Mastering IRB 6700 Installation

Installation Phase 1

Before You Unpack: Critical Pre-Installation Checks

Rushing the initial checks can lead to costly delays or operational issues down the line. The manual emphasizes several prerequisites.

Environmental Suitability

Temperature: Operating range is +5°C to +50°C (41°F to 122°F). Below 10°C might require a warm-up phase.
Humidity: Max 95% relative humidity at a constant temperature. Avoid rapid changes causing condensation.
Protection Class: Standard and Foundry Plus variants boast an IP67 rating, signifying high resistance to dust and water ingress.

Foundation Fitness

Levelness: Maximum deviation across attachment points is only 0.2 mm, affecting robot's repeatability.
Tilt: Maximum tilt allowed is 0°. Any tilt reduces maximum payload capacity.
Resonance: Minimum foundation resonance frequency must be 22 Hz to handle dynamic forces.
Loads: Foundation must withstand significant forces (Fxy, Fz) and torques (Txy, Tz) during operation and emergency stops.

View load specifications

Safety Infrastructure

Fencing: Must withstand potential impacts from dropped loads or malfunctioning tools at maximum speed.
Emergency Stops: Ensure E-stop buttons are easily accessible outside the working range.
Personnel Training: Only ABB-trained personnel with required mechanical/electrical knowledge should perform installation.

Safety regulations details

Foundation Stress Forces

Reference: Manual Figure xx1100000521

The diagram illustrates the significant forces exerted on the foundation during operation and emergency stops. These values are crucial for structural engineers designing the foundation and choosing appropriate anchoring hardware.

Hilti HDA-P M20 bolts are recommended for anchoring the robot to the foundation.

Installation Phase 2

Handling the Heavyweight: Transportation & Lifting Insights

The IRB 6700 weighs approximately 1300 kg (excluding DressPack and tooling). Improper handling can cause severe damage not covered by warranty.

Transport Position

The robot must be in its designated shipping/transport position before moving. This configuration provides maximum stability.

Attempting to move the robot in other positions significantly increases the risk of tipping.

Refer to Section 2.2.3, Figure xx1300000356 in the manual for the exact transport position specifications.

Reference: Manual Figure xx1300000356

Approved Transport Methods

1

Method 1 (Recommended)

Tool removed, robot in transport position. This is the safest default method.

Recommended for most situations

2

Method 2 (Alternative)

Tool attached, requires a specific transport support and a dedicated transport position.

Only if Method 1 is impossible

Securing to this support involves careful jogging and manual brake release (Section 2.3.2).

Lifting Options

Forklift Option

Requires the specific ABB Fork Lift Device Set (3HAC047054-002).

Critical Requirements:

All four pockets must be used
Robot must be in shipping position
No extra load allowed

Reference: Manual Figure xx1300001602

Roundslings Option

Requires specific sling lengths, M20 lifting eyes, and precise attachment points.

Specific Lifting Position Required:

Axis 1: 0°
Axis 2: -45°
Axis 3: +65°
Axis 5: +70°

Critical Safety: Securing slings must be attached correctly at front and rear to prevent tipping during the lift.

Reference: Manual Figure xx1300001574

Universal Safety Warning

Personnel must never be under a suspended load (Sections 2.4.1, 2.4.4).

Installation Process Flow

graph TD A[Site Preparation] -->|Check foundation| B[Foundation Preparation] B -->|Install base plate if used| C[Robot Transport] C -->|Choose Method 1 or 2| D{Lifting Method} D -->|Forklift| E[Use Fork Lift Device Set] D -->|Roundslings| F[Configure to Lifting Position] E --> G[Place Robot on Foundation] F --> G G -->|Use guide sleeves| H[Secure Robot] H -->|Use M24 bolts, 625 Nm torque| I[Cabling Connection] I -->|Connect to controller| J[Initial Calibration] J -->|Update revolution counters| K[Working Range Configuration] K -->|Optional mechanical stops| L[Testing & Commissioning] classDef process fill:#e9f0f7,stroke:#0f4c81,color:#0f4c81; classDef decision fill:#ffe5d9,stroke:#ff6b35,color:#000; classDef warning fill:#ffd7d7,stroke:#ff4d4d,color:#000; class A,B,C,G,H,I,J,K,L process; class D decision; class E,F warning;

Installation Phase 3

Securing Your Investment: Installation Best Practices

Once at the site, precise securing is key to ensure your robot performs at its best.

Base Plate Option

If used, the base plate (3HAC12937-7) must be installed and leveled first. It includes guide sleeves crucial for alignment.

Refer to Section 2.4.3, Figure xx1000001055 for guide sleeve details.

Robot Placement

Use guide sleeves for accurate positioning. Gently lower the robot onto these guides.
Use M24 x 100, quality 8.8 bolts with 4mm flat washers. Lightly lubricate threads before assembly.
Tightening Torque: 625 Nm in a criss-cross pattern to ensure even contact.

Load Definition

After physical installation and before programming, any tooling or equipment fitted to the robot must be accurately defined in the robot's software (mass, center of gravity, moments of inertia).

Insight: Incorrect load data is a common cause of poor performance, unexpected stops, increased wear, or even damage to motors and gears.

Working Range Restriction

If necessary, the working range of Axis 1 can be mechanically restricted using optional stops (Section 2.5.2, Figure xx1300001971).

Insight: This requires both fitting the hardware and adjusting corresponding software system parameters (Lower/Upper Joint Bound). Axes 2 and 3 can be restricted via software only.

Reference: Manual Figure xx1300001971

Critical Safety Component

The All-Important Balancing Device: A Note of Caution

Located at the rear of the frame, the balancing device counteracts gravity's effect on the arms. It contains high-tension springs under significant compression.

Danger

The manual repeatedly warns against tampering with the balancing device outside of specified procedures (Sections 1.2.3.1, 6.3). Attempting to open it is potentially lethal due to stored energy.

Regular Inspection (Section 3.3.7)

Check for dissonance (tapping/squeaking sounds)
Check for damage (scratches on piston rod)
Check for leaks (grease from front ear seals)
Ensure free movement

Decommissioning (Section 6.3)

Requires specialized procedures involving cutting the housing and springs, ideally performed by a professional decommissioning company aware of the hazards.

Balancing Device Location/Inspection Points

Reference: Manual Figure xx1300000413

Installation Phase 4

First Connections & Calibration Awareness

Proper connections and calibration are essential for accurate robot operation.

Cabling

Robot power and signal cables connect the manipulator (R1.MP, R1.SMB) to the IRC5 controller (XS1, XS2). Ensure correct cable lengths are used.

Optional customer cabling handles tooling I/O and power. See Section 2.6.1 for details.

Initial Calibration

After connecting the robot and controller for the first time, the revolution counters must be updated.

This involves jogging the robot to its calibration marks (Section 5.3, Figure xx1200001075) and using the FlexPendant's calibration menu.

Insight: Failure to update counters correctly results in the robot not knowing its true position, leading to inaccurate movements.

Full Calibration

A full standard calibration (e.g., using Calibration Pendulum) is required if components affecting the kinematic chain (motors, gearboxes) are replaced.

Robots with the Absolute Accuracy option require recalibration with CalibWare for optimal TCP accuracy after such repairs.

Ongoing Operation

Beyond Installation: Maintenance & Safety Essentials

A successful installation is just the beginning. Ensuring long-term reliability requires ongoing attention.

Proactive Maintenance: Keeping Your IRB 6700 in Peak Condition

Component	Check Interval	Service Interval	Key Actions
Gearbox Oil (All Axes)	Every 6 months	Every 20,000 hours	Check oil levels, change oil when needed
Balancing Device	Monthly	As needed	Check for unusual sounds, damage, or leaks
Cable Harness	Monthly	When damaged	Visual check for wear, especially around moving axes
SMB Battery	When warning appears	Upon "Battery charge low" warning	Replace with controller powered ON if possible
Mechanical Stops	Quarterly	When damaged	Check for deformation, especially after collisions

Regular Inspections

Gearbox oil levels must be checked per robot position requirements (Sections 3.3.1 - 3.3.6)
Cable harness needs inspection for wear, especially around moving joints
All safety labels must remain legible and intact

Lubrication & Fluid Changes

Use only specified lubricant types for each gearbox
Never mix lubricants unless explicitly instructed
The balancing device front spherical roller bearing requires periodic greasing

Critical Safety Procedures During Operation & Maintenance

Electrical Safety

ALWAYS switch off and lock out the main power at the controller cabinet before performing any repair or maintenance.

Be aware of stored energy (capacitors) even after power down.

ESD Precautions

Electronic components like the SMB are sensitive to Electrostatic Discharge.

Use a grounded wrist strap connected to the designated point on the controller
Use ESD-safe mats and work surfaces

Brake Release Procedures

Buttons on the Brake Release Unit (BU) inside the SMB recess allow manual axis movement.

This is hazardous, as axes can move unexpectedly due to gravity. Ensure the area is clear and the arm is supported if necessary.

Reference: Manual Figure xx1200000964

Working Inside the Cell

ALWAYS switch the controller to Manual Mode (preferably Reduced Speed - max 250 mm/s)
Keep the FlexPendant with you (using the enabling device)
Test brakes before entry
Never stand under the robot arm

First Test Run Post-Service

Clear the area
Ensure tooling is secure
Check all safety devices
Run the first cycle cautiously, watching the serviced component

Advanced Maintenance

Tackling Major Repairs: Precision and Procedure are Paramount

While routine maintenance aims to prevent issues, component failures or wear can necessitate major repairs, such as replacing motors or gearboxes.

Component Handling

Motors and gearboxes for the IRB 6700 are heavy components:

Component	Weight	Lifting Accessory
Axis 1 motor	21 kg	3HAC14459-1
Axis 2 motor	26 kg	3HAC15534-1
Axis 1 gearbox	92 kg	3HAC046112-001

Using the specified lifting accessories is not just recommended, it's essential for safety and preventing damage.

Disassembly Order

Procedures often involve a specific sequence that must be followed to ensure safety and prevent damage.

Remove covers and access panels
Disconnect cables before unbolting the main component
Secure adjacent parts (like locking the lower arm when working on Axis 2)
Use guide pins during removal/installation to maintain alignment
Carefully check all O-rings before reassembly
Conduct leak-down test after reassembly
Perform required calibration

Insight: Deviating from this sequence can make the task harder or risk damage to components.

Alignment is Critical

When removing and refitting heavy components like motors or gearboxes that mesh together, maintaining alignment is vital. The manual consistently calls for the use of guide pins.

Insight: Guide pins prevent the component from tilting during removal/installation, which could damage mating surfaces, gears, or pinions. They also ensure the component goes back exactly in place, crucial for maintaining gear mesh and overall robot geometry.

For certain critical interfaces (like the Axis 1 gearbox to frame), a dedicated Aligning Tool (3HAC046645-001) is specified. This ensures precise concentricity, which is vital for minimizing gear backlash and ensuring optimal motor performance.

Seal Integrity

Every motor and gearbox replacement involves disturbing seals (O-rings). Proper handling is essential to prevent future leaks.

Clean mating surfaces and O-ring grooves thoroughly
Check O-rings for damage and replace if necessary
Lubricate O-rings with specific grease (often 3HAB3537-1)

Crucially, after refitting a motor or gearbox, a Leak-Down Test using a dedicated tester (3HAC0207-1) is mandated. This pressurizes the gearbox slightly (0.2-0.25 bar) to confirm all seals are correctly seated.

Recalibration is Non-Negotiable

Replacing any motor or gearbox directly affects the robot's kinematic chain and calibration. After such a repair, recalibration is mandatory.

Simply updating revolution counters is insufficient after major component replacement.

Standard Calibration

Using Calibration Pendulum is the minimum requirement after component replacement. This establishes the robot's "home" or zero position accurately.

Absolute Accuracy Robots

Require a full CalibWare routine to restore full performance. This is indicated by an Absolute Accuracy sticker on the robot.

Performance Optimization

Calibration: The Foundation of Performance and Safety

Calibration translates the robot's physical position into the digital world of the controller. Its accuracy is fundamental to everything the robot does.

Path Accuracy

Ensures the robot follows the programmed path precisely. Deviations can cause inconsistencies in applications like welding, sealing, or machining.

TCP Accuracy

Critical for applications where the Tool Center Point must be exactly positioned (e.g., assembly, dispensing). Poor calibration leads to misplaced parts.

Safety

Correct calibration ensures the robot "knows" where it is, vital for collision avoidance and accurate working range limits.

Performance

Optimal calibration allows for smoother motion and potentially faster cycle times, as the controller can accurately predict robot dynamics.

Standard vs. Absolute Accuracy

Standard Calibration (Calibration Pendulum)

Establishes the robot's "home" or zero position accurately. Sufficient for many applications, especially after replacing components like motors or gearboxes without dismantling the main structure.

Absolute Accuracy (CalibWare)

Builds upon standard calibration, adding compensation for minor mechanical tolerances and load deflections. This provides higher accuracy in the Cartesian coordinate system, essential for high-precision tasks.

Insight: If your robot has the Absolute Accuracy option (indicated by a sticker), replacing structural components necessitates a CalibWare recalibration.

Revolution Counter Updates

This is a rough calibration, only telling the controller which full rotation each axis is in. It's needed after battery loss or initial setup but does not replace a full standard or absolute accuracy calibration.

Critical Error Potential: Axes 4 and 6 on some robots have non-integer gear ratios. If these axes are manually rotated before the initial revolution counter update, their true zero position can be lost.

Always update counters immediately after initial power-up or battery replacement, ensuring axes are at their calibration marks.

Calibration Decision Flow

graph TD A[Start Calibration Assessment] --> B{Initial Setup?} B -->|Yes| C[Update Revolution Counters] B -->|No| D{Component Replaced?} D -->|No| E{SMB Battery Changed?} D -->|Yes| F{What Component?} E -->|Yes| C E -->|No| G[No Calibration Needed] F -->|Motor/Gearbox| H{Absolute Accuracy?} F -->|Other Electronics| C F -->|Structural| I[Full CalibWare Required] H -->|Yes| I H -->|No| J[Standard Calibration] C --> K{Is Robot Functioning
Correctly?} J --> K I --> K K -->|Yes| L[Done] K -->|No| M[Further Diagnosis Needed] classDef default fill:#e9f0f7,stroke:#0f4c81,color:#0f4c81; classDef process fill:#e9f0f7,stroke:#0f4c81,color:#0f4c81; classDef decision fill:#ffe5d9,stroke:#ff6b35,color:#000; classDef terminal fill:#d1e7dd,stroke:#198754,color:#000; class A,C,G,I,J,L,M process; class B,D,E,F,H,K decision;

End-of-Life

Responsible End-of-Life: Decommissioning the IRB 6700

When an IRB 6700 reaches the end of its service life, safe and environmentally responsible decommissioning is necessary.

Safety First

Before scrapping begins, critical safety steps must be taken:

Disconnect Power: Ensure all electrical power is off and locked out.
Remove Batteries: Critically important, as batteries (especially Lithium SMB batteries) can explode if exposed to heat.
Drain Fluids: Remove all oils and greases from gearboxes to prevent fire hazards and environmental contamination.
Support Structure: Be aware that removing motors can cause the robot structure to collapse if not properly supported.
Balancing Device: Requires specialized handling due to high stored energy.

Material Disposal

The robot contains various materials that must be separated and disposed of or recycled according to local environmental regulations:

Steel
Cast iron
Aluminum
Copper
Plastics

Neodymium magnets
Electronic components
Oils and greases
Batteries

Oils and greases should never be dumped onto soil or into drains.

Final Synthesis

The ABB IRB 6700 is an advanced piece of industrial machinery. Achieving its full potential requires not only understanding its features but also diligently applying the prescribed procedures for installation, maintenance, repair, and calibration.

The official manual serves as the definitive guide, but appreciating the reasons behind the steps—the emphasis on alignment during repairs, the necessity of leak checks, the critical role of calibration for accuracy and safety, and the hazards associated with stored energy and materials—elevates operational practice from mere execution to true mastery.

This deeper understanding ensures safety, maximizes performance, and extends the valuable service life of the IRB 6700.

Related Technical Guides

Expand your knowledge with these additional resources

Foundation & Mounting: Ensuring Stability

Essential safety and performance requirements for proper foundation design and robot mounting.

Maximizing Precision & Uptime: Calibration Guide

In-depth coverage of calibration methods to ensure peak performance.

Consumables Quick Reference: Oils, Greases & Parts

Comprehensive list of all required consumables for the IRB 6700.

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