Risk management

during installation
of paint robots

INTRODUCTION
Risk 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

STEPS INVOLVED IN RISK MANAGEMENT

PROCESSING RISK
MANAGEMENT

Process of dealing with risks is carried

out in following four steps.
1. Identifying the risk.
2. Assessing the risk involved.
3. Evaluation of the factors causing risks
and processing how to deal with it.
4. Controlling and monitoring the risks
involved.

Safety risks related to

installation
GENERAL
The 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 Personnel
Those who install the robot must have the appropriate
training for the robot system and in any safety matters
associated with it.

Emergency Stop Buttons

The 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 Release

If 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 Regulations

To 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 System
The 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 Signals

Installation 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 Grinding

Welding, 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 Precautions
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. 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 Area

The 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 Base

The 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 Area

The 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 emergency

Stop

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 Buttons

Emergency 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 management
i. Identify
ii. Assess
iii. Evaluate
iv. Control monitor
. The 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.

CONCLUSION
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.