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Risk management during installation of paint robotsIntroductionRisk management refers to the practice of identifying potential risks in advance, analyzing them and taking precautionary steps to reduce/curb the risk (defined as the effect of uncertainty on objectives).Risk management is prioritization of risks followed by coordinated and economical application of resources to minimize, monitor and control the probability and/or impact of unfortunate events or to maximize the realization of opportunities. 2

Steps involved in risk managementProcess of dealing with risks is carried out in following four steps.Identifying the risk.Assessing the risk involved.Evaluation of the factors causing risks and processing how to deal with it.Controlling and monitoring the risks involved.

Processing risk managementSafety risks related to installationGENERALThe robot must not be used for other purposes than intended for as described in the robot manuals or accepted by ABB. Electronic components must not be installed in the control cabinet unless certified by ABB. All components used together with the robot must comply to national standards.Qualified PersonnelThose who install the robot must have the appropriate training for the robot system and in any safety matters associated with it.Emergency Stop ButtonsThe robot includes emergency stop switches on the control cabinet and on the pendant. Additional emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. Note that the control cabinet may be supplied without emergency stop.Emergency Brake ReleaseIf required, an emergency brake release button may be installed. The need for this button to be installed must be determined by those responsible for the installation and the hazards involved.Safety Instructions Those in charge of operations must make sure that safety instructions are available for the installation.Nation/Region Specific RegulationsTo prevent injuries and damage during installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics, must be complied with.Ex Installation Installing the robot in an area with explosion hazard must be performed in accordance with the local standards for the area. To be Observed by the Supplier of the Complete SystemThe supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function. The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.Fail Safe Valves Any valves etc. used for controlling the applicator and other external equipment must be installed in a fail safe manner. Valves opening for fluid, air etc. must be installed in such a manner that they will be closed by emergency stop / general mode stop.Fluid Supply According to requirement in applicable standards, it must be possible to switch off the fluid supply system in a safe manner from outside of the spray booth.Ground Connections Ground connections must be installed in accordance with local standards.

Applicator Control SignalsInstallation of applicator control signals must comply with user specifications and local standards concerning interlocking with spray booth ventilation to ensure that the applicator cannot be operated with spraying material when the cabin ventilation is stopped or is out of function etc. Purging Air Purging air supply and purging time must be according to requirements stated on the robot certification label.Associated Components All components associated with the robot which are installed in the hazardous area must be of a type certified for such use and connected accordingly.Ex: Lights.Welding, Burning and GrindingWelding, burning and grinding work must only be carried out on the installation/robot if this has been approved explicitly. Be aware for fire and explosion hazard. Before welding, burning and grinding, clean installation/robot and its environment from dust and combustible materials and ensure that there is enough ventilation.

Welding Safety PrecautionsWelding on the control cabinet, manipulator or any other components of the robot system should be avoided as it can cause severe damage to the electronic components in the system. If welding can not be avoided, all electronic components should be removed or disconnected before welding is performed. Also make sure that the ground connection of the welding equipment is made directly on the component where the welding is performed. If welding is performed in the robot installation, all cables should be disconnected from the control cabinet before welding. By new installations, all welding work must be performed before any cables are connected. All welding work must be performed with great care. It is the full responsibility of the user to make sure that the welding work does not damage any electronic components.Safeguarding the Working AreaThe working site for the manipulator must be safe guarded in such a way that no person can enter the working area unintentionally. Following points must be followed when arranging the working area for the manipulator.The entrance door to the spray booth must be interlocked with the robots control system. This will stop the robot in auto mode, and requires that the enabling device on the pendant is held depressed to keep robot active in manual reduced speed and high speed mode when the door is opened.

Other entrances such as the entrance and exit for the conveyor must be safeguarded by means of light curtain, sensitive mats etc. These entrances must be included in the emergency stop chain. If required, indicators for indication of applicator operation must be installed at the booth. It is the full responsibility of the user to make sure that all entrances to the working area of the robot are protected by Auto Mode Stop switches. This is essential to prevent personnel from entering the working area of the robot while the robot is in operating mode (Auto).

If the manipulator is not installed in the confined space of the spray booth, necessary fences, guards, sensitive mats, light curtains etc. must be provided to prevent people from entering the working area of the manipulator during operation. The fence must be dimensioned to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. The maximum speed is determined from the max. velocities of the robot axes and from the position at which the robot is working in the work-cell.Manipulator Mounting BaseThe manipulator should be installed on a strong concrete floor or a strong mounting base. The mounting base must be strong enough to support the weight of the manipulator and to take up the dynamic forces applied by the manipulator during operation. For information on design, applicable forces etc., refer to Product Manual, Robot / Installation and Commissioning.Fire Extinguishing The spray booth shall fulfil safety requirement of applicable standards. If an electrostatic spraying system is used, the spray booth shall be equipped with an automatic fire extinguishing system. Fire extinguishers located by the installation must be CARBON DIOXIDE (CO2) extinguishers in the event of a fire in the robot (manipulator or controller).Alternative Installation Special measures must be taken if the manipulator is installed in an upside/down position or on a wall etc.

Passing Obstructions The manipulator must be positioned so that obstructions can be passed at a safe distance. This applies especially to spaces where personnel may be located for programming and testing purposes.Manipulator Working AreaThe working area for the manipulator must be restricted by mechanical stops to the largest possible extent within the limits for being able to perform the required operations.

How to deal with an emergencyStop the System

Action If an emergency situation occurs, press any Emergency Stop Button to stop the robot and the operation in the spray booth.

Emergency Situations Stop the system immediately if: The robot has caused personal injury. The robot is at risk of causing personal injury. A person is spotted within the robot working area, while the robot is running. The robot has caused harm to mechanical equipment. The robot is at risk of causing harm to mechanical equipment.Location of Emergency Stop ButtonsEmergency stop buttons are located on the pendant and on the control cabinet front panel. Additional emergency stop buttons may be located in convenient places at the spray booth. Other emergency stops such as auto mode stop and general mode stop shall be installed as part of the safety system for a complete installation such as safeguarding spray booth entrance door etc.

Definition of Emergency Stop

An emergency stop is a state that overrides any other robot control, disconnects drive power from the robots motors, stops all moving parts and disconnects power from any potentially dangerous functions controlled by the robot system such as paint supply, high voltage etc.The robot system can be configured so that the state results in either: An uncontrolled stop, immediately stopping the robots action by disconnecting power from its motors and activating motor axis brakes (Emergency Stop Category 0). Category 0 stops are; Emergency Stop, Auto Mode Stop, General Mode Stop and Test Mode Stop. A controlled stop, stopping the robots action with power available to its motors so that the robots programmed path can be maintained. When the stop sequence is completed, power is disconnected and motor axis brakes activated. Category 1 stop is named Delayed Stop. Controlled stops are preferred since it minimizes the actions needed to return the robot system back to production and stop the movement fastest. Please consult your plant or spray booth documentation to see how your robot system is configured.Overview Risk management is prioritization of risks followed by coordinated and economical application of resources to minimize, monitor and control the probability and/or impact of unfortunate events or to maximize the realization of opportunities.Steps involved in risk managementIdentifyAssessEvaluateControl monitorThe Emergency stop buttons should be fail safe.Check for poor ground connection of objects.Risk analysis of the complete installation must be performed before the installation is permitted to be set into operation.Welding on the control cabinet, manipulator or any other components of the robot system should be avoided as it can cause severe damage to the electronic components in the system. The working site for the manipulator must be safe guarded in such a way that no person can enter the working area unintentionally.

Risk Analysis Risk analysis of the complete installation must be performed before the installation is permitted to be set into operation.Conclusive Action The installation check list must be signed when the installation has been finished. The installation check list is part of the documents on delivery and is filed in the control cabinet.

Conclusion