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Procedure

Preparation​

  • Notify all affected employees that a lockout/tagout procedure is about to be performed and the reason for it.

  • Review the system's energy sources (electrical, pneumatic, etc.) and understand the hazards.

    • Electrical Sources:

      • 480V, 3-phase, 200A service PER RACK

        • 24V, 960W isolated AC-DC Isolated Converter in Primary Rack HV cabinet

        • 24Vdc -> 120Vac inverter on shelf under robot controller

      • 24V, 20A UPS (12V, 7.5Ah SLA batteries x2) inside LV control cabinet (enclosure with HMI screen)

    • Pneumatic Sources: ▪ Air Compressor – on shelf under robot controller

      • 1 gal capacity, 110 psi

    • Drain on bottom of tank

    • Supplies regulator at base of robot arm

  • Trapped air in control circuit between joint 4 and 6 on robot arm

    • ¼” tube

Shutdown​

  • Power down the PowerHive system by pressing the E-Stop button near the HMI when the robot is at the “Home” position without a battery on the end of the arm.

  • Ensure the robot and all other automated systems are in a fully stopped state.

Isolation​

  • Locate and isolate all energy sources:

    • Electrical Power :

      • Switch off the main power supply to all high voltage panels (All Rack HV Enclosures – External Handles w/ LOTO capability) using the main disconnect handle.

    • Pneumatic Power :

      • Shut off the air supply at the base-of-arm regulator and drain any residual pressure from the system.

      • Drain the two (2) end of arm tool circuits by alternately pressing the red circuit override switches repeatedly on the joint 4 pneumatic solenoid. (see picture)

Lockout/Tagout Application​

  • Apply lockout devices to each energy isolating device. Ensure that each lock has a unique key.

  • Attach a tag to each lock indicating the following:

    • The name of the person who applied the lock

    • The date and time of application

    • The reason for the lockout

  • Verify that the locks and tags are securely attached and clearly visible.

Release Stored Energy​

  • Discharge any stored energy by grounding and/or blocking any residual energy sources.

    • UPS Battery (Fuse) in LV Box (see picture)

  • Verify that the system is de-energized using a multi-meter or appropriate testing device.

    • Grace Technologies Voltage Indicator (R-3W-KB) on each HV enclosure

Verification of Isolation​

  • Attempt to start the system using the HMI to ensure that all energy sources are isolated, and the system cannot be powered on.

  • Verify zero energy state by checking for the absence of voltage and air pressure.

Perform Maintenance or Service​

  • Conduct the necessary maintenance or service activities on the PowerHive system.

  • Ensure continuous monitoring for any changes in the energy state.

Re-energization​

  • After maintenance or service is complete, ensure all tools and personnel are clear of the work area.

  • Notify all affected employees that the system is about to be re-energized.

  • Remove lockout devices and tags. Each lock and tag must be removed by the person who applied it.

  • Reconnect the energy sources:

    • Electrical Power : Reconnect the main power supply at the high voltage panel.

    • o Pneumatic Power :

      • Open the air supply at the base-of-arm regulator.

      • Close the air/water drain on the air compressor tank.

      • Turn on the air compressor.

  • Verify the system's functionality by performing a controlled startup using the HMI, then a battery swap or some robot movement after startup.