Risks arising from the robot have been reduced. However a residual risk remains since the robot is moved and operated with electrical voltage and electrical currents.
If activities involve residual risks, a safety message is made at the appropriate points. This includes potential hazards that may arise, their possible consequences, and describes preventive measures to avoid the hazards.
The following sign, applied on different parts of the robot, indicates that there is a potential electrical danger and that only qualified service personnel may install or service the robot system.
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ELECTRICAL SHOCK |
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Disconnect the electrical and pneumatic power supplies before carrying out any work on the robot. |
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Failure to follow these instructions will result in death or serious injury. |
Before powering up the system, make sure that all the electrical protection systems have been fitted and that there is no risk of electric shocks.
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ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH |
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oDisconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment. oAlways use a properly rated voltage sensing device to confirm the power is off where and when indicated. oOperate electrical components only with a connected protective ground (earth) cable. oVerify the secure connection of the protective ground (earth) cable to all electrical devices to ensure that connection complies with the connection diagram. oDo not touch the electrical connection points of the components when the module is energized. oProvide protection against indirect contact (EN 50178). oInsulate any unused conductors on both ends of the motor cable. |
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Failure to follow these instructions will result in death or serious injury. |
The robot mechanics are not supplied with external brakes nor an emergency stop switch to trigger any external brakes.
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ENTRAPMENT BY ROBOT MECHANICS |
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oProvide means for ensuring that the motors can be put into a voltage-free state with any internal holding brake or external service brake released. oMake available those means to allow one person to manually move the robot within reach of the zone of operation. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
The opening of the brakes may cause the robot to sag.
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SAGGING OF THE ROBOT |
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Ensure that the release of the motor brakes poses no subsequent risks in the zone of operation. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
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UNINTENDED MOVEMENT OR MACHINE OPERATION |
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Be sure that the "emergency stop" button is within reach and at hand to the controls used to power the robot. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
The safety devices must form an integral part of the design and installation of the machine. Operator training and compliance with the operating procedures constitute a major element in setting up the safety devices and systems.
Lexium S robots feature various interfaces that help the user to develop safety systems and devices for the machine.
NOTE: Do not use the emergency stop to power down the robot during normal conditions of use.
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CRUSHING, SHEARING, CUTTING AND HITTING DURING HANDLING |
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oObserve the general construction and safety regulations for handling and assembly. oUse appropriate mounting and transport equipment and use appropriate tools. oPrevent clamping and crushing by taking appropriate precautions. oCover edges and angles to protect against cutting damage. oWear suitable protective clothing (for example, protective goggles, protective boots, protective gloves). |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
Parts of the mechanics can move at high speeds. In such cases, the payload weight, additionally installed gripper, and shifts in the center of gravity of the moving parts contribute to the total energy of the forces generated.
Motion sequences can occur when operating with robot mechanics, which allow operational staff to make misjudgments. For safety considerations (according to EN ISO 13849-1), consider the controller and the brakes as non-safety-related elements. Ensure that necessary protective measures are implemented.
The safety standards and directives for the respective country where the equipment is in use define which protective measures are appropriate. Additionally, the system engineer who is responsible for the integration of the robot mechanics must evaluate which measures have to be taken.
NOTE: The configuration of the robot mechanics, the Tool Center Point (TCP) velocity, as well as the additional payload have an effect on the total energy, which can potentially be a source of damage and injury.
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CRUSHING, SHEARING, CUTTING AND IMPACT INJURY |
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oThe robot must be operated only within an enclosure. oOpen or enter the enclosure for cleaning and maintenance purposes only. oDesign the enclosure to withstand an impact from the robot and to resist ejected parts from escaping the zone of operation. oDesign the enclosure to safely deactivate the robot as soon as a person enters the zone of operation of the robot. oAll barriers, protective doors, contact mats, light barriers, and other protective equipment, must be configured correctly and enabled whenever the robot mechanics are under power. oDefine the clearance distance to the zone of operation of the robot so the operational staff do not have access to, nor can be enclosed in, the robot mechanics zone of operation. oDesign the enclosure to account for the maximum possible travel paths of the robot; that is, the maximum path until the hardware safety system limits as well as the additional run-on paths, in case of a power interruption. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
Certain robot working modes such as releasing the joint brake can lead to unforeseeable robot movements. For detailed information about travel path and power loss, refer to Run-on Motions of the Robot for Risk Analysis.
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UNINTENDED MOVEMENTS |
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Be sure that all persons are prohibited from entering or remaining in the isolation area in which the robot operates. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
Following maintenance work, whether it involves mechanical, electrical, pneumatic, or software operations, it is advisable to make sure that the robot functions correctly. First verify this at low speed while the person stays outside the enclosure, and then during normal conditions of use. In particular, make sure that all the protective and safety systems are correctly in place, and that calibration of the robot is correct.
The robot is capable of strong accelerations and decelerations. Verify in the application whether:
oThe robot hand and the tool are correctly sized and firmly fixed in place.
oThe gripper is designed to hold the load with programmed accelerations and in the event of an electrical power or air failure affecting it.
oThe robot is correctly attached.
The controlled area or isolation area in which the robot moves must be determined using protective devices (protective elements).
NOTE: Protective elements are devices protecting persons from a dangerous area. See the standards currently in force concerning safety for industrial handling equipment.
At the time of an emergency stop, the final position of the robot cannot be determined precisely because of the kinetic energy involved. It is thus necessary to make sure that no persons or obstructions are present in the working area of the robot when the robot is powered up.
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UNINTENDED MOVEMENTS |
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Be sure that all persons are prohibited from entering or remaining in the isolation area in which the robot operates. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
The metal surfaces of the robot may exceed 80 °C (176 °F) during operation.
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HOT SURFACES |
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oAvoid unprotected contact with hot surfaces. oDo not allow flammable or heat-sensitive parts in the immediate vicinity of hot surfaces. oVerify that the heat dissipation is sufficient by performing a test run under maximum load conditions. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
There can be different sources of hazardous movements:
oNo or incorrect calibration of the drive
oWiring or cabling errors
oErrors in the application program
oComponent errors
oError in the measured value and signal transmitter
NOTE: Provide for personal safety by primary equipment monitoring or measures. Do not rely only on the internal monitoring of the drive components. Adapt the monitoring or other arrangements and measures to the specific conditions of the installation in accordance with a hazard and risk analysis.
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UNAVAILABLE OR INADEQUATE PROTECTION DEVICE(S) |
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oPrevent entry to a zone of operation with, for example, protective fencing, mesh guards, protective coverings, or light barriers. oDimension the protective devices properly and do not remove or modify them. oDo not make any modifications that can degrade, incapacitate, or in any way invalidate protection devices. oBring the drives and the motors they control to a stop before accessing the drives or entering the zone of operation. oProtect existing workstations and operating terminals against unauthorized operation. oPosition emergency stop switches so that they are easily accessible and can be reached quickly. oValidate the functionality of emergency stop equipment before start-up and during maintenance periods. oPrevent unintentional start-up by disconnecting the power connection of the drives using the emergency stop circuit or using an appropriate lock-out tag-out sequence. oValidate the system and installation before the initial start-up. oAvoid operating high-frequency, remote control, and radio devices close to the system electronics and their feed lines. oPerform, if necessary, a special electromagnetic compatibility (EMC) verification of the system. |
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Failure to follow these instructions will result in death or serious injury. |
Drive systems may perform unanticipated movements because of incorrect wiring, incorrect settings, incorrect data, or other errors.
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UNINTENDED MOVEMENT OR MACHINE OPERATION |
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oCarefully install the wiring in accordance with EMC standards. oDo not operate the robot with undetermined settings and data. oPerform comprehensive commissioning tests that include verification of configuration settings and data that determine position and movement. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
The robot is mounted in a way that provides the maximum angular amplitudes defined in Mechanical Data.
Depending on the axes, the axis range can be limited by:
oSoftware settings
oAdjustable mechanical limit stop (available for axis 1 and axis 2)
Only the mechanical limit stops meet the safety requirements specified by the ISO 10218-1 standard to establish a restricted space around the robot. The range limitation system using software limits must only be used to protect the equipment and not to provide functional safety in the system.
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DEVIATION FROM THE SAFETY REQUIREMENTS |
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oUse the mechanical limit stops to comply with the safety requirements specified by the ISO 10218-1 standard. oDo not use software-based range limitations for safety functions in the system. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
The range limitation for moving the adjustable mechanical limit stops is set out in Information About Modification of Ranges.
The noise level of the mechanics depends on the basic cycle and the payload, as well as on further application-specific accessory parts. Be aware of the fact that noise emissions multiply when several mechanics are in use at the same time. If noise emissions reach a value of more than 70 dBA, wear hearing protection.
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NOISE EMISSIONS OF THE ROBOT MECHANICS |
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oWear hearing protection in accordance with the locally applicable regulations. oAttach a sign on the robot mechanics if the noise emissions reach an excessive value. |
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Failure to follow these instructions can result in injury or equipment damage. |
NOTE: Attach the following symbol where it can easily be seen on the robot mechanics.
Some small amounts of grease lubricant emissions are to be expected over time. However, excessive grease lubricant emissions on or at the gearbox may be an indication of a damaged robot.
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NOTICE |
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INOPERABLE EQUIPMENT INDICATED BY GEARBOX LUBRICANT EMISSIONS |
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oVerify the mechanics before, during, and after use. oShut down the mechanics immediately if lubricant emissions appear on the robot mechanics. |
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Failure to follow these instructions can result in equipment damage. |
The robot is capable of suspending heavy loads.
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FALLING LOADS |
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Keep away from loads that are suspended. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
None of the axes is equipped with a counter balancing system.
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SAGGING OF AXES 3 AND 4 |
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When the joint brake is released, engaging the cross-circuit of the motor is the only way of limiting the fall speed. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
If different customer end products are transported by the robot mechanics, then the product pickup must be modified accordingly. For this reason, you can mount different product pickups (gripper mounting) to the tool flange. In doing so, ensure that the articulation movement is not restricted and/or that no motion errors can result from the modifications. Attachments and rebuilds may not influence the operation of the protective devices in any way and all EMERGENCY STOP buttons must be accessible all the time.
Analysis of Safety Around the Machine
Take into account the safety for the machine from the design and development stage on.
Before planning the installation of the machine, study the following points:
oPlan the safety strategies that reduce risks to an acceptable level.
oDefine the tasks required for the foreseeable applications and assess the access and/or approach requirements.
oIdentify the sources of risks including the detected failures and the failure modes associated with each of the tasks. The risks can involve:
oThe frame itself
oIts association with other items of equipment
oThe interactions between persons and the frame.
oAssess and estimate the risks stemming from frame operation:
oProgramming risks
oOperating risks
oRisks during use
oMaintenance risks for the machine.
oSelect the protective methods:
oUse of protective devices
oInstallation of signaling means
oCompliance with safe working procedures.
These points are taken from the standards applicable to robots.
NOTE: This list is not exhaustive. Above all, comply with the applicable local, regional and/or national standards.
Information on Electrostatic Discharges (ESD)
A high ESD voltage (several thousand volts) creates danger for electronic components. A semi-conductor must be handled carefully to prevent degradation or destruction by ESD.
The following table indicates typical ESD voltages.
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Source |
Low relative humidity 10 - 20% |
Average relative humidity 40% |
High relative humidity 65 - 90% |
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Walking on carpet |
35 kV |
15 kV |
1.5 kV |
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Walking on vinyl |
12 kV |
5 kV |
0.3 kV |
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Working at the workstation |
6 kV |
2.5 kV |
0.1 kV |
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Plastified instructions |
7 kV |
2.6 kV |
0.6 kV |
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Polyethylene bags |
20 kV |
2 kV |
1.2 kV |
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Cellular polyurethane |
18 kV |
11 kV |
1.5 kV |
It is essential to guard against electrostatic discharges during an intervention concerning electronic components, subassemblies, and complete systems.
To handle electronic cards, Schneider Electric workstations are given a grounded coating that dissipates static electricity. Anti-static measures are nonetheless required to handle boards or electronic components.
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NOTICE |
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ELECTROSTATIC DISCHARGE |
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Use anti-static wrist straps connected to the robot body and to ground (earth) while handling boards, electronic components, or the electric harness to which they are connected. |
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Failure to follow these instructions can result in equipment damage. |
The robot features the following safety devices:
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Device |
Paragraph |
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Axis limitation devices |
A Category 3 PLd safety function is adequate for a temporary protection of the operator. A permanent protection of the operator may require a higher performance of the safety function. The required safety performance level can only be determined by an application-specific risk analysis.
The robot must only be operated in faultless conditions. Some safety functions require specific conditions of use to guaranty their integrity. Keep records of all safety-related actions on the robot and on the frame in a safety book, or the like. Take special care during maintenance and restarting phases.
Safe operation in the frame does not rely only on the safety functions of the robot. Refer to the instruction manuals of robot conditions of use. These considerations do not prevent from a detailed risk analysis related to the specificities of the frame. Take special care during installation and maintenance phases.
ISO 10218-1, 5.7.3 recommends that "wherever possible, a manual mode of operation shall be performed with all persons outside the safeguarded space".
Secure the robot before any operation under its mechanical parts, in manual mode, maintenance, or when using the manual brake release function.
Before operating near the robot, ensure that the brakes are operational.
Risks near the robot:
oRisks of impingement between the moving robot and the frame environment.
oRisks of contact with moving edges or hot parts of the robot, even at low speed.
oRisks of potentially dangerous situations (falling part when opening the gripper, command of other moving parts in the frame...) due to the activation of output signals.
oRisks of reduced attention to other hazards in the frame (steps, other moving parts, sharp edges...) when paying attention to the robot.
oRisk of a sudden operator reaction to an unexpected robot movement, even at low speed (incorrect command for an operation, major axis movement caused by a small movement of the tool center, untoward program command).
oRisks of crushing during robot lifting or movement, or release of a joint brake.
When the robot is powered-on, a yellow indicator lamp (1), below on the robot is on to indicate that there is a potential danger. Robot movements are possible then and constitute a potential risk for the operator. This light is also on when the joint brake is released (on axis 3).
Options for Moving the Robot Without Drive Energy
The robot mechanics are not equipped with a security enclosure.
NOTE: Take appropriate security measures concerning the specific use before operating the robot.
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SAGGING OF THE ROBOT |
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Ensure that the release of the motor brakes poses no subsequent risks in the zone of operation. |
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Failure to follow these instructions can result in death, serious injury, or equipment damage. |
If you have to move the complete robot manually, perform the following steps:
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Step |
Action |
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1 |
Switch the robot into a torque-free state. |
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Manually hold the robot in position. |
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Open the motor brakes. NOTE: The function for opening the brakes as well as for torque-free switching of the motors is not controlled by the equipment delivered with the product reference, but must be addressed by the application. |
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Manually move the robot. NOTE: A greater force could be necessary because the motor and the gearbox may pose resistance to movement. |
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5 |
Close the brakes. |
