation checks is a common pitfall that can lead to delays or even damage. Here's what truly matters:
Verify Robot Integrity
Upon arrival, conduct a thorough visual inspection. Any signs of damage during transit should be documented and addressed immediately.
Lifting Readiness
Confirm your lifting equipment (cranes, forklifts, slings) is rated for the robot's weight (approx. 1300 kg, excluding DressPack and tooling). Overlooking this is a serious safety hazard.
Environmental Conditions
Storage: If immediate installation isn't planned, ensure the storage environment meets the specified temperature (-25°C to +55°C, short term +70°C) and humidity (max 95% non-condensing) limits. Extreme temperatures can affect lubricants and seals even before operation.
Operation: The operating environment (+5°C to +50°C, max 95% humidity) is critical. Note the recommendation for a warm-up phase below 10°C – cold lubricants increase viscosity, potentially causing faults or reduced performance.
Foundation Fitness: Non-Negotiable Requirements
Levelness & Flatness
The requirement of 0.2 mm maximum deviation across attachment points directly impacts the robot's repeatability and absolute accuracy. While recalibration can compensate for minor unevenness, starting with a flat, level foundation minimizes deviation from factory settings.
Tilt & Resonance
A maximum tilt of 0° is specified. Any tilt reduces the robot's effective payload capacity. Consult ABB if tilting is unavoidable. The foundation should have a minimum resonance frequency of 22 Hz to avoid operational vibrations.
Load Capabilities
Understand the forces and torques the robot exerts. While maximum load values (emergency stops) are rarely simultaneous, the foundation must withstand these potential peaks. The diagram shows the force directions (Fxy, Fz, Txy, Tz).
Handling & Transportation
Critical Stability Warning
The IRB 6700 is inherently unstable if not secured to its foundation. Do not move the robot arms from the shipping position before it's bolted down. Doing so shifts the center of gravity and can easily cause the robot to tip over.
Safety and Stability First
Moving a 1300 kg robot requires careful planning. The shipping position shown is the most stable configuration for transport and initial handling.
Always follow approved transportation methods:
Method 1 (Recommended)
Robot without tool, secured in its shipping position. This minimizes stress on the robot structure.
Method 2 (If Necessary)
Robot with tool, using the specified ABB transport support. Failure to use the correct support can damage the robot and void the warranty.
Lifting the Robot
Precision and Safety During Lifting
Choose the appropriate lifting method based on your equipment and site conditions. Always ensure lifting accessories are correctly rated for at least 1300 kg plus any attachments. Crucially, no personnel should ever be under a suspended load.
Fork Lift Method
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Requires the specific ABB fork lift device set (4 pockets, P/N 3HAC047054-002).
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Attach all four pockets securely (M20x60, 8.8 grade, 280 Nm torque). Never lift with fewer than four pockets.
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Robot must be in shipping position with no tool/load.
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Lift and move slowly and carefully.
Roundslings Method
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Requires specific robot positioning (Axis 1: 0°, Axis 2: -45°, Axis 3: +65°, Axis 5: +70°).
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Use 4 lifting eyes (M20, 2000 kg WLL) in the designated base holes.
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The front and rear securing slings are crucial for stability and must not be strained during the lift.
Manually Releasing Brakes
The brake release buttons are located on the frame. If the controller isn't connected, power (24VDC) must be supplied to the R1.MP connector (Pin 11: +24V, Pin 12: 0V).
DANGER: Releasing brakes can cause rapid, unexpected arm movement. Ensure the area is clear.
Securing the Robot
The Final Foundation
Properly securing the robot ensures stability and accuracy throughout its service life.
Base Plate (Optional, but common)
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If using a base plate (P/N 3HAC12937-7), install and level it first. Use the grooves for orientation and leveling bolts.
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Ensure it's flat (max 0.2mm deviation).
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The base plate has specific dimensions and features, including guide sleeve holes.
Robot to Foundation/Base Plate
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Use the correct hole configuration on the robot base.
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Fit guide sleeves into the base plate/foundation.
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Use specified bolts (M24 x 100, Grade 8.8) and washers (4mm flat).
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Lightly lubricate screws and tighten in a criss-cross pattern to the specified torque (625 Nm). This prevents base distortion.
Connections & Configuration
Initial Connections and Configuration
Once secured, proceed with connections and configure the robot for first use:
Robot Cabling
Connect the main Robot Power (R1.MP) and Signal (R1.SMB) cables between the robot base and the IRC5 controller cabinet (XS1/XS2). Use the correct cable lengths specified.
Fitting Extra Equipment
Extra loads can be mounted on the frame, lower arm, and upper arm using provided mounting holes. Any added load must be accurately defined in the robot's software.
Tool Flange
Note the standard tool flange dimensions and hole patterns. The LeanID option (780-4) has a different flange.
Restricting Working Range
Axis 1 range can be physically limited using optional mechanical stops (P/N 3HAC044287-001, 15° increments) fitted to the base.
Important Safety Configuration
Critical: Any mechanical restriction must be mirrored by adjusting software limits (system parameters) to prevent collisions and errors. Refer to the Technical reference manual - System parameters.
Final Safety Check Before Power-Up
Before the first power-up and test run, complete these critical safety checks:
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Double-check all mechanical fastenings and electrical connections.
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Ensure the work cell is clear of tools, debris, and personnel.
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Verify all safety guards and systems (fences, light curtains, E-stops) are correctly installed and functioning.
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Review the safety procedures in the manual, paying special attention to the first test run precautions.
Essential Maintenance and Calibration
Proactive Maintenance: The Key to Longevity
Regular maintenance isn't just about ticking boxes; it's a crucial investment in preventing downtime and ensuring consistent performance. The IRB 6700 manual outlines a detailed schedule, but let's highlight some key areas and their significance.
Lubrication is Lifeblood
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Regular Checks: Routine inspections of oil levels in all six axes gearboxes are vital. Low oil levels lead to increased friction, heat, and rapid wear.
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Correct Levels: Each axis has a specific procedure and correct oil level (e.g., Axis 1: 58mm ±5mm below sealing surface).
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Oil Changes: Follow the scheduled intervals (typically 20,000 hours) for changing the oil. Use only the specified oil type for each gearbox.
Balancing Device Vigilance
This component counteracts gravity's effect on the arms and operates under high stress. Regular inspection is crucial.
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Listen: Check for unusual noises (dissonance, tapping, squeaking) which can indicate bearing wear or internal issues.
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Look: Inspect for visible damage on the piston rod and check for grease leaks around the front link ear seals.
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Safety: Remember the high stored energy. Never attempt disassembly beyond the manual's procedures.
Cable Harness Health
The robot's "nervous system" requires checks for wear, chafing, or damage, especially around high-flex areas like Axis 2 and 3 bends.
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Ensure all clamps and brackets are secure. Damaged cables can cause intermittent faults, communication errors, or complete failure.
SMB Battery Management
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The Serial Measurement Board (SMB) battery maintains revolution counter data when the controller is off.
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Replace promptly when the "Battery charge low" alert (38213) appears, or at the scheduled interval (every 10,000 hours).
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After replacement, always update the revolution counters to avoid losing synchronization.
Calibration: When and Why it's Needed
Calibration ensures the robot knows precisely where its joints are. While the initial setup involves updating revolution counters, certain maintenance or repair actions necessitate recalibration.
Updating Revolution Counters (Rough Calibration)
When Required: This is required any time the link between the physical axis position and the controller's stored count is lost. This happens:
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After replacing the SMB battery (if power was lost).
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If a resolver error occurs or resolver cables are disconnected/damaged.
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If an axis is moved manually while controller power is off (e.g., during brake release).
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During initial commissioning.
How: Manually jog each axis until its physical calibration marks align. Then, use the FlexPendant's Calibration menu to "Update Revolution Counters."
Critical Axis 4/6 Note
Be extremely careful with axes 4 and 6. Due to their gear ratios, they can be updated one full revolution off while still appearing close to the marks. Always verify against the exact calibration values on the robot's label, not just the visual marks.
Standard Calibration (Calibration Pendulum)
When Required: This more precise method is required after replacing components that directly affect the relationship between the motor/resolver and the axis's zero position. This typically includes:
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Replacing a motor.
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Replacing a gearbox.
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Significant disassembly/reassembly of drive train components.
Why: Replacing these parts changes the mechanical zero point relative to the resolver's reading. Standard calibration re-establishes this accurate relationship.
Absolute Accuracy Calibration (CalibWare)
When Required: Required if your robot has the Absolute Accuracy option and you need to restore its full Cartesian positioning precision after:
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Major structural repairs (e.g., replacing arms).
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Replacing multiple motors/gearboxes.
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Any event significantly altering the robot's geometry or deflection characteristics.
Why: Absolute Accuracy compensates for minor mechanical variations and deflections throughout the entire robot structure.
Advanced Operational Topics
Deep Dive: Replacing the Axis-2 Gearbox
Replacing a major component like the Axis-2 gearbox is a complex task requiring meticulous planning and execution. While the manual provides the procedure, here are some practical considerations and potential challenges.
Supporting the Arm System (Crucial Safety & Stability)
The Challenge: The lower and upper arms (approx. 335 kg combined) must be securely supported before disconnecting the gearbox.
Before releasing the Axis-2 motor brake or removing the motor/gearbox, always insert the M16x120 lock screw into the frame to physically prevent the lower arm from dropping. This is a non-negotiable safety step.
Practical Insight: Ensuring the arm assembly is lifted perfectly level and stable is key. Any tilting during removal or refitting can make aligning guide pins difficult and potentially damage mating surfaces.
Key Tools Required
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Distance Tool (3HAC030662-001)
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Hydraulic Press Tool (3HAC020902-001)
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Puller tool (3HAC028920-001)
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Rotation Tool (3HAC7887-1)
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M16x120 lock screw
Managing the Cable Harness
The Goal: The procedure aims to avoid full removal of the main harness and DressPack (if fitted). This saves significant time but requires careful handling.
Practical Insight: Loosening the specific internal cable clamps provides the necessary slack. When lifting the arm assembly away, ensure no tension is placed on any cables. The harness must be gently guided and protected.
Have an assistant monitor the harness during the lift. Mishandling can lead to hard-to-diagnose intermittent electrical faults later.
Unloading/Handling the Balancing Device
Procedure Nuance: The manual describes using the Distance Tool for temporary unloading if refitting the same balancing device. This involves jogging Axis 2 to +/- 20° before fitting the tool.
Alternative Method: If replacing the balancing device or if it cannot be compressed, the hydraulic Press Tool and a specific unloading procedure are mandatory.
Using the wrong method is extremely dangerous due to the high stored energy.
Gearbox Mating (Precision Required)
The Challenge: Aligning the replacement gearbox (83 kg) with the frame and the lower arm assembly requires precision.
Tools & Technique: Guide pins (M12 for gearbox-to-frame, M16 for lower arm-to-gearbox) are essential. Lubricating them helps. When mating the lower arm back to the new gearbox, the hole patterns must align perfectly.
If they don't align, the Axis-2 motor brake must be released (24VDC supply) and the Rotation Tool used on the motor shaft to slightly turn the input gear for alignment. Never force the assembly.
Post-Replacement Essentials
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Perform a leak-down test to confirm oil seal integrity
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Use the correct oil type and volume
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Standard Calibration is always required
Load Data Precision: More Than Just Numbers
The loads mounted on the robot must be defined correctly. This point cannot be overstressed. Inaccurate load data is a common cause of numerous problems.
Poor Performance & Accuracy
The robot's control system relies on accurate mass, Center of Gravity (CoG), and Moments of Inertia (MoI) for its motion planning and dynamics compensation. Incorrect data leads to:
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Path deviations, especially at higher speeds or during complex moves.
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Oscillations or vibrations at the Tool Center Point (TCP).
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Inaccurate positioning, failing to meet tolerances.
Increased Wear and Tear
The control system may demand excessive torque from motors if it "thinks" the load is lighter or has less inertia than reality. This overloads motors and gearboxes, accelerating wear and leading to premature component failure.
Conversely, defining a load as much heavier than actual can make movements sluggish and inefficient.
Safety Implications
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Collision Avoidance: Path planning relies on accurate dynamic models. Incorrect load data can affect the predicted stopping distance and path, potentially increasing collision risks.
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Braking Performance: Motor brake holding torque and stopping distances are calculated based on the defined load. Underestimating the load means the actual stopping distance in an emergency could be longer than anticipated.
Common Pitfalls
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Ignoring Tool Changers: Failing to update load data automatically when a tool changer swaps tools.
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Estimating vs. Measuring: Guessing CoG or MoI instead of using CAD data or physical measurement techniques. CoG is often not intuitive.
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Forgetting Auxiliaries: Neglecting the weight and CoG of cables, hoses, sensors, or brackets attached to the tool or arm.
Best Practices
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Use accurate CAD data whenever possible to determine mass, CoG, and MoI.
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If CAD isn't available, use measurement techniques.
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Always include all elements attached to the flange in the load definition.
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Utilize the robot's built-in load identification functions (if available).
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Regularly review and verify load data, especially if tooling or processes change.
IRB 6700 Technical Specifications
| Model Variant | Max Payload | Reach | Weight | Protection Class |
|---|---|---|---|---|
| IRB 6700-235/2.65 | 235 kg | 2.65 m | ~1300 kg | IP67 |
| IRB 6700-205/2.80 | 205 kg | 2.80 m | ~1300 kg | IP67 |
| IRB 6700-175/3.05 | 175 kg | 3.05 m | ~1300 kg | IP67 |
| IRB 6700-150/3.20 | 150 kg | 3.20 m | ~1300 kg | IP67 |
Environmental
- Operating Temperature: +5°C to +50°C
- Storage Temperature: -25°C to +55°C
- Max Humidity: 95% non-condensing
- Noise Level: < 70 dB(A)
Foundation
- Max Flatness Deviation: 0.2 mm
- Max Tilt: 0°
- Min Resonance Freq: 22 Hz
- Bolt Size: M24
Maintenance
- Oil Change Interval: ~20,000 hours
- SMB Battery Life: ~10,000 hours
- Calibration Type: Standard/AbsAcc
- Controller: IRC5
Related Resources
Maintenance Schedule
Your essential IRB 6700 Broader guide covering common add-ons beyond DressPacks.
Calibration Guide
Centralizes critical consumable info (oils, greases, specific O-rings/gaskets for repairs) for easier maintenance/repair planning. Improves usability.
DressPack Options
Comprehensive guide to ABB IRB 6700 DressPack options, including advanced LeanID integration.