Overview of the ABB IRB 6700 Series
Built for Safety
Comprehensive safety features including mechanical stops, brake systems, and carefully designed operational protocols to ensure operator and equipment protection.
Performance Optimized
With payloads up to 235kg and reach extending to 3.20m, these robots deliver exceptional precision and reliability across diverse industrial applications.
Maintainability
Designed with serviceability in mind, featuring accessible components and a structured maintenance schedule to maximize uptime and operational life.
Versatile Applications
Adaptable to diverse industrial environments from automotive manufacturing to material handling, with optional Foundry Plus protection for harsh conditions.
Complete Installation Guide
Installation Process Overview
Critical Safety Precautions
Installation and maintenance must be performed by personnel trained by ABB. Failure to follow safety protocols can result in serious injury or death.
Safety First: Non-Negotiable Principles
Moving Parts & Unexpected Motion
Treat any powered robot as potentially live and capable of sudden movement, even during manual operation or service.
- Always ensure safety fences, light curtains, and emergency stops are correctly installed and tested before power-up.
- Never assume a robot in "manual" mode is safe without proper enabling device control.
- Maintain awareness of all axes, not just the end effector position.
Electrical Hazards
High voltages (up to 800 VDC for motors) are present throughout the system.
- Always perform lockout/tagout procedures by switching off the main power at the controller and verifying zero energy state.
- Be aware of stored energy in capacitors even after shutdown.
- Use insulated tools when working on electrical components.
ESD Sensitivity
The Serial Measurement Board (SMB) and other electronic components are highly sensitive to Electrostatic Discharge.
- Always use a properly grounded wrist strap connected to the designated point when handling these components.
- Failure to do so can cause latent or immediate damage, leading to difficult-to-diagnose faults.
ESD Wrist Strap Connection Point Example
Manual Brake Release & Safety Labels
Releasing the brakes is hazardous. Gravity will cause the arm to fall unpredictably unless properly supported.
- The brake release buttons can jam after service – always manually check that buttons move freely after reassembly before applying power.
- Familiarize yourself with the graphical safety symbols on the robot. They provide critical warnings at points of potential hazard.
Example Safety Labels
Unpacking and Handling: Getting the IRB 6700 On-Site
With a weight around 1300 kg, moving the IRB 6700 requires careful planning and the right equipment.
Transport Fixture Method
This is the most stable and safest method, minimizing stress on the robot structure. The robot arrives secured to its transport fixture from ABB.
- Maintains the robot in its designed shipping position
- Distributes weight properly to prevent stress on axes
- Provides stable lifting points for forklifts and cranes
- Minimizes risk of tipping during transport
Transport Method 1: Robot secured to transport fixture
Support Structure Method
Using a dedicated transport support structure if Method 1 isn't feasible (e.g., moving with tooling attached, though removing tools first is always recommended).
- Requires specific procedures and the correct support bracket
- Less stable than the transport fixture method
- May be necessary in specific situations where the original transport fixture is unavailable
- Requires careful attention to weight distribution
Transport Method 2: Using a support structure
Incorrect transport methods can exert forces the robot isn't designed to handle off-foundation, potentially leading to misalignments or internal damage not covered by warranty.
Lifting Safely: Two Approved Methods
Forklift Method
- Requires the dedicated Fork Lift Device Set (Option)
- Ensure all four pockets are used and the forklift has adequate capacity
- Move slowly and avoid any personnel under the load
- Ensure forklift tines are fully inserted and secure
Fork Lift Device Set
Roundsling Method
- Requires specific sling lengths, lifting eyes (M20, 2000kg WLL), and precise attachment points
- Pay close attention to the robot's posture and the routing of the securing slings
- Slings prevent tipping but should not bear the main load
- Ensure slings don't chafe on sharp edges or the brake release unit
Roundsling Attachment Diagram
Stability Alert: The Critical Shipping Position
Critical Warning: Until the robot is securely bolted to its foundation, it is mechanically unstable. Moving the arms will shift the center of gravity and can easily cause the 1300kg robot to tip over.
Action: Keep the robot in its designated shipping/transport position until it is fully secured to the foundation. Releasing brakes or moving axes before bolting down is extremely hazardous.
Robot Shipping Position - Maintain this until secured to foundation
Installation: Securing Your Investment
Foundation & Site Preparation
Levelness Requirements
- Maximum foundation levelness deviation of just 0.2 mm
- While the robot can be recalibrated to compensate for some unevenness, a perfectly level foundation is ideal
- An uneven foundation directly impacts the robot's absolute accuracy and repeatability
- Even minor deviations can cause unexpected stress on the base and axis 1 gearbox over time
Environmental Conditions
- Operating temperature: +5°C to +50°C
- Maximum humidity: 95% non-condensing
- Standard protection: IP67
- Consider Foundry Plus option for environments with high contamination or potential fluid exposure
Orienting and Securing the Robot
- Use the M24 guide sleeves provided with the base plate (or specified for direct mounting) to accurately position the robot
- Lubricate the M24 x 100 (Grade 8.8) securing bolts lightly before insertion
- Tighten the bolts in a criss-cross pattern to the specified torque (625 Nm) to ensure even clamping
- Use a calibrated torque wrench to achieve proper bolt tension
Robot Base Hole Configuration
Important Note:
Never attempt to move or adjust the robot once it's been placed in position without first loosening the mounting bolts. Attempting to shift the robot while bolted can damage the base plate and mounting holes.
Defining Loads: Crucial for Performance
While load definition happens in the software (IRC5 controller), the physical equipment mounting occurs during installation.
Why it Matters:
- The robot controller uses load data (mass, center of gravity, inertia) to optimize motion, speed, and motor control
- Incorrectly defined loads lead to jerky movements, excessive vibration, increased wear on gearboxes and motors
- Can result in potential overloads and inaccurate positioning
- Affects the robot's ability to execute smooth, efficient trajectories
Required Action:
Ensure any additional equipment fitted to the arm is within the specified limits (e.g., M1 ≤ 50 kg on the upper arm) and its load data is accurately configured in the controller later. Refer to the Product Specification for detailed load diagrams.
Equipment Mounting Holes Example
Tool Flange Example (Standard)
Initial Setup Considerations
Restricting the Working Range
If the robot's full range poses a collision risk with peripherals or structures, restrictions can be implemented:
- Axis 1: Can be restricted mechanically using optional stop sets (15° increments) and corresponding software parameter adjustments
- Axes 2 & 3: Restricted via software parameters in the controller
- Importance: Implementing range restrictions correctly (both mechanically where applicable, and in software) is a critical safety function
Axis 1 Mechanical Stop Example
Electrical Connections
Proper electrical connection is essential for robot operation and safety:
- Connect the main robot power (R1.MP) and signal (R1.SMB) cables between the robot base and the IRC5 controller
- Ensure connectors are properly seated and secured
- Customer cabling (optional) for tools and I/O follows separate paths and connection points
- Double-check all connections before initial power-up
Pro Tip:
Label all customer cables during installation to simplify future maintenance and troubleshooting. This small step can save significant time during service operations.
Maintenance Schedule & Procedures
Understanding Maintenance Intervals
Regular maintenance isn't just about fixing problems; it's about preventing them. The IRB 6700 manual outlines a comprehensive schedule based on operating hours and calendar time. Adhering to this schedule is critical for maximizing uptime and lifespan.
The schedule uses both calendar time (e.g., monthly checks) and operating hours (tracked by the Duty Time Counter - DTC). It's crucial to follow whichever interval comes first for a given task. Ignoring scheduled maintenance can lead to unexpected failures and potentially costly repairs.
Visual inspection of all axes] C -.-> G[Check: Oil levels,
Mechanical stops,
Motion range] D -.-> H[Replace: SMB Battery if needed,
Check: All fasteners,
Lubricate specified points] E -.-> I[Replace: Oil in all gearboxes,
Potentially cable harness] style A fill:#4192f6,color:white style B fill:#4192f6,color:white style C fill:#4192f6,color:white style D fill:#4192f6,color:white style E fill:#4192f6,color:white
Oil Level Checks
The manual details procedures for checking oil levels in all six gearboxes. Although typically checked during scheduled maintenance, familiarizing yourself with the plug locations and correct levels is beneficial.
Incorrect oil levels can lead to overheating or insufficient lubrication, causing premature gearbox failure.
Example Oil Plug Location (Axis 1)
Balancing Device
This critical component counteracts gravity's effect on the arm, reducing motor load and improving performance. Regular inspections are essential.
- Check for unusual noises (dissonance) during operation
- Inspect for physical damage or deformation
- Check for leaks from seals
- Ensure it has free space to move without obstruction
Failure of the balancing device can lead to severe performance degradation or dangerous uncontrolled movements if brakes fail.
Balancing Device Inspection Points
Cable Harness
Regular visual and tactile inspection, especially around high-flex areas near axes 2 and 3, is essential. Look for chafing, cuts, cracks, or loose connections.
Damaged cables can cause intermittent faults that are hard to diagnose or lead to complete system failure. Pay attention to routing and securing elements (brackets, straps).
Cable Harness Inspection Area Example
SMB Battery Replacement
This battery maintains the revolution counter memory when the robot controller is powered off. Replace it according to the schedule or when the "Battery charge low" warning (38213) appears.
Delaying replacement risks losing the robot's synchronization, requiring recalibration. Always update revolution counters after replacement.
SMB Battery Location
Component Life Expectancy
The manual provides estimates for major components like the cable harness and gearboxes (e.g., 40,000 hours under normal usage). These are guidelines, and actual life depends heavily on application intensity, environment, and maintenance adherence.
Use these figures for proactive planning, especially for components like the harness which might require replacement before outright failure based on inspection and age.
Pro Tip:
Consider keeping a log of the robot's duty cycles and operating conditions. Robots used in high-intensity applications or harsh environments may require more frequent maintenance than the standard schedule indicates.
Mechanical Stops & Dampers
Check for deformation or damage, especially after any suspected collision. Damaged stops or dampers won't provide the intended protection, potentially leading to more severe damage in a future incident.
Axis 2/3 Damper Locations
Replacement & Lubrication Activities
Oil Changes
Gearbox oil degrades over time. Scheduled changes (e.g., every 20,000 operating hours for most axes) are vital for gearbox longevity.
- Always use the specified oil type
- Follow procedures carefully to avoid over/underfilling or contamination
- Remember safety precautions for handling hot oil
- Dispose of used oil according to environmental regulations
Proper oil maintenance is directly correlated with gearbox lifespan and performance quality.
Balancing Device Lubrication
The spherical roller bearing in the balancing device link ear requires periodic greasing to ensure smooth operation.
- Use only the recommended grease type
- Apply according to the maintenance schedule
- Inspect for proper grease distribution
- Wipe away excess grease to prevent contamination
Proper lubrication significantly extends component life and maintains optimal performance.
Calibration: Ensuring Precision
Calibration ensures the robot knows precisely where its axes are, which is fundamental to accurate path following and positioning. It's not just a setup task; it's fundamental to the robot's performance and safety. Incorrect calibration is a common source of errors and potential damage.
When is Calibration Necessary?
- After replacing components affecting axis positioning (motors, gearboxes, arm segments)
- Following a significant crash or mechanical overload
- After loss of revolution counter data (e.g., dead SMB battery, resolver fault)
- When relocating the robot to a new position or foundation
Standard Calibration
Uses the Calibration Pendulum method to set the robot's zero position accurately. This is the baseline calibration ensuring the robot knows its zero position accurately relative to its internal motor resolvers.
- Essential for repeatable programmed paths
- Data is stored on the Serial Measurement Board (SMB)
- Required after component replacement
- Establishes the foundation for all robot movements
Absolute Accuracy (Optional)
A more advanced calibration (using CalibWare) that compensates for minor mechanical deviations throughout the robot structure, providing higher TCP accuracy in Cartesian space.
- Builds upon standard calibration
- Compensates for minute mechanical tolerances and deflections
- Results in much higher positioning accuracy in the Cartesian (XYZ) workspace
- Indicated by a special label on robots with this option
Revolution Counter Updates
This is the most common calibration-related task. If the robot loses track of how many full turns an axis has made (e.g., after battery replacement or moving an axis manually while powered off), its absolute position is unknown.
The Process:
- Manually jog the robot so the calibration marks on each axis align
- Use the FlexPendant's Calibration menu to update the counters
- Verify the calibration by moving to the zero position
- Check that all marks align perfectly
Calibration Marks Example
Critical Point for Axes 4 & 6
Due to gear ratios, these axes can appear aligned at the wrong revolution. Always verify against the calibration label values, not just the visual marks, before updating. Losing the correct turn count requires a full standard calibration.
Checking Calibration
Always verify the calibration after updating revolution counters or performing any calibration. This step is crucial but often overlooked.
Verification Methods:
- Use the Jogging menu to move each axis to its 0 position
- Run a simple
MoveAbsJprogram to[[0,0,0,0,0,0],...] - Visually confirm that all calibration marks align perfectly
- Check that position readouts on the FlexPendant show zero for each axis
Repairs & Troubleshooting
While the IRB 6700 is built for demanding environments, components will eventually require repair or replacement. The manual provides detailed step-by-step procedures, but approaching these tasks requires careful planning and a troubleshooting mindset.
Understanding Repair Complexity & Essential Tools
Tiered Difficulty
Repairs range vastly in complexity. Replacing an SMB battery is relatively straightforward compared to replacing a major gearbox or the entire cable harness.
Major component replacements often involve partial disassembly of the robot structure.
Special Tools are Not Optional
The manual lists required special tools for many procedures. These include specific lifting accessories, guide pins, rotation tools, and potentially calibration equipment.
Attempting major repairs without the correct tools is highly likely to result in component damage, incorrect assembly, prolonged downtime, and safety hazards.
Lifting Equipment is Critical
Many components are heavy (e.g., Axis 1 motor ~21kg, Axis 2/3 motors ~24-26kg, Axis 2 gearbox ~83kg, Wrist ~110kg, Upper Arm ~200kg).
Never underestimate the weight or attempt manual lifts beyond safe limits. Using the designated lifting points and accessories ensures both personnel safety and prevents damage to the robot.
Common Pitfalls During Repair & Reassembly
- Cable Management: Pay meticulous attention to the specified routing paths during reassembly. Incorrect routing can lead to chafing, pinching, or exceeding the cable's bend radius.
- Seal Integrity: Always inspect seals and O-rings during reassembly, lubricate them lightly with appropriate grease, and replace any that appear damaged.
- Motor/Gearbox Mating: Ensure the motor pinion meshes correctly with the gearbox gear. Use the rotation tool and potentially release the brakes (with the arm safely supported!) to gently align the gears.
- Torque Specifications: Adhere strictly to the specified tightening torques for all screw joints. Use calibrated torque wrenches.
- Post-Repair Calibration: Replacing motors or gearboxes requires recalibration (standard calibration minimum, potentially AbsAcc).
Example Lifting Accessory Attachment (Upper Arm)
Troubleshooting Mindset
1 Observe and Document
When issues arise, note the exact symptoms, error codes displayed on the FlexPendant, and the robot's operational state when the fault occurred.
2 Check the Basics
Before assuming a major component failure, check simple things: Are all cables securely connected? Are safety circuits engaged (E-stops, gates)? Is power supply stable?
3 Consult Logs
The controller logs events and errors. Reviewing these can provide vital clues to the root cause of a problem (Refer to Operating manual - Trouble shooting IRC5).
4 Isolate the Problem
If possible, try to determine which axis or component is causing the issue. Jogging axes individually or running specific test routines can help pinpoint the source.
Cabling Integration: DressPack and Beyond
How external cables and hoses for tooling (air, power, signals) are routed along the robot arm significantly impacts reliability and maintenance.
Standard vs. Integrated DressPack (LeanID - Option 780-4)
Standard Routing
External cabling is typically routed along the outside of the arm using brackets and clamps. This offers flexibility but can be prone to snagging, chafing, or interference depending on the application and routing quality.
LeanID (Integrated)
Routes the main process cabling inside the upper arm and wrist. Offers superior protection for the tool cabling, reducing wear and snagging risks, which can increase uptime in complex or harsh environments.
LeanID may have slightly different working range limitations on axes 5 and 6 and requires specific procedures during maintenance or repair that involves the upper arm or wrist. Accessing or replacing the integrated cabling also follows a different process.
LeanID Tool Flange
Decommissioning: Handling End-of-Life Safely
The manual outlines decommissioning, emphasizing environmental responsibility and safe scrapping procedures.
Balancing Device Hazard
The most critical point is the safe handling of the balancing device. It contains highly tensioned springs storing significant potential energy. Never attempt to disassemble it yourself. It requires specialized procedures involving carefully cutting the springs with a torch in a controlled environment by a qualified decommissioning company. Improper handling is extremely dangerous.
Other Decommissioning Considerations
- Drain all oils/greases and remove batteries before scrapping begins to prevent fires or explosions when cutting torches are used
- Follow local environmental regulations for disposal of electronics, oils, and other materials
- Ensure all lockout/tagout procedures are followed during dismantling
- Document the decommissioning process for future reference
Decommissioning an industrial robot is not a simple task. It requires careful planning and expert knowledge to ensure safety and environmental compliance.
Balancing Device Decommissioning Cut Zone
Optimizing Performance: Working Range, Motion, and Operational Modes
Beyond the physical installation and basic maintenance, understanding how the IRB 6700 moves and how to interact with it safely during operation and programming is key to maximizing efficiency and preventing accidents.
Mastering the Workspace: Working Range Insights
Visualizing the Envelope
The diagrams illustrate the maximum reach. It's crucial for system designers to consider not just the maximum reach but the entire usable envelope for the specific application.
- Will the robot need to work close to its base?
- Does it need to reach below its mounting plane?
- Ensure the chosen model (e.g., 2.65m reach vs. 3.20m reach) comfortably accommodates all required tool points without exceeding joint limits
Working Range Example (IRB 6700-150/3.20)
Turning Radius & Rear Swing
Pay attention to the turning radius diagrams. The rear swing of the robot (axis 1 rotation) requires significant clearance behind the base. This is a common oversight in cell design that can lead to collisions or necessitate restrictive working range limits.
Turning Radius Diagram
Axis Limitations & Singularities
- While Axis 1 has mechanical stops (and optional added stops), and Axes 2 & 3 have software limits, Axes 4, 5, and 6 also have defined ranges
- Axis 4 often defaults to ±300°, Axis 5 to ±120°/130°, and Axis 6 to ±360° (or ±220° with LeanID)
- Exceeding these limits during programming will cause errors
Beyond the Manual (Singularities):
Programmers must be aware of potential wrist singularities (where axes 4 and 6 align) and potentially shoulder/elbow singularities. Programming movements through a singularity can cause unpredictable high-speed axis rotations or halts.
LeanID Working Range
Note the specific working range limitations for Axis 5 (±120°) and Axis 6 (±220°) when using the LeanID option (780-4). This slightly reduced wrist flexibility is a trade-off for the integrated cabling's protection and potentially longer life.
LeanID Axis 5/6 Working Area
Safe Operation: Understanding Modes and the FlexPendant
Interacting with the robot, especially during setup, programming, and testing, requires strict adherence to safety procedures related to operating modes.
Manual vs. Automatic Mode
This is the primary safety division. The mode selector key switch on the IRC5 controller dictates how the robot can be operated.
-
Automatic Mode: Allows production runs controlled by the program. Safety fences must be closed and interlocked. Personnel are never permitted inside the safeguarded space.
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Manual Mode: Required for programming, testing, and some maintenance tasks inside the cell. This mode enables specific safety features on the FlexPendant.
The Critical Enabling Device
Located on the FlexPendant, this 3-position device is the programmer's primary safety control in manual mode. It allows motion only when held in the middle position. Releasing it or squeezing it fully triggers an immediate "Motors Off" state.
Why it Matters:
It acts as a dead-man's switch combined with a panic function. It must never be taped down or bypassed. Anyone entering the cell in manual mode must take the FlexPendant with them to maintain control and prevent unexpected remote activation.
Manual Mode Speeds
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Reduced Speed (≤250 mm/s): This is the default and recommended speed for manual operation inside the cell. It provides reaction time for the operator.
-
Full Speed (Manual Mode 100%): Allows testing at production speed but significantly increases risk. It should only be used by highly trained personnel fully aware of the program path and potential hazards.
Working Inside the Cell
- Always be in Manual Reduced Speed mode unless absolutely necessary and risks are fully assessed
- Keep the FlexPendant with you (with the enabling device)
- Be aware of all moving axes, not just the TCP
- Keep clear of potential pinch points or entanglement areas
- Never position yourself under the arm – unexpected drops can occur
- Perform brake tests regularly, especially before performing tasks requiring close proximity
Related Guides & Resources
Getting Started: Unboxing & Initial Checklist
Practical first steps for new users and installers, including a comprehensive checklist to ensure proper initial setup.
Essential Maintenance Schedule & Component Life Guide
A detailed maintenance timeline and lifespan estimates for all major components to maximize robot uptime and longevity.
Maximizing Precision: Calibration Guide
In-depth explanation of the calibration process, covering standard calibration and Absolute Accuracy for optimal precision.
Essential Safety Protocols Guide
Comprehensive safety guidelines for operating and maintaining the IRB 6700, addressing all critical safety concerns.
Troubleshooting Common IRB 6700 Problems
Solutions for frequent issues including SMB communication errors, motion problems, and error code interpretation.
IRB 6700 Variants Deep Dive
Detailed comparison of the different IRB 6700 models from 150/3.20 to 235/2.65, analyzing payload, reach, and performance metrics.
Conclusion
Installing and maintaining the ABB IRB 6700 robot is a task demanding precision, adherence to safety protocols, and the right expertise. While the product manual provides the essential steps, understanding the reasons behind these procedures empowers installation teams to perform their tasks more effectively and safely.
Careful planning, meticulous execution of lifting and securing procedures, and unwavering attention to safety are paramount to unlocking the full potential and ensuring the long-term reliability of this robotic powerhouse. Following these guidelines sets the stage for successful commissioning and productive operation.
This guide has provided insights beyond the basic manual, focusing on practical knowledge that helps maintenance personnel, system integrators, and operators get the most out of their investment in ABB robotics technology.