MRE 1011 Lab2
Lockout Tagout
Points: 10
Student Names:
Process:
Obtain a copy of the procedure for locking out the equipment in to be maintained.
Read and understand the procedure.
Shut down, lock, and tag appropriate device.
CONFIRM that that power is not applied to the equipment – test with meter, attempt to operate, etc.
When work is complete, remove locks and tags.
Locks / tags:
Each student is assigned a lock to lockout equipment as necessary. If multiple people are working on one
equipment, multiple locks can be used on one lockout point.
In an industrial setting, you will likely have your
own lock assigned to you permanently. You will
place the lock when you are working on
equipment and remove it when the work is
complete. You NEVER remove another persons
lock. NEVER share your key. Lockout/Tagout
procedures may also have you place a tag on
certain equipment to inform other personnel
what type of work is being done and when it is
expected to be completed.
Safety Gate:
When working inside a safety cage, you may be required to lock the cage access door to make sure
robots can not be activated while you are inside.
Circuit Breakers / Electrical Disconnects:
MRE 1011 Lab2
Lockout Tagout
Points: 10
Many disconnects have provisions for a lock. Others may need an
add-on device. Depending on the circuit configuration, you may need
to lock out multiple electrical
sources.
Mechanical Lockout:
Robotic arms often have brakes built into the drive motors to hold them in position, but when the
motors or gear trains are removed for maintenance the can fall with serious consequences. External
supports or lock devices are used to support the weight of heavy objects during work.
Hydraulic, Pneumatic, Thermal Systems:
You may need to lock out a valve, put a support on a cylinder, check for pressures or temperatures. `
MRE 1011 Lab2
Lockout Tagout
Points: 10
Lab Exercises:
Each student shall get a lock and key from the instructor. This will be “your” lock for the duration of this
exercise. Remember: Never remove someone else’s lock!!! We will not be filling out tags for this lab.
Divide into groups of two (preferred) or three and follow the procedures below. Be sure to confirm that
the lockout device is effective.
Whole Class Exercises:
The following two exercises are done by the whole class
Gate:
Install a hasp that can hold multiple locks in the gate handle as
shown. One member of the team will install their lock on the
hasp.
Can the gate be closed and latched with the lock in place?
No
Can the automatic robot program be started by pressing the
green button? No
Can the robots be operated in T1 mode? (Instructor will assist) Yes Explain:
The process is slowed, and meant to be used to teach and show how it works step by step
Robot Shutdown (two large groups):
Shutdown the robot using the teach pendant.
Press the button in the lower right to bring up the menus.
Select “Configuration” “User Group” “Expert” and log on
with the password “kuka”.
Go to “Shutdown” and shut the robot down.
Confirm that the robot does not move.
Did this go as expected? Yes
MRE 1011 Lab2
Lockout Tagout
Points: 10
Team Exercises:
The remainder of the exercises will be done in your teams of two or three.
Robot Control Cabinet:
Switch off the power switch on the front of the cabinet and install a lock. Open the cabinet front and
check to see that there are no illuminated lights, and fans are not running.
Did this go as expected? Yes
How do you know it is off? There is no indication of power (LEDs and fans are off)
Is there something else you could have done to make sure the power is disconnected? What?
Check with a multimeter
Remove your lock and return switch to on position for the next team.
PLC Power:
The PLCs and desktop computer are powered by the same circuit. Make sure the computer is properly
shutdown.
Open circuit breaker 6 in the cabinet at the back of the lab and install the lockout device over the
breaker handle and tighten the screw. Confirm that the outlet on the front corner of the cage has no
power.
Can the breaker be turned on with this device in place? It shouldn’t.
Did this go as expected? No.
Explain: The locking mechanism wouldn’t keep it in place.
MRE 1011 Lab2
Lockout Tagout
Remove the lockout device and turn the breaker back on for the next group.
Other opportunities:
Are there other devices that could / should be locked out in the lab? Outlets
How would it be done? Unplug devices connected to it, and encase the outlet.
Closeout:
Remove any remaining lockout devices from the gate and anywhere else that they may be.
Restore all power.
Points: 10