Stored Energy, Soldering, and Chemical Safety

Respect stored energy — the hidden hazard

A robot that looks "off" can still hurt you. The Safety Manual devotes a full section to stored energy, and the FIRST best practice is to always de-energize the robot before working on it unless work on an energized robot is truly necessary. Stored energy comes in several forms — electrical, mechanical, pneumatic, chemical, and thermal — and each must be addressed:

• Electrical: Disconnect the power source. For FRC, open the 120A main circuit breaker (release the re-set lever) and unplug the battery.
• Pneumatic (FRC only): Always vent all compressed air to the atmosphere — open the manual vent valve and verify every pressure gauge reads zero.
• Mechanical/miscellaneous: Relieve compressed or stretched springs and surgical tubing, and lower any raised mechanisms that could drop. Constant-force springs, elevators, and gas struts are classic surprises.

Make sure all team members know when work is being done on the robot, and never work alone underneath an unsupported, energized, or unstable robot.

Soldering safely

Soldering combines a very hot iron with chemical fumes, so the manual lists specific precautions:

• Lead-free solder is highly recommended, and use only an electrically heated iron or gun. Even lead-free solder can contain toxic ingredients — wash your hands after handling.
• Wear eye and face protection and solder in a well-ventilated area.
• Never touch the iron or gun — it reaches extreme temperatures that cause severe burns. Keep it in its protective holder when not in use, and never leave hot tools where someone could touch the element.
• Wear cotton clothing covering arms and legs to prevent burns, work on a fire-resistant surface, and keep no food or drink in the soldering area.
• Dispose of solder waste appropriately — it can be hazardous even when lead-free.

Chemical safety and Safety Data Sheets

Teams use chemicals constantly — Loctite, WD-40, adhesives, paints, battery electrolyte. The manual requires you to:

• Keep chemical containers in good condition with legible manufacturer labels.
• Read the precautions on each label and store incompatible chemicals separately.
• Store flammable chemicals in non-flammable storage, away from flammable materials, when not in use.
• Do not use highly flammable materials (like some cleaning solutions) at FIRST events.

The central tool here is the Safety Data Sheet (SDS). Mentors and student leads should collect and store an SDS for every chemical, compound, or mixture the team uses (including the contents of batteries). An SDS gives safe-use instructions, hazards, and emergency and first-aid procedures. Appendix C of the manual links sample SDSs (for example, a non-spillable battery SDS, Loctite, and WD-40). Keep an SDS binder at your shop and bring it to events, and make sure your Safety Captain knows where it is.