Safety Isolation System

Click to enlarge - 2030_(Typical System 6 RLSs)_Diagram
 
Typical System

Description

The ElectroGuard system is designed to simplify the Lock Out/Tag Out (LOTO) task performed by a machine operator or maintenance personnel. The ElectroGuard system can control single or multiple energy sources simultaneously. Simplifying the procedure helps increase the likelihood that personnel will perform the LOTO on large processors or drive systems.


The ElectroGuard allows the system engineer to design LOTO into the system. Locating the Remote Lockout Stations (RLS) at hazard entry points can result in the shortest down time during set-up or maintenance.

Standard Features


Optional Features


Specifications

Certifications cULus
TÜV Rheinland Certified
CE marked for all applicable directives
Standards IEC/EN 60204-1
IEC/EN 60439-1
Category 4 to EN 954-1/ISO 13849-1
98/37/EC Machinery Directive
89/336/EC EMC Directive
73/23/EC Low Voltage Directive
UL508A
Estimated Component Life Remote Lockout Station Power Contactors (Isolation & Grounding) 23… 85 A: 2,000,000 operations
110…1200 A: 1,000,000 operations
Storage Temperature [C (F)] -10…+60° (14…140°)
Operating Temperature [C (F)] 0…+40° (32…104°)
Relative Humidity (noncondensing) 90% (Ambient)
Power Panel Construction NEMA Type 12/IP54
UL Type 4/IP66
UL Type 4x
MCC (Bulletin 2100) with and without Bus
Expansion Module Construction 4-port: Supports up to 4 remote lockout stations
10 port: Supports up to 10 remote lockout stations
Safety Isolation System Inputs Remote Lockout Stations
Input Options Safety Mats, Light Curtains, and
E-Stop Stations
System Operational Limits +10%, -15% of the line voltage
  

Sequence of Operation

After using the normal stopping method of the machine or process, the machine operator turns a Remote Lockout Station (RLS) handle from the ON to the OFF position.

The RLS signals the:

1. Isolation contactors (1IC and 2IC) to drop out, isolating the supply voltage from the loads (see Power Circuit below).

2. The grounding contactor (GC) is then energized, connecting the load to ground (see Power Circuit). The grounding contactor and the isolation contactors are both electrically and mechanically interlocked.

3. The System Isolated light will then illuminate on the RLS to indicate the system is isolated.

4. The person performing the LOTO then applies a lock to the RLS, locking it in the OFF position. The equipment is now locked out.


Click to enlarge - power circuit
 
Power Circuit

ElectroGuard Factory Installed Options

Communication

The optional Communication Module allows the ElectroGuard system to communicate status to the process or machine control system. Although the communication module can be field installed, it is recommended that this option be ordered as part of the ElectroGuard system. The customer is responsible for configuring and programming their control system to receive the status signals from the ElectroGuard.



Click to enlarge - IMPORTANT The communication option allows a remote PLC to receive status signals from the ElectroGuard safety isolation system.
 

Door Mounted Metering

Optional door mounted ampere meter, volt meter, or both, are available as factory installed options. They provide visual indication of line side system current and voltage. See the ElectroGuard or accessories for ordering instructions.

Expansion Module

Expansion Modules are used to add more Remote Lockout Stations in addition to the base inputs (four remote lockout stations for 23…85 A units and six for the 110…1200 A systems). See expansion module section for details.

Multiplexer and Multiplexer Permissive

The Multiplexer Module allows the Remote Lockout Station to control two or more ElectroGuard systems. The permissive function allows the equipment control system to determine if the ElectroGuard can be locked out. See Multiplexer and Multiplexer Permissive section for sequence of operation and details.

Click to enlarge - IMPORTANT Only one of these options can be installed in the power panel, and are not available on the 23…85 A units, or 2031-A0630JX or 2031-A860JX units.
 

Product Selection

ElectroGuard cat. nos. can be configured by selecting the appropriate codes from the tables below.

2302 A   0420   J   B 29J 1TD
a   b   c   d   e   f   g

a
Safety Type
Code Description
2031 Noncombination
2032 Fusible Disconnect
2033 Thermal-Magnetic Circuit Breaker

b
Construction Code
Code Description
A Free-standing enclosure
B§  Motor control center enclosure for North America with line side incoming power cables and 1200 A load side outgoing bus¬ .
F§  Motor control center enclosure for North America with line side incoming power cables and 600 A load side outgoing bus¬ .
M§  Motor control center enclosure for North America with 600 A line side incoming bus¬  and outgoing power cables.
S§  Motor control center enclosure for North America with 1200 A line side incoming bus¬  and outgoing power cables.

¬  Bus Type: copper with tin plating.
§ Only available in NEMA Type 12/IP54.


c
Ratings¬ 
Ampere
Rating
(AC-3)
3-Phase Max. Hp rating (60Hz) 3-Phase Max. kW rating (50 Hz) 2032 Fuse Clip OptionsT  2033 Circuit Breaker Options‡ 
200V 230V 460V 575V 230V 400V 500V 600V
0023 5 7.5 15 15 7.5 11 11 11 24B, 24J, 25B, 25J 39, 39k, 40, 40k, 41, 41k, 42, 42k
0043 10 15 30 30 13 22 22 22 25B, 25J, 26B, 26J 40, 40k, 41, 41k, 42, 42k, 43, 43k, 44, 44k, 45
0085 25 30 60 60 25 45 45 45 26B, 26J, 27B, 27D, 27J 42, 42k, 43, 43k, 44, 44k, 45, 46, 46k, 47, 47k, 48, 48k
0110 40 40 74 100 32 55 63 100 27B, 27D, 27J, 28B, 28D, 28J 45, 46, 46k, 49, 49k, 50k
0180 50 60 150 150 55 90 110 160 27B, 27D, 27J, 28B, 28D, 28J 47, 47k, 48, 48k, 50k, 51, 51k, 52, 52k, 55k
0210 60 75 200 63 110 150 200 28B, 28D, 28J 48, 48k, 49, 49k, 53, 53k, 54, 54k, 59k
0300 100 125 250 300 90 160 200 300 28B, 28D, 28J, 29B, 29D, 29J 49, 49k, 50k, 51, 51k, 53, 53k, 54, 54k, 55k, 56, 56k, 57, 57k, 58, 58k, 59, 59k
0420 150 175 350 400 132 220 300 425 29B, 29D, 29J, 30B, 30D, 30L 51, 51k, 52, 52k, 53, 53k, 55k, 57, 57k, 58, 58k, 59, 59k, 60, 60k, 61, 61k, 62, 62k, 63, 63k, 64k
0630 200 250 500 600 200 355 450 500 30B, 30D, 30L, 31B, 31D, 32B, 34L 53, 53k, 54, 54k, 55k, 56, 56k, 59, 59k, 60, 60k, 61, 61k, 62, 62k, 63, 63k, 64k, 65k, 66k
0860 250 300 600 700 250 500 560 600 31D, 32B, 34L 56, 56k, 57, 57k, 58k, 59k, 60k, 61k, 62k, 63, 63k, 64k, 65k, 66k
1200 450 450 900 900 391 710 888 1043 31D, 34L 57, 57k, 58, 58k, 59, 59k, 60, 60k, 61k, 62k, 63, 63k, 64k, 65k, 66k
 

¬ Consult your local Rockwell Automation sales office or Allen-Bradley distributor for additional options.
T Available for 2032 fusible discconect only.
‡ Available for 2033 Thermal-Magnetic circuit breaker. Consult your local Rockwell Automation sales office or Allen-Bradley distributor for additional options.


d
Enclosure Type
Code Description
C§  Type 4X watertight stainless steel
F§  Type 4 watertight painted steel/IP65
J Type 12 dusttight/IP54

§ Cooling to be supplied by customer.


e
Input Line Voltage
Code Description
A 240V 60 Hz/220V 50 Hz
B 480V 60 Hz/440V 50 Hz
C 600V 60 Hz/550V 50 Hz
G 400…415V 50 Hz
H 208V/60 Hz
M 500V 50 Hz
N 380…400V 50 Hz

f
2032
Fuse Clip Rating/Type§ 
Code Rated Amps [A] Fuse Type
24B 32 A BS88
24J 30 A Class J
25B 60 A BS88
25J 60 A Class J
26B 100 A BS88
26J 100 A Class J
27B 200 A BS88
27D 160 A DIN
27J 200 A Class J
28D 250 A DIN
28J 400 A Class J
29B 400 A BS88
29D 400 A DIN
29J 600 A Class J
30B 600 A BS88
30D 630 A DIN
30L 800 A Class L
31B 800 A BS88
1D 1600 A DIN
32B 1250 A BS88
34L 2000 A Class L

§ Fuse to be supplied by customer per local electrical code.


f
2033
Circuit Breaker Hp/kW RatingØ 
Code Hp Code Power
39 5 Hp 39k 4 kW
40 7.5 Hp 40k 5.5 kW
41 10 Hp 41k 7.5 kW
42 15 Hp 42k 11 kW
43 20 Hp 43k 13 kW
44 25 Hp 44k 15 kW
45 30 Hp
46 40 Hp 46k 22 kW
47 50 Hp 47k 25 kW
48 60 Hp 48k 32 kW
49 75 Hp 49k 37 kW
50k 45 kW
51 125 Hp 51k 55 kW
52 150 Hp 52k 63 kW
53 175 Hp 53k 75 kW
54 200 Hp 54k 90 kW
55k 100 kW
56 250 Hp 56k 110 kW
57 300 Hp 57k 132 kW
58 350 Hp 58k 150 kW
59 400 Hp 59k 160 kW
60 450 Hp 60k 185 kW
61 500 Hp 61k 200 kW
62 600 Hp 62k 220 kW
63 700 Hp 63k 250 kW
64k 300 kW
65k 355 kW
66 900 Hp 66k 390 kW

Ø Consult your local Rockwell Automation sales office or Allen-Bradley distributor for additional circuit breaker options.


g
Factory-Installed Options
Code Description
1AMz  Single-phase ampere meter
3AMz  3-phase ampere meter
1VMª  Single-phase voltmeter
3VMª  3-phase voltmeter
1COMv  Remote I/O module (16 points of I/O)
1CNETv  ControlNet™ module (16 points of I/O)
1DNETv  DeviceNet™ module (16 points of I/O)
1ENETv  EtherNet module (16 points of I/O)
1PNETv  PROFIBUS module (16 points of I/O)
1TD Control module with factory-set 30-second time delay
1EUFª  Four port expansion module
1EUTª  Ten port expansion module
1SYSª  System multiplexer module
1SYSPª  System multiplexer permissive module
1HPMª  Hydraulic/pneumatic multiplexer module

z Only one can be selected for current monitoring.
ª Only one can be selected for voltage monitoring.
v Only one of these can be installed in ElectroGuard.
ª No module can be installed in the 23 A, 43 A and 85 A units and the 2031-x0630xx and 2931-x860xx units.


Replacement Control Module

2030-CH0085x

2030-CH0085x-ITD

2030-CH1200x

2030-CH1200x-ITD

x = See table "e" for input line voltages


Click to enlarge - 2030 Pneumatic IsoMod_4C
 
1-1/2 in. Pneumatic Isolation Module

Pneumatic Isolation Module

The ElectroGuard Safety Isolation System is available with an optional means of isolating the pneumatic energy source for the machine or process. The Pneumatic Isolation Module is designed to work in conjunction with the power panel. This option blocks the pneumatic line leading to the pneumatic hazard. The valve then bleeds or dumps the residual pneumatic energy leading to the machine. After the valve is in the blocked position and the pressure drops to less than five psi (pounds per square inch), a signal is sent to the power panel indicating the pneumatic energy is isolated. The system isolated light, located on the Remote Lockout Station (RLS) that was switched to the OFF position, is then illuminated.

Click to enlarge - 2030 Hydraulic IsoMod_4C
 
Hydraulic Isolation Module

Hydraulic Isolation Module

The ElectroGuard Safety Isolation System is available with an optional means of isolating the hydraulic energy source for the machine or process. The Hydraulic Isolation Module is designed to work in conjunction with the power panel. The valve blocks the hydraulic line leading to the hydraulic hazard. Then the residual hydraulic energy is returned to the tank. After the valve is in the blocked position and the pressure drops to less than 100 psi (pounds per square inch), a signal is sent to the power panel indicating the hydraulic energy is isolated. The system isolated light, located on the RLS that was switched to the OFF position, is then illuminated.

Bulletin 2030 Pneumatic and Hydraulic Isolation Modules

2030 P   J   120   4
    a   b       c

a
Product Descriptor
Code Description
P Pneumatic isolation module
H Hydraulic isolation module

b
Enclosure Type
Code Description
C Type 4X watertight stainless steel
F Type 4 watertight painted steel/IP65
J Type 12 dusttight/IP54

c
Port Size
Code Description Pneumatic CFM at 90 PSI Hydraulic GPM
2 1/2 in. NPT 160 T 
3 3/4 in. NPT 380 25
4 1 in. NPT 650 T 
5 1-1/4 SAE #20 straight thread ¬  120
6 1-1/2 in. NPT 1750 T 

¬  Not available in Pneumatic Isolation Module
T  Not available in Hydraulic Isolation Module
CFM = Cubic feet per minute
GPM = Gallons per minute
NPT = National pipe thread
SAE = Society of Automotive Engineers


Click to enlarge - Mulitplexer
 
4-Port Expansion Module

Optional Expansion Module

Optional Expansion Modules are available for applications requiring more than the maximum allowable Remote Lockout Stations (RLS) (e.g. more than four for 23…85 A systems or more than six for 110…1200 A systems). The Expansion Modules are available in 4- or 10-port configurations. This allows up to four RLSs for a 4-port and ten RLSs for a 10-port module. An example would be adding a 4-port expansion module to a 23A ElectroGuard. This then allows up to seven RLSs to connect to the system.

Expansion Modules may be ordered with an adjustable time-delay feature (1…30 seconds) in order to allow time for the machine operator to shut down drives or other equipment that requires a controlled stop after a RLS handle has been turned to the OFF position. Consult your Rockwell Automation sales office or Allen­Bradley distributor for other time settings. Enclosed Expansion Modules are available with optional Flex modules to provide status communication to a remote PLC. Communication can be via ethernet, ControlNet, DeviceNet, Profibus or Remote I/O.

NOTE: The status communication option allows a remote PLC to receive status signals from the Expansion Module.


Bulletin 2030 Expansion Module

2030 EU   N   F   1CNET   1TD
    a   b   c   d   d

a
Product Descriptor
Code Description
EU Expansion module

b
Enclosure Type
Code Description
C Type 4X watertight stainless steel
F Type 4 watertight painted steel/IP65
J Type 12 dusttight/IP54
N Open type

c
Number of Expansion Ports
Code Description
F 4-port
T 10-port

d
Options
Code Description
1COM Flex I/O module
(16 points of I/O)
1CNET ControlNet™ module
1DNET DeviceNet™ module
1ENET EtherNet module
1PNET PROFIBUS module
1TD Expansion module with factory-set 30-second time delay

Click to enlarge - Mulitplexer
Remote Lockout Station

Remote Lockout Station

The Remote Lockout Station (RLS) is a key component of the ElectroGuard system. The RLS is typically located at the hazard location and provides the signal to the power panel to initiate the LOTO process. The RLS is available in several configuration and enclosure types.

Dual Remote Lockout Station

The Dual Remote Lockout Station functions the same as a single or standard Remote Lockout Station. The difference between a single and a dual RLS is that the dual RLS can be used to control two ElectroGuard systems from the same RLS. A good example of this is a machine that has two separate incoming power sources. Using a dual RLS and two ElectroGuard both ElectroGuard can be controlled from the same station.

Bulletin 2030 Remote Lockout Station

2030 RLS   J   G   D
        a   b   c

a
Enclosure Type
Code Description
C Type 4X watertight stainless steel
F Type 4 watertight painted steel/IP65
J Type 12 dusttight/IP54
E Type 7 and 9 hazardous location bolted

b
System Isolated Light Color
Code Color
G Green

c
Dual RLS
Code Description
D Dual
Blank Single

Replacement Switch Module: 2030-RSA1

Click to enlarge - VM panel_angled_GS
Verification Module

Verification Module

The optional Verification Module (VM) is connected between the solenoid locking safety switch, similar to a Guardmaster Atlas™ 5 and the Remote Lockout Station (RLS) input on an ElectroGuard system. When the VM receives the system isolated signal from the ElectroGuard, the VM provides the signal to the solenoid on the Atlas 5, unlocking the Atlas 5 and allowing access to the machine.

Once the Atlas 5 is unlocked, the VM provides a redundant signal to the ElectroGuard emulating a RLS that has been switched to the OFF position. The emulated signal is then switched to the on state, to indicate the gate has been closed. If all of the RLSs connected to the ElectroGuard are switched to the ON position and the safety gate is closed, the ElectroGuard will attempt to lock the gate and restore energy the machine. If the verification module has not verified the gate is locked, the energy is removed from the machine and the locking process is repeated.


Specifications

Dry Contact (B300 6A/125V AC or P300 3A/24V DC) provided to control solenoid voltage.

Bulletin 2030 Verification Module

2030 VM   C
    a   b

a
Product Description
Code Description
VM Verification module

b
Enclosure Type
Code Description
C Type 4X watertight stainless steel
J Type 12 dusttight/IP54

Multiplexer/Permissive Module

When multiple energy sources must be controlled simultaneously or the system must be stopped at a pre-determined stopping point, the LOTO process becomes more complicated with multi-step procedures and locks. The Hydraulic/Pneumatic Multiplexer and the system Multiplexer/Permissive Module were developed to help provide simultaneous control of multiple hazards from a single lockout point.

Coordination between the process or drive system control and the LOTO process, is a concern. In a typical system, a signal from the LOTO device is sent to the control system. This provides indication that the device has been switched to the OFF position. This requires the person switching the device to ensure the process or machine has stopped. Ideally this would be coordinated so the power is not disconnected until the process or drive system is at an acceptable stopping point. The addition of the Permissive function to the System Multiplexer allows the control system to signal the ElectroGuard system when it is at the desired stopping point. This function would only allow the stopping function (i.e., the control system can not restore power). That function can only be accomplished via the RLSs attached to the System Multiplexer/Permissive Module.

The diagram below depicts a system with multiple motors or drives that require a synchronized lockout. This system also requires that the power to the drives must be maintained during certain phases of the process. The control system is interfaced with the ElectroGuard systems via the Permissive option in the System Multiplexer/Permissive Module. This allows the control system to delay disconnecting power until the drives are at an allowable point in the process.


Functional Description

The System Multiplexer Module allows a Remote Lockout Station (RLS) to control up to four ElectroGuard systems simultaneously. The System Multiplexer Module will accept up to six RLS inputs. If there is a need to control more than four ElectroGuard systems, the System Multiplexer Modules can be daisy-chained as shown in the drawing below. For applications where more than four RLSs are required, an expansion module may be used.

The System Multiplexer Module is also available with a Permissive option. The Permissive option allows the machine controlling the process or drive system to bring the machine or process to a pre-determined stopping point prior to removal of power by the ElectroGuard system. Once the ElectroGuard system isolates the energy, the machine control can not re-energize the ElectroGuard.


Sequence of Events for System Multiplexer Module:

1. When a RLS is turned OFF, the outputs of the System Multiplexer Module are switched to the off or open state, see diagram below.
2. This signal is connected to the input of the ElectroGuard systems initiating the isolation process.
3. When all of the ElectroGuard systems are in the isolated state the System Multiplexer Module sends the Isolated signal to the RLS and the RLS System Isolated pilot light will be illuminated.

Sequence of Events for System Multiplexer Module with Permissive Option:

1. A PLC output is connected to the System Multiplexer/Permissive Module. This signal is used by the System Multiplexer/Permissive Module as a heart beat. This holds the output of the System Multiplexer/Permissive Module in the on or closed state, holding the ElectroGuard system in the on or non-isolated state.
2. When a RLS is turned OFF, a signal is transmitted to the control system via a PLC connection on the RLS auxiliary contacts, see diagram below. Note that the outputs of the System Multiplexer/Permissive Module remain in the on or closed state.
3. When the customer’s control system is at a predetermined stopping point, the control system, via the PLC output, is turned to an off state (no heart beat) and the outputs of the System Multiplexer/Permissive Module are then switched to the off or open state.
4. The system isolation function is then initiated on all of the ElectroGuard systems simultaneously.
5. When all of the ElectroGuard systems are in the isolated state, the System Multiplexer/Permissive Module sends the Isolated signal to the RLS and the RLS System Isolated pilot light on the RLS will be illuminated. The RLS now has control of the ElectroGuard and the energy can only be restored to the machine or process by switching all of the RLSs connected to the multiplexers to the on state.
  NOTE: Modification to the logic in the customer’s control system is required if the Permissive option is used. See user manual for details.

Click to enlarge - 2030_(Multiple Energy Sources)_Diagram
Multiple Energy Sources

Bulletin 2030 Multiplexer/Permissive Module

2030-MLX J   F   SYS
    a   b   c

a
Enclosure Type
Code Description
C Type 4X watertight stainless steel
F Type 4 watertight painted steel/IP65
J Type 12 dusttight/IP54
N Open
M Open Type installed in ElectroGuard¬ 

¬ Can be installed in most 110…1200 A systems


b
Number of Systems to Control
Code Description
F 4 systems

c
System Type
Code Description
SYS EG system
SYSP EG system with permissive option
HPM Hydraulic/pneumatic module

System Selection Process

1. Determine the catalog number of the Safety Isolation System based on the rating of the load(s) to which it will be connected as follows:
  — If the Safety Isolation System is connected to a single motor load, the horsepower or kilowatt rating of the system should be determined as follows:
      a. Select the Safety Isolation System that meets or exceeds the horsepower or kilowatt rating of the load at the required voltage and frequency.
      — If the Safety Isolation System is connected to two or more motors or one or more motors in combination with other loads; the horsepower or kilowatt rating of the system should be determined as follows:
      b. Identify the types of loads (i.e. motor, resistive) and the values of the currents of each of the loads (i.e. steady-state current for resistive loads, full-load and locked-rotor currents for motor loads) to be connected to the Safety Isolation System.
      c. Sum the full-load currents of all the motor loads to be connected to the Safety Isolation System. To this value add the current values of all resistive loads to be connected to the Safety Isolation System. This value is the combined load full-load current.
      d. Find the horsepower or kilowatt rating of a single motor with a full-load current value greater than or equal to the combined load full-load current value determined in step b.
      e. Select the Safety Isolation System that meets or exceeds this horsepower or kilowatt rating at the required voltage and frequency.