Overview
The ABB IRB 6700 is a powerful and versatile industrial robot capable of significantly enhancing productivity. However, its power and speed also necessitate a rigorous approach to safety. Missteps during installation, operation, or maintenance can lead to severe injury or costly equipment damage. This guide consolidates critical safety information, drawing directly from the product manual, but goes further to explain why these protocols matter and how to implement them effectively in real-world scenarios.
Safety Mindset: Beyond Rules
Safety isn't just about following rules; it's a mindset and a shared responsibility. Only through comprehensive understanding and consistent application of safety protocols can we ensure protection for both personnel and equipment.
Key Audiences
- System Integrators
- Maintenance Personnel
- Operators
- Installation Engineers
Reference Documents
- ABB IRB 6700 Product Manual
- Operating Manuals
- Maintenance Schedule (Section 3.2.2)
- Local Safety Regulations
The Foundation: Understanding Shared Responsibility
System Integrator & User Responsibility
While ABB provides built-in safety features and guidelines, the ultimate responsibility for designing, installing, and operating a complete safe system lies with the system integrator and the end-user. This includes:
- Implementing appropriate guarding and barriers
- Interlocking external devices correctly
- Ensuring compliance with all local and national safety regulations
- Creating comprehensive risk assessments
Personnel Qualification
Only qualified personnel should interact with the IRB 6700 robot system:
Required Training
- ABB-provided training courses
- Mechanical expertise
- Electrical qualification
Critical Restrictions
- Never allow untrained personnel to operate the robot
- Never permit operation under the influence of alcohol or drugs
Non-Approved Parts & Modifications
Warning: Unauthorized Modifications
Using non-ABB-approved spare parts or making unauthorized modifications (like drilling holes or welding) can compromise the robot's structural integrity and safety systems. ABB is not liable for damages or injuries resulting from such actions.
Key Risks During Installation and Service
Installation and maintenance present unique hazards due to the potential for unexpected movement and the need to interact closely with the hardware.
Gravitational Force & Stored Energy
Robot axes are heavy and affected by gravity. Releasing brakes (manually or through system state changes) can cause sudden, forceful movements, leading to crushing or impact injuries. Additionally, the balancing device contains significant stored energy.
Mechanical Instability & Collapse
Never assume the robot is stable unless securely bolted to its foundation. Removing components, especially motors or parts of the arm structure, can lead to collapse if the remaining structure isn't properly supported.
Hot Components
Motors and gearboxes become very hot during operation. Contact can cause severe burns. Always check for radiating heat before touching components and allow adequate cooling time before handling.
Do Not Climb
Never use the manipulator as a ladder. Surfaces can be hot, oily, and slippery, posing a significant fall risk.
Hazard Deep Dives: Specific Dangers and Mitigation
Understanding specific hazards is crucial for targeted prevention. This section explores each category of risk in detail along with proven mitigation strategies.
ABB IRB 6700 Hazard Map
1. Electrical Hazards
Industrial robots operate with high voltages and potentially store dangerous levels of electrical energy even when switched off.
High Risk Areas
- Controller: Mains supply, power units, drive systems up to 700 VDC
- Manipulator: Motor power up to 800 VDC, user connections
- Stored Energy: DC link and Ultracapacitor units can retain a dangerous charge long after power is off
- External Power: I/O modules or connected equipment might remain live even when the robot controller is off
Mitigation - Lockout/Tagout (LOTO)
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ALWAYS switch off and lock out the main power supply at the controller cabinet before performing any electrical repairs.
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Use a personal safety lock and tag to prevent others from re-energizing equipment.
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Only qualified electricians should perform work on electrical equipment.
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Ensure the mains supply can be disconnected from outside the robot's working cell.
Best Practice
Work should ideally be done in an isolated state (disconnected from power and protected against reconnection). Follow discharge procedures to safely dissipate stored energy before handling components.
2. Thermal Hazards (Hot Components)
Motors and gears generate significant heat during operation, posing burn risks to personnel.
Risk Factors
- Direct contact causes burns
- High ambient temperatures exacerbate risks
- Components remain hot for extended periods after operation
Mitigation Strategies
Cautious Testing
Test surfaces cautiously for heat before touching. Approach components slowly and feel for radiating heat.
Cooling Time
Allow ample cooling time before maintenance or removal of hot components.
Protective Gear
Wear appropriate thermal-resistant gloves if handling warm components is unavoidable.
Warning Signs
Use warning signs or labels to indicate recently operated equipment that may still be hot.
3. Mechanical Hazards
The physical movement and mechanical nature of the robot create several significant risk categories.
Crushing & Pinch Points
Be aware of pinch points between moving arms, the robot base, and peripheral equipment or guarding.
Mitigation
Maintain safe distances and utilize proper guarding (safety fences). Always be aware of the robot's potential movement envelope.
Unexpected Movement
Robots can move unexpectedly, even during programming or manual operation.
Mitigation
Always use the enabling device ("Dead Man's Switch") correctly when inside the cell. Release it immediately when motion is not required.
Tipping & Instability
An unsecured robot is inherently unstable. Do not unbolt or move the robot unless it's in the designated transport position and properly secured.
Mitigation
Always secure the robot to its foundation before operation. Follow correct procedures for transportation and positioning.
Brake Release
Releasing brakes can cause sudden movement due to gravity. Significant harm can result from improper handling.
Mitigation
Follow correct procedures when releasing brakes or moving axes manually. Never release a brake unless the axis is properly supported.
Critical Safety Rule
NEVER stand beneath any robot axis. Maintain awareness of all moving parts, including tooling. Stay clear of potential pinch points and rotating axes.
4. Pneumatic/Hydraulic Hazards
These systems can store residual energy and cause unexpected movements or injuries.
Risk Factors
- Stored pressure can cause sudden movements
- Forceful ejection of components upon disconnection
- Hydraulic fluid leaks can cause injection injuries
- Fire hazards from hydraulic fluids
Mitigation Strategies
Release System Pressure
Always release system pressure completely before starting repairs or maintenance. Look for designated drain facilities and warning signs.
Specialized Training
Only personnel with specialized hydraulics training should work on hydraulic systems.
Regular Inspection
Regularly inspect hoses and connections for leaks or damage. Repair immediately to prevent escalation into hazardous failures.
5. Tooling & Workpiece Hazards
End-effectors (grippers, tools) and the parts they handle introduce specific risks beyond the robot itself.
Primary Risks
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Workpiece Drops: Parts can be dropped due to power failure, system disturbances, or incorrect gripping
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Rotating Tools: Milling cutters and other rotating tools pose cutting and entanglement hazards
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Gripper Force: Powerful grippers can crush fingers or hands if caught between jaws
Mitigation Requirements
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End-effectors must be designed to retain the workpiece safely in case of power loss (fail-safe design)
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Ensure rotating tools have guards that remain closed until the tool stops completely
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Implement manual overrides (e.g., valves) to safely release parts or stop tools if necessary
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Tool change procedures must ensure no accidental dropping of tools during exchange
6. Chemical Hazards (Lubricants)
Gearbox oils and greases require careful handling to prevent injuries and environmental damage.
Risk Factors
- Hot lubricants can cause burns
- Some individuals may have allergic reactions to lubricants
- Spills pollute the environment
- Pressurized gearboxes can spray lubricant when opened
Mitigation Strategies
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Wear protective goggles and gloves when handling lubricants
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Handle hot lubricants with extreme care; allow adequate cooling time
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Open drain/fill plugs carefully to release any potential pressure buildup
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Dispose of used oil and grease according to local environmental regulations
Important Note on Lubricant Selection
Use the correct type of lubricant specified by ABB; mixing oils can damage the gearbox. Never overfill gearboxes - check levels correctly after filling by following the proper procedure in the manual (usually allowing time for the oil to settle).
7. Electrostatic Discharge (ESD) Hazards
Sensitive electronic components, particularly on the Serial Measurement Board (SMB), can be damaged by static electricity.
Risk
Static discharge from ungrounded personnel can destroy electronic boards, leading to equipment malfunction, data loss, and costly replacements.
Mitigation Measures
- Always use a tested and functional ESD wrist strap connected to the designated grounding point on the controller or robot before handling sensitive components
- Utilize ESD protective mats (floor, table) when available
- Keep components in their anti-static packaging until installation
- Avoid wearing synthetic fabrics that generate static electricity when working with electronic components
8. Battery Handling Risks
Batteries (used for SMB memory backup) contain potentially hazardous materials that require proper handling.
Risks
- Short-circuiting can lead to fire or explosion
- Charging non-rechargeable batteries can cause rupture
- Puncturing or exposing to high temperatures can release toxic materials
- Leakage can cause chemical burns
Mitigation
- Handle batteries carefully, wearing safety glasses
- Never attempt to recharge non-rechargeable batteries
- Store and dispose of batteries according to local regulations
- Follow replacement intervals or heed "Battery Low" warnings
Essential Safety Actions & Procedures
Beyond understanding risks, knowing the correct safety actions is vital for protecting both personnel and equipment.
Emergency Stops (E-Stops)
E-Stop Function
An E-stop overrides all other controls, cutting drive power to motors and stopping motion immediately.
Emergency Stop Types
Category 0 Stop (Uncontrolled)
Immediate power cut to motors. The robot may deviate from its programmed path as it stops immediately. This is the default and most immediate stop type.
Category 1 Stop (Controlled)
Path maintained during stop, then power cut. The robot follows its programmed path during deceleration, minimizing wear on mechanical components.
E-Stop Locations
- Controller cabinet
- FlexPendant
- Additional cell-specific E-stops (cell integration)
Important Usage Notes
- E-stops are for emergencies only. Do not use them for routine program stops, as this causes unnecessary wear.
- Ensure E-stops are clearly marked and easily accessible from all necessary locations.
Working Safely Inside the Robot Cell
Entering the safeguarded space requires strict adherence to procedures to prevent accidents.
Safe Cell Entry Protocol
Mode Selection
ALWAYS switch the controller to Manual Mode (usually <250mm/s or "Reduced Speed").
Enabling Device
Use the 3-position "Dead Man's Switch" on the FlexPendant. It allows motion only when held in the middle position.
Take Control
Anyone entering the cell must take the FlexPendant with them to prevent others from starting the robot unexpectedly.
Critical Safety Awareness
Pay close attention to all moving parts, including tooling. Stay clear of potential pinch points and rotating axes. NEVER stand beneath any robot axis.
Emergency Brake Release
In emergencies (e.g., freeing a trapped person), brakes can be manually released via buttons on the robot. This is an extreme measure that must be handled with proper training and caution.
Extreme Caution Required
Warning: Releasing brakes allows axes to fall due to gravity. Ensure releasing a brake will not worsen the situation for a trapped person.
Larger robots may require overhead cranes to support the arm during manual movement.
Post-Service Check
After service involving the brake release unit, always check that the release buttons are not jammed in the pressed position before reapplying power (Section 1.3.5). A jammed button means the brake for that axis is disengaged.
Manual Brake Release Procedure
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1
Assess the situation carefully. Determine if releasing the brake will help or harm the trapped person.
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2
If the controller is off, supply power to the R1.MP connector to enable the brake release.
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3
For heavy axes, provide mechanical support (such as a crane) before releasing the brake.
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4
Press and hold the brake release button for the specific axis that needs to be moved.
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5
Carefully move the axis to free the trapped person, minimizing additional movement.
Brake Testing
Holding brakes wear over time. Regular testing ensures they can still hold the arm and payload safely.
Test Procedure
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1Jog the robot axis to its maximum static load position (where gravity has the greatest effect).
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2Switch the controller to MOTORS OFF.
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3Observe if the axis maintains its position. If there is no drift, the brake function is adequate.
Testing Frequency
- Perform periodically as part of preventative maintenance
- After any work on the brake system
- If any unusual drift is suspected
- After long periods of inactivity
Documentation
Document all brake tests in your maintenance log, noting the date, results, and any observations. This creates a valuable record of brake performance over time, helping to identify degradation before failure occurs.
Critical Procedures Demanding Extra Vigilance
While all safety protocols are important, certain situations carry heightened risk and require meticulous execution.
First Test Run After Service or Installation
Performing the first operational test after any repair, component replacement, or initial installation is one of the most critical phases. Disassembled or newly fitted components may not function as expected, creating significant potential for injury or damage.
Why the Heightened Risk?
- Incorrect Assembly: Components might be misaligned, improperly secured, or incorrectly connected.
- Software/Hardware Mismatch: Parameter changes or component swaps might not be correctly reflected in the robot's control system.
- Foreign Objects: Tools or debris might have been inadvertently left within the robot's mechanism or workspace.
- Unexpected Motion: The robot's actual movement might deviate significantly from the programmed path due to calibration issues or incorrect repairs.
Mandatory Pre-Test Run Safety Checklist
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1Clear the Zone: Remove ALL tools, spare parts, rags, and any other foreign objects.
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2Secure Fixtures/Workpieces: Double-check that any workpiece, fixture, or tooling is securely mounted.
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3Verify Safety Equipment: Ensure all safety guards, fences, light curtains, and E-stops are functional.
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4Personnel Distance: ALL personnel must be outside the safeguarded space.
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5Focus on Serviced Parts: Pay extra attention to recently serviced components.
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6Anticipate Collisions: Verify robot paths carefully at low speed before increasing velocity.
Protecting Integrated Safety Functions
The IRB 6700 relies on precisely configured parameters for its safety functions, particularly the "Reduced Speed 250 mm/s" limit crucial for safe manual operation within the cell. Altering certain parameters improperly can disable or compromise these vital protections.
Kinematic Parameters (e.g., Transm gear ratio)
DO NOT change the transmission gear ratio or other core kinematic system parameters via the FlexPendant or an external PC unless explicitly instructed by authorized ABB procedures. Modifying these can directly affect the robot's calculation of its speed, potentially causing it to move much faster than the intended 250 mm/s limit in Reduced Speed mode, creating an extreme hazard for anyone inside the cell.
Revolution Counters
If internal measurement system cables (SMB cables) are disconnected during maintenance or repair, the robot loses track of its absolute axis positions. Failure to correctly update the revolution counters before operating the robot can lead to large, unexpected movements as the controller attempts to move to what it thinks is the correct position. Always follow the correct revolution counter update procedure after such work.
Configuration Files
Only use ABB-approved methods and software (like RobotStudio) for modifying robot configuration files (.cfg). Incorrect changes can impact safety logic and performance.
The core takeaway:
Treat the robot's core configuration parameters with extreme caution. Unauthorized or incorrect changes directly impact safety integrity.
Jammed Brake Release Buttons: A Hidden Danger
After performing service work within the SMB recess (where the brake release buttons are housed), especially if the brake release unit was removed and refitted, there's a risk the buttons could become jammed in the depressed state.
The Hazard
If power is applied while a button is jammed down, the corresponding motor brake will be released, allowing the axis to potentially fall unexpectedly due to gravity.
Verification Procedure
ALWAYS manually check each brake release button after working in the SMB area before restoring power. Press each one individually. They should move freely and return to their normal position.
If a button is stuck, the brake release unit must be readjusted or repaired before powering on.
Physical Handling: Lifting, Transporting, and Stability Risks
Moving and installing a heavy industrial robot like the IRB 6700 involves significant risks if not done correctly. Tipping and instability are major concerns.
The Cardinal Rule: Secure the Robot FIRST!
An unbolted IRB 6700 is mechanically unstable throughout most of its working range. Moving the arms shifts the center of gravity, creating a serious tipping hazard.
Transport Position
The designated shipping/transport position is the most stable configuration for an unsecured robot. Do not jog the robot out of this position until it is securely bolted to its foundation or properly prepared for lifting according to ABB-approved methods.
Foundation Requirements
The robot base must be secured to a foundation that meets the specified requirements for levelness (max deviation 0.2 mm across attachment points) and rigidity (minimum resonance frequency 22 Hz) to ensure stability and accurate performance.
Safe Lifting Procedures: Use Approved Methods ONLY
ABB provides specific, approved methods for lifting the IRB 6700. Deviating from these can lead to equipment damage or catastrophic failure of the lifting setup.
Method 1: Roundslings (Recommended)
- Use the designated lifting eyes (M20, 4 pcs) on the robot base
- Employ roundslings with the correct length (specified based on robot variant, e.g., 2.5m or 2.0m) and adequate lifting capacity (min. 2000 kg per relevant sling)
- Use the additional securing roundsling attached near the robot's upper arm/frame to prevent tipping during the lift
- Ensure slings are not damaged and do not rub against sharp edges
- Lift slowly and smoothly, ensuring the load is balanced
Method 2: Forklift (Requires Special Aid)
- This method is only permissible if the dedicated Fork Lift Device set (4 pockets, P/N 3HAC047054-002) is correctly installed on the robot base
- All four fork lift pockets must be fitted and properly tightened (Torque: 280 Nm) before attempting to lift
- Ensure the forklift has adequate capacity
- Move the robot slowly and maintain low ground clearance
Personnel Safety During Lifts
NEVER allow personnel to stand under a suspended load under any circumstances. Clear the area during lifting operations.
Handling the Balancing Device: Extreme Danger!
The balancing device (counteracting gravity on certain axes) contains powerful internal springs under high compression. Mishandling this unit is potentially lethal.
Stored Energy Hazard
The compressed springs store a massive amount of mechanical energy. Uncontrolled release can cause components to eject violently.
Under no circumstances should personnel attempt to open or disassemble the balancing device itself.
Specific Tools for Handling
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Distance Tool (3HAC030662-001): For locking the spring unit in a compressed state while installed on the robot. Used when refitting the same balancing device.
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Hydraulic Press Tool (3HAC020902-001): The only approved tool for safely unloading the springs of a new balancing device before installation or for unloading a device that cannot be compressed by jogging the robot.
Decommissioning
When scrapping the robot, the balancing device must be removed and sent to a specialized company or handled according to ABB's specific decommissioning procedure (using the hydraulic press tool and cutting torch) to safely release the stored energy before disposal.
Proactive Safety: The Role of Maintenance Inspections
Regular inspections, as outlined in the maintenance schedule (Section 3.2.2), are not just for ensuring uptime; they are fundamental safety practices.
Preventative Benefits
Early Detection
Inspecting oil levels, checking for leaks, examining the balancing device, inspecting dampers, and checking the cable harness allows for the early detection of wear or damage that could lead to component failure.
Preventing Failures
A failing gearbox (due to low oil), a damaged cable harness (causing short circuits or loss of control), or a leaking balancing device can all create unpredictable and hazardous situations during operation.
Key Inspection Examples
Cable Harness Inspection
Regularly checking the harness for wear, chafing (especially around axes 2 and 3), and secure connections prevents potential shorts or signal loss that could lead to erratic robot behavior.
Oil Level Checks
Ensuring correct oil levels prevents gearbox overheating and seizure, which could cause sudden stops or mechanical failure.
Maintenance as Safety Culture
Treat scheduled maintenance inspections as integral parts of your safety program. Addressing minor issues found during inspections prevents them from escalating into potentially dangerous failures.
By incorporating detailed considerations for physical handling and proactive maintenance into your standard operating procedures, you build multiple layers of safety around your IRB 6700 operations, protecting both personnel and equipment.
Conclusion
Working safely with the ABB IRB 6700 requires more than just knowledge; it demands constant vigilance, adherence to procedures, and a culture where safety is the top priority. By understanding the inherent risks, meticulously following the established protocols for installation, operation, and maintenance, and utilizing the robot's built-in safety features correctly, you can harness the power of the IRB 6700 productively and, most importantly, safely.
Beyond the Manual: Cultivating a Proactive Safety Mindset
- Risk Assessment: Before any non-routine task, perform a mental or formal risk assessment. What could go wrong? How can I prevent it?
- Never Bypass: Safety devices and software limits are there for protection. Never bypass or disable them.
- Documentation: Keep safety procedures readily available. Consult the manuals if unsure about any step.
- Situational Awareness: Always be aware of the robot's status, position, and potential movement paths, especially when working nearby or within the cell.
Always prioritize safety – shortcuts can have devastating consequences.
Back to TopUnderstanding Safety Symbols
Familiarize yourself with the graphical safety labels on the robot and controller. They provide quick, language-independent warnings about specific hazards.
Electrical Hazard
Risk of electric shock or electrocution
Hot Surface
Risk of burns from high temperature
Crush Hazard
Risk of hands being crushed
Heavy Load
Risk from suspended or heavy items
Lethal Danger
Risk of death or severe injury
Chemical Hazard
Risk from corrosive or toxic substances
Automatic Start
Equipment may start automatically
Hand Protection
Wear protective gloves
ESD Sensitive
Sensitive to electrostatic discharge
Eye Protection
Wear protective eyewear
Label Maintenance
Regularly inspect all safety and information labels on the robot and controller. Ensure they are present, clean, and legible. Replace any missing or damaged labels immediately.
Quick Safety Reference & Essential Tips
Fire Safety
In case of fire involving the robot or controller, use a CARBON DIOXIDE (CO₂) extinguisher.
Safety Labels
Regularly inspect all safety and information labels. Ensure they are present, clean, and legible. Replace any missing or damaged labels immediately.
Safety Fences
Design and install safety fencing robust enough to withstand the potential impact of the robot dropping its maximum payload at maximum speed, or the force from a malfunctioning rotating tool.
Check Connections
Before operation, ensure all electrical, pneumatic, and hydraulic connections are secure and undamaged. Look for signs of wear, loose connections, or leaks.