Safety Isolation System ElectroGuard Overview Status Communication Capability to a Remote PLC • Optional Remote I/O via Flex modules. Communication can be via the DeviceNet communication platform or the Remote I/O communication platform. Available from 23-1200 Amperes. Specifications Approvals Standards The ElectroGuard Safety Isolation System is used in place of a disconnect switch for Lockout and Tagout (LOTO). It uses power contactors and Remote Lockout Stations to accomplish LOTO. Isolating the electrical energy usually involves calling an electrician to turn “Off ” the main disconnecting means. The electrician would then perform LOTO of the disconnecting means operating handle. This same procedure is required to perform cleaning, maintenance, setup, lubrication or adjustment. Machines or processes with multiple access points may require operator/maintenance intervention several times a shift (perhaps as often as 60 times per shift). To perform these activities, the operator/maintenance person may be required to place part of his or her body into an area not accessed during normal operation. This may cause serious or fatal injury if LOTO procedures are not followed. Estimated Component Life Remote Lockout Station Power Contactors (Isolation & Grounding) Environmental Storage Temperature Operating Temperature Relative Humidity, Non condensing Power Panel Construction The ElectroGuard Safety Isolation System allows the machine operator to safely and quickly accomplish LOTO with dramatically reduced downtime. Provides Energy Isolation • Power isolation accomplished by means of contactors rather than disconnect switches. • Uses redundant, independent and self-monitoring circuits to detect a system fault. • Prevents accumulation of faults in order to maintain the integrity of the safety system. • Tamper-resistant design. Convenient Remote Lockout Station • Allows remote isolation of the electrical power to the machine or process—machine operator simply turns “Off ” a Remote Lockout Station. • A light on the Remote Lockout Station indicates that the threephase power source to the machine or process has been isolated. No Light Means No Entry. • If a fault occurs in the Safety Isolation System, the “System Isolated” light on the Remote Lockout Stations will not illuminate. • Easy Lockout/Tagout. Certified by TUV to meet requirements of Category 4 • Certified by TUV to meet Category 4, the most stringent safety category defined within International Standard EN 954-1/ISO 13849-1. • Subjected by TUV to rigorous third party testing and verification of the Failure Mode & Effect Analysis (FMEA). Remote Lockout Station Construction Expansion Module Construction Safety Isolation Sys. Inputs Standard Inputs from Optional Inputs from Rockwell Automation Safety Products System Operational Limits CULUS Listed Industrial Control Panel; TUV Rheinland certified; CE marked for all applicable directives IEC/EN 60204-1; IEC/EN 60439-1; Category 4 to International Standard EN 954-1/ISO 13849-1; 98/37/EC Machinery Directive; 89/336/EC EMC Directive; 73/23/EC Low Voltage Directive; Fulfils the function of an energy isolating device in accordance with the conditions set forth in the FedOSHA letter of interpretation pertaining to Section 1910.147(b); Cal/OSHA 3314. 250,000 operations 23A - 85A: 2,000,000 operations 110A-1200A: 1,000,000 operations -10°C...+60°C (14°F...140°F) 0°C...+40°C (32°F...104°F) (Ambient) 90% Relative Humidity Tamper-resistant Control Module 23A-85A systems support up to 4 Remote Lockout Stations without an Expansion Module 110A-1200A systems support up to 6 Remote Lockout Stations without an Expansion Module Control Module with viewing window for visual check of status indicator lights Top and bottom 25.4mm (1.0in) conduit entry (removable plug in bottom conduit hole) Sealing provision for tamper-resistance Operating handle accepts up to 3 padlocks 4 port—supports up to 4 lockout stations • allows the systems to accommodate up to 24 Remote Lockout Stations 10 port—supports up to 10 lockout stations • allows the systems to accommodate up to 60 Remote Lockout Stations Window for viewing status indicator lights; Sealed for tamper-resistance Remote Lockout Stations Safety Mats, ➊ Light Curtains, ➊ E-Stop Stations, ➊ Proximity Switches, ➊ Photo Switches ➊ +10%, -15% of the line voltage ➊ Use of any of these input devices will not meet Lockout/Tagout (LOTO) requirements. 12-2 Safety Isolation System ElectroGuard Overview Principle of Operation After using the normal stopping method of the machine or process, the machine operator turns a Remote Lockout Station handle from the “On” to “Off ” position. The station signals the isolation contactors (1IC and 2IC) to drop out and isolate the supply voltage from the loads (see Control Circuit). Power Circuit 1IC 2IC Incoming 3 Phase Power To Motor Controllers H1 X1 H2 Control Power Disconnecting Means/Branch Circuit Protection ➊ Trans. X2 To Loads GC Voltage Decay Relays (VDR) Grd When system residual voltage decays to pre-determined levels, the grounding contactor (GC) is energized, connecting the load to ground (see Power Circuit). The grounding contactor (GC) is electrically and mechanically interlocked with the isolation contactors (1IC and 2IC). Control Circuit Remote Lockout Station Off On GC 1IC GC 2IC VDR 1IC 2IC GC GC 1IC 2IC Mechanically Interlocked The “System Isolated” Light will now illuminate on the Remote Lockout Station to indicate the system is isolated. The machine operator then Locks-Out and Tags-Out the station in the “Off ” position. 1IC, 2IC, & GC are mechanically and electrically interlocked System Isolated (*) (*) = “On” when the Remote Lockout Station switch is “Off” ➊ Available factory installed within the ElectroGuard as an option. Optional Features • Four (4) or ten (10) port Expansion Modules to permit additional Remote Lockout Stations to be used (see page 12-16 for details). • Pneumatic Isolation Module to isolate pneumatic energy (see page 12-15 for details). • Status communication to a remote PLC (see page 12-17 for details). • Fusible disconnect switch (Bulletin 2032) or thermal-magnetic circuit breaker (Bulletin 2033) to provide branch circuit protection. Optional Pneumatic Isolation Module 12-3 Safety Isolation System ElectroGuard Combination Systems with Thermal-magnetic Circuit Breaker ! Bussing Designation The Catalogue Number as listed is incomplete. Select a Bussing Designation Code from the table below. Example: Cat. No. 2033-!0085J⊗-44 becomes Cat. No. 2033-M0085J⊗-44 for “600A Line Side Incoming Bus and Outgoing Power Cables” bussing designation. Type of Bussing ➊ Catalogue Number Code 600A Line Side Incoming Bus and Outgoing Power Cables M 1200A Line Side Incoming Bus and Outgoing Power Cables S Line Side Incoming Power Cables and 600A Load Side Outgoing Bus F Line Side Incoming Power Cables and 1200A Load Side Outgoing Bus B ⊗ Input Line Voltage Code The Catalogue Number as listed is incomplete. Select an Input Line Voltage Code from the table below. Example: Catalogue Number 2033-A0085J⊗-44 becomes Catalogue Number 2033-A0085JB-44 for a 480V 60Hz Input Line Voltage application. Input Line Voltage 208V 60Hz 240V 60Hz 480V 60Hz 600V 60Hz H A B C Voltage Code for Catalogue Number Product Selection: Remote Lockout Station ➋ Catalogue Number “System Isolated” Light Colour Type 1 General Purpose Enclosure Type 12 Dust tight Enclosure Type 4 Watertight Painted Steel Enclosure Type 4X Watertight Stainless Steel Enclosure 2030-RLSAW 2030-RLSJW 2030-RLSFW 2030-RLSCW White Combination Systems with Thermal-magnetic Circuit Breaker Product Selection for Outside of North America (see page 12-19 for Ordering Instructions) 3-Phase Max. kW Rating (50Hz) Ampere Rating (AC-3) 23 43 85 110 Catalogue Number ➌ 230V 400V 500V 600V IP 30 Enclosure IP 54 Enclosure IP 54 Motor Control Centre Type Enclosure (w/bussing) 4 4 4 4 2033-C0023P⊗-39K 2033-C0023H ⊗-39K 2033-!0023H⊗-39K 2033-C0023W⊗-39K 5.5 5.5 5.5 5.5 2033-C0023P⊗-40K 2033-C0023H ⊗-40K 2033-!0023H⊗-40K 2033-C0023W⊗-40K 7.5 7.5 7.5 7.5 2033-C0023P⊗-41K 2033-C0023H ⊗-41K 2033-!0023H⊗-41K 2033-C0023W⊗-41K - 11 11 11 2033-C0023P⊗-42K 2033-C0023H ⊗-42K 2033-!0023H⊗-42K 2033-C0023W⊗-42K 11 - - - 2033-C0043P⊗-42K 2033-C0043H ⊗-42K 2033-!0043H⊗-42K 2033-C0043W⊗-42K 13 13 13 13 2033-C0043P⊗-43K 2033-C0043H ⊗-43K 2033-!0043H⊗-43K 2033-C0043W⊗-43K - 15 15 15 2033-C0043P⊗-44K 2033-C0043H ⊗-44K 2033-!0043H⊗-44K 2033-C0043W⊗-44K - 18.5 18.5 18.5 2033-C0043P⊗-45K 2033-C0043H ⊗-45K 2033-!0043H⊗-45K 2033-C0043W⊗-45K - 22 22 22 2033-C0043P⊗-46K 2033-C0043H ⊗-46K 2033-!0043H⊗-46K 2033-C0043W⊗-46K 15 - - - 2033-C0085P⊗-44K 2033-C0085H ⊗-44K 2033-!0085H⊗-44K 2033-C0085W⊗-44K 18.5 - - - 2033-C0085P⊗-45K 2033-C0085H ⊗-45K 2033-!0085H⊗-45K 2033-C0085W⊗-45K 22 - - - 2033-C0085P⊗-46K 2033-C0085H ⊗-46K 2033-!0085H⊗-46K 2033-C0085W⊗-46K 25 25 25 25 2033-C0085P⊗-47K 2033-C0085H ⊗-47K 2033-!0085H⊗-47K 2033-C0085W⊗-47K - 32 32 32 2033-C0085P⊗-48K 2033-C0085H ⊗-48K 2033-!0085H⊗-48K 2033-C0085W⊗-48K - 37 37 37 2033-C0085P⊗-49K 2033-C0085H ⊗-49K 2033-!0085H⊗-49K 2033-C0085W⊗-49K - 45 45 45 2033-C0085P⊗-50K 2033-C0085H ⊗-50K 2033-!0085H⊗-50K 2033-C0085W⊗-50K 32 - - - 2033-C0110P⊗-48K 2033-C0110H ⊗-48K 2033-!0110H⊗-48K 2033-C0110W⊗-48K - 55 55 55 2033-C0110P⊗-51K 2033-C0110H ⊗-51K 2033-!0110H⊗-51K 2033-C0110W⊗-51K - - 63 63 2033-C0110P⊗-52K 2033-C0110H ⊗-52K 2033-!0110H⊗-52K 2033-C0110W⊗-52K IP 65 Enclosure ➊ Bus Type: Copper with tin plating. Consult factory for other types of bussing. ➋ Safety Isolation Systems rated up through 85A can support a maximum of four (4) Remote Lockout Stations (RLS). Systems rated from 110A - 1200A can support a maximum of six (6) RLS. If additional RLS are required, order the optional Expansion Module(s) (see page 12-16). ➌ Optional Time Delay Feature. The Safety Isolation System may be ordered with a factory set time delay feature (30 seconds) in order to allow time for the machine operator to shut-down drives or other equipment that requires a controlled stop, after the operating handle on a Remote Lockout Station has been moved to the “Off” position. See page 12-14 for instructions on how to order the optional time delay feature. Consult your local Rockwell Automation sales office for other time settings. 12-12 Safety Isolation System ElectroGuard Combination Systems with Thermal-magnetic Circuit Breaker Product Selection for Outside of North America (see page 12-19 for Ordering Instructions) 3-Phase Max. kW Rating (50Hz) Ampere Rating (AC-3) 110 180 210 300 420 Catalogue Number ➊ 230V 400V 500V 600V IP 30 Enclosure IP 54 Enclosure IP 54 Motor Control Centre Type Enclosure (w/bussing) - - - 75 2033-C0110P⊗-53K 2033-C0110H⊗-53K 2033-!0110H⊗-53K 2033-C0110W⊗-53K IP 65 Enclosure - - - 100 2033-C0110P⊗-55K 2033-C0110H⊗-55K 2033-!0110H⊗-55K 2033-C0110W⊗-55K 37 - - - 2033-C0180P⊗-49K 2033-C0180H⊗-49K 2033-!0180H⊗-49K 2033-C0180W⊗-49K 45 - - - 2033-C0180P⊗-50K 2033-C0180H⊗-50K 2033-!0180H⊗-50K 2033-C0180W⊗-50K 55 - - - 2033-C0180P⊗-51K 2033-C0180H⊗-51K 2033-!0180H⊗-51K 2033-C0180W⊗-51K - 63 - - 2033-C0180P⊗-52K 2033-C0180H⊗-52K 2033-!0180H⊗-52K 2033-C0180W⊗-52K - 75 75 - 2033-C0180P⊗-53K 2033-C0180H⊗-53K 2033-!0180H⊗-53K 2033-C0180W⊗-53K - 90 90 - 2033-C0180P⊗-54K 2033-C0180H⊗-54K 2033-!0180H⊗-54K 2033-C0180W⊗-54K - - 110 110 2033-C0180P⊗-56K 2033-C0180H⊗-56K 2033-!0180H⊗-56K 2033-C0180W⊗-56K - - - 132 2033-C0180P⊗-57K 2033-C0180H⊗-57K 2033-!0180H⊗-57K 2033-C0180W⊗-57K - - - 150 2033-C0180P⊗-58K 2033-C0180H⊗-58K 2033-!0180H⊗-58K 2033-C0180W⊗-58K - - - 160 2033-C0180P⊗-59K 2033-C0180H⊗-59K 2033-!0180H⊗-59K 2033-C0180W⊗-59K 63 - - - 2033-C0210P⊗-52K 2033-C0210H⊗-52K 2033-!0210H⊗-52K 2033-C0210W⊗-52K - 110 - - 2033-C0210P⊗-56K 2033-C0210H⊗-56K 2033-!0210H⊗-56K 2033-C0210W⊗-56K - - 132 - 2033-C0210P⊗-57K 2033-C0210H⊗-57K 2033-!0210H⊗-57K 2033-C0210W⊗-57K - - 150 - 2033-C0210P⊗-58K 2033-C0210H⊗-58K 2033-!0210H⊗-58K 2033-C0210W⊗-58K - - - 185 2033-C0210P⊗-60K 2033-C0210H⊗-60K 2033-!0210H⊗-60K 2033-C0210W⊗-60K - - - 200 2033-C0210P⊗-61K 2033-C0210H⊗-61K 2033-!0210H⊗-61K 2033-C0210W⊗-61K 75 - - - 2033-C0300P⊗-53K 2033-C0300H⊗-53K 2033-!0300H⊗-53K 2033-C0300W⊗-53K 90 - - - 2033-C0300P⊗-54K 2033-C0300H⊗-54K 2033-!0300H⊗-54K 2033-C0300W⊗-54K - 132 - - 2033-C0300P⊗-57K 2033-C0300H⊗-57K 2033-!0300H⊗-57K 2033-C0300W⊗-57K - 150 - - 2033-C0300P⊗-58K 2033-C0300H⊗-58K 2033-!0300H⊗-58K 2033-C0300W⊗-58K - 160 160 - 2033-C0300P⊗-59K 2033-C0300H⊗-59K 2033-!0300H⊗-59K 2033-C0300W⊗-59K - - 185 - 2033-C0300P⊗-60K 2033-C0300H⊗-60K 2033-!0300H⊗-60K 2033-C0300W⊗-60K - - 200 - 2033-C0300P⊗-61K 2033-C0300H⊗-61K 2033-!0300H⊗-61K 2033-C0300W⊗-61K - - - 220 2033-C0300P⊗-62K 2033-C0300H⊗-62K 2033-!0300H⊗-62K 2033-C0300W⊗-62K - - - 250 2033-C0300P⊗-63K 2033-C0300H⊗-63K 2033-!0300H⊗-63K 2033-C0300W⊗-63K - - - 300 2033-C0300P⊗-64K 2033-C0300H⊗-64K 2033-!0300H⊗-64K 2033-C0300W⊗-64K 110 - - - 2033-C0420P⊗-56K 2033-C0420H⊗-56K 2033-!0420H⊗-56K 2033-C0420W⊗-56K 132 - - - 2033-C0420P⊗-57K 2033-C0420H⊗-57K 2033-!0420H⊗-57K 2033-C0420W⊗-57K - 185 - - 2033-C0420P⊗-60K 2033-C0420H⊗-60K 2033-!0420H⊗-60K 2033-C0420W⊗-60K ➊ Optional Time Delay Feature. The Safety Isolation System may be ordered with a factory set time delay feature (30 seconds) in order to allow time for the machine operator to shut-down drives or other equipment that requires a controlled stop, after the operating handle on a Remote Lockout Station has been moved to the “Off” position. See next page for instructions on how to order the optional time delay feature. Consult your local Rockwell Automation sales office for other time settings. 12-13 Safety Isolation System ElectroGuard Combination Systems with Thermal-magnetic Circuit Breaker Product Selection for Outside of North America (see page 12-19 for Ordering Instructions) 3-Phase Max. kW Rating (50Hz) Ampere Rating (AC-3) 230V 400V 500V 600V 420 630 860 1200 Catalogue Number ➊ IP 30 Enclosure IP 54 Enclosure IP 54 Motor Control Centre Type Enclosure (w/bussing) - 2033-C0420P⊗-61K 2033-C0420H⊗-61K 2033-!0420H⊗-61K 2033-C0420W⊗-61K 220 - 2033-C0420P⊗-62K 2033-C0420H⊗-62K 2033-!0420H⊗-62K 2033-C0420W⊗-62K 250 - 2033-C0420P⊗-63K 2033-C0420H⊗-63K 2033-!0420H⊗-63K 2033-C0420W⊗-63K 300 - 2033-C0420P⊗-64K 2033-C0420H⊗-64K 2033-!0420H⊗-64K 2033-C0420W⊗-64K - - 355 2033-C0420P⊗-65K 2033-C0420H⊗-65K 2033-!0420H⊗-65K 2033-C0420W⊗-65K - - - 390 2033-C0420P⊗-66K 2033-C0420H⊗-66K 2033-!0420H⊗-66K 2033-C0420W⊗-66K - - - 425 2033-C0420P⊗-67K 2033-C0420H⊗-67K 2033-!0420H⊗-67K 2033-C0420W⊗-67K 150 - - - 2033*-C0630P⊗-58K 2033*-C0630H⊗-58K 2033-!0630H⊗-58K 2033*-C0630W⊗-58K 160 - - - 2033*-C0630P⊗-59K 2033*-C0630H⊗-59K 2033-!0630H⊗-59K 2033*-C0630W⊗-59K 185 - - - 2033*-C0630P⊗-60K 2033*-C0630H⊗-60K 2033-!0630H⊗-60K 2033*-C0630W⊗-60K 200 - - - 2033*-C0630P⊗-61K 2033*-C0630H⊗-61K 2033-!0630H⊗-61K 2033*-C0630W⊗-61K - 250 - - 2033*-C0630P⊗-63K 2033*-C0630H⊗-63K 2033-!0630H⊗-63K 2033*-C0630W⊗-63K - 300 - - 2033*-C0630P⊗-64K 2033*-C0630H⊗-64K 2033-!0630H⊗-64K 2033*-C0630W⊗-64K - 355 355 - 2033*-C0630P⊗-65K 2033*-C0630H⊗-65K 2033-!0630H⊗-65K 2033*-C0630W⊗-65K - - 390 - 2033*-C0630P⊗-66K 2033*-C0630H⊗-66K 2033-!0630H⊗-66K 2033*-C0630W⊗-66K - - 450 450 2033*-C0630P⊗-68K 2033*-C0630H⊗-68K 2033-!0630H⊗-68K 2033*-C0630W⊗-68K - - - 500 2033*-C0630P⊗-69K 2033*-C0630H⊗-69K 2033-!0630H⊗-69K 2033*-C0630W⊗-69K 250 - - - 2033*-C0860P⊗-63K 2033*-C0860H⊗-63K 2033-!0860H⊗-63K 2033*-C0860W⊗-63K - 450 - - 2033*-C0860P⊗-68K 2033*-C0860H⊗-68K 2033-!0860H⊗-68K 2033*-C0860W⊗-68K - 500 500 - 2033*-C0860P⊗-69K 2033*-C0860H⊗-69K 2033-!0860H⊗-69K 2033*-C0860W⊗-69K - - 560 560 2033*-C0860P⊗-70K 2033*-C0860H⊗-70K 2033-!0860H⊗-70K 2033*-C0860W⊗-70K - - - 600 2033*-C0860P⊗-71K 2033*-C0860H⊗-71K 2033-!0860H⊗-71K 2033*-C0860W⊗-71K 300 - - - 2033*-C1200P⊗-64K 2033*-C1200H⊗-64K 2033-!1200H⊗-64K 2033*-C1200W⊗-64K 390 - - - 2033*-C1200P⊗-66K 2033*-C1200H⊗-66K 2033-!1200H⊗-66K 2033*-C1200W⊗-66K - 600 600 - 2033*-C1200P⊗-71K 2033*-C1200H⊗-71K 2033-!1200H⊗-71K 2033*-C1200W⊗-71K - 710 710 710 2033*-C1200P⊗-72K 2033*-C1200H⊗-72K 2033-!1200H⊗-72K 2033*-C1200W⊗-72K - - 750 750 2033*-C1200P⊗-73K 2033*-C1200H⊗-73K 2033-!1200H⊗-73K 2033*-C1200W⊗-73K - - 850 850 2033*-C1200P⊗-74K 2033*-C1200H⊗-74K 2033-!1200H⊗-74K 2033*-C1200W⊗-74K - - 888 888 2033*-C1200P⊗-75K 2033*-C1200H⊗-75K 2033-!1200H⊗-75K 2033*-C1200W⊗-75K - - - 1043 2033*-C1200P⊗-76K 2033*-C1200H⊗-76K 2033-!1200H⊗-76K 2033*-C1200W⊗-76K - 200 - 220 - - - - - - IP 65 Enclosure To order the Time Delay feature, add the following Catalogue String to the end of the Cat. No. shown in the table: Factory set 30 second time delay feature: -1TD Example: Catalogue Number 2033-C0180P⊗-54K becomes Catalogue Number 2033-C0180P⊗-54K-1TD to include the time delay feature. * Input Power Feed Catalogue Number Code The Catalogue Number as listed is incomplete. Select an Input Power Feed Code from the table below. Example: Catalogue Number 2033*-C0630P⊗-58K becomes Catalogue Number 2033T-C0630P⊗-58K for a “Top Feed” input power requirement. Input Power Feed Catalogue Number Code Top Feed T Bottom Feed B ➊ Optional Time Delay Feature. The Safety Isolation System may be ordered with a factory set time delay feature (30 seconds) in order to allow time for the machine operator to shut-down drives or other equipment that requires a controlled stop, after the operating handle on a Remote Lockout Station has been moved to the “Off” position. Consult your local Rockwell Automation sales office for other time settings. 12-14 Safety Isolation System ElectroGuard Combination Systems with Thermal-magnetic Circuit Breaker/Optional Features Product Selection for Outside of North America (see page 12-19 for Ordering Instructions) ! Bussing Designation The Catalogue Number as listed is incomplete. Select a Bussing Designation Code from the table below. Example: Catalogue Number 2033-!0085H⊗-44K becomes Catalogue Number 2033-E0085H⊗-44K for “600A Line Side Incoming Bus and Outgoing Power Cables” bussing designation. Type of Bussing ➊ Catalogue Number Code 600A Line Side Incoming Bus and Outgoing Power Cables E 1200A Line Side Incoming Bus and Outgoing Power Cables D Line Side Incoming Power Cables and 600A Load Side Outgoing Bus H Line Side Incoming Power Cables and 1200A Load Side Outgoing Bus R ⊗ Input Line Voltage Code The Catalogue Number as listed is incomplete. Select an Input Line Voltage Code from the table below. Example: Catalogue Number 2033-C0085W⊗-48K becomes Catalogue Number 2033-C0085WN-48K for a 380V 50Hz Input Line Voltage application. Input Line Voltage 220V 50Hz 380-400V 50Hz 400-415V 50Hz 440V 50Hz 500V 50Hz 550V 50Hz Voltage Code for Catalogue Number A N G B M C Product Selection: Remote Lockout Station ➋ Catalogue Number “System Isolated” Light Colour IP 30 Enclosure IP 54 Enclosure IP 65 Enclosure 2030-RLSPG 2030-RLSHG 2030-RLSWG Green Optional Features Pneumatic Isolation Module (Must be ordered with Safety Isolation System): The Safety Isolation System is available with an optional means of isolating the pneumatic energy source for the machine or process. If the machine operator/maintenance personnel initiates isolation of the electrical energy by operating one of the Remote Lockout Stations, a safety valve is simultaneously actuated to bleed pressure from the air line between the valve and the machine. When the air pressure has fallen to a predetermined level, the unit will allow the light on the Remote Lockout Station to illuminate, if electrical isolation has also been achieved. To order the Pneumatic Isolation option: Step 1: Add the following Catalogue String to the Safety Isolation System Catalogue Number: To indicate that the Safety Isolation System should be supplied as “Pneumatic Ready.” -1PN e.g. 2031-A0085JB-1PN to indicate an 85A Safety Isolation System that is to be “Pneumatic Ready.” Step 2: Order suitably enclosed Pneumatic Isolation Module as separate item: For North America: Catalogue Number Pressure Range Valve Port Size Type 1 General Purpose Enclosure Type 12 Dust tight Enclosure 1in 2030-PA1201 2030-PJ1201 2030-PF1201 2030-PC1201 3/4in 2030-PA1203 2030-PJ1203 2030-PF1203 2030-PC1203 30-120 psi Type 4 Watertight Type 4X Watertight Painted Steel Enclosure Stainless Steel Enclosure For Outside of North America: Catalogue Number Pressure Range 2-7 bar Valve Port Size IP 30 Enclosure IP 54 Enclosure IP 65 Enclosure 1in 2030-PP0071 2030-PH0071 2030-PW0071 3/4in 2030-PP0073 2030-PH0073 2030-PW0073 ➊ Bus Type: Copper with tin plating. Consult factory for other types of bussing. ➋ Safety Isolation Systems rated up through 85A can support a maximum of four (4) Remote Lockout Stations (RLS). Systems rated from 110A - 1200A can support a maximum of six (6) RLS. If additional RLS are required, order the optional Expansion Module(s) (see page 12-16). 12-15 Safety Isolation System ElectroGuard Optional Features (continued) Expansion Module (Can be ordered separately): For applications requiring more than the maximum allowable Remote Lockout Stations, or total wire lengths longer than those permitted with the Remote Lockout Stations. Expansion Modules are available in 4 or 10 port configurations. Each Expansion Module is wired to a port on the Control Module, and takes the connection port that would normally accommodate a Remote Lockout Station (see page 12-18 to determine if an Expansion Module is required due to wire length considerations). The 23A through 85A systems will accommodate connection of a maximum of 4 Expansion Modules, and the 110A through 1200A systems will accommodate connection of a maximum of 6 Expansion Modules. Certain ampere size Safety Isolation System Power Panels can accommodate either 1 or 2 Expansion Modules installed internally. In all other instances the Expansion Module(s) must be located external to the Safety Isolation System in a suitably rated enclosure. Ampere Size of Safety Isolation System Internal Provisions to Accommodate Expansion Modules 23A - 85A None 110A - 420A Provisions to accept one (1) Expansion Module (Bulletins 2031, 2032 or 2033) 630A - 1200A Note: The time delay feature affects all input devices wired to the Expansion Module. For Expansion Module(s) Factory Installed: Add One of the Following Catalogue Number Strings to the Safety Isolation System Catalogue Number: Number of Expansion Modules Number of Ports per Expansion Module One (available on Bulletin 2031, 2032, or 2033, 110A– 1200A Systems only) Two (available on 630A – 1200A Bulletin 2032 or 2033 Systems only) 4 -1EUF 4 w/time delay -1EUFTDA 10 -1EUT 10 w/time delay -1EUTTDA 4 -2EUF 4 w/time delay -2EUFTDA 10 -2EUT 10 w/time delay -2EUTTDA ➊ e.g. Catalogue Number 2032T-A0630JB-30L becomes Catalogue Number 2032T-A0630JB-30L-2EUT to indicate a 630A Safety Isolation System that includes 2 internally installed 10 port Expansion Modules without the time delay feature. Open Type Expansion Module for Field Addition Open Type ➋ Description Provisions to accept up to two (2) Expansion Modules in Bulletin 2032 or 2033 combination systems, or one (1) Expansion Module in Bulletin 2031 non combination systems. 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 Remote Lockout Station has been switched to the “Off ” position. Consult your Rockwell Automation sales office 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 DeviceNet or Remote I/O. Note: The status communication option allows a remote PLC to receive status signals from the Expansion Module. The Expansion Module does not accept input signals from DeviceNet or Remote I/O. Catalogue Number String ➊ Catalogue Number 4 port 2030-EUNF 4 port w/ time delay 2030-EUNF-1TDA 10 port 2030-EUNT 10 port w/time delay 2030-EUNT-1TDA ➋ Requires user supplied enclosure if not installed in the Safety Isolation System Power Panel. ➌ To order the Status Communication to a remote PLC option installed in an enclosed Expansion Module, add one of the following Catalogue Strings to the Expansion Module Catalogue Number: Communication Platform Number of I/O Points Catalogue Number String ➍ Remote I/O 16 points -1COM DeviceNet 16 points -1DNET ➍ e.g. Catalogue Number 2030-EUJF becomes Catalogue Number 2030-EUJF1COM to indicate a Type 12 enclosed, 4-port expansion module, with 16 points of remote I/O. To order the optional enclosed Expansion Module for field addition for North America: Catalogue Number ➌ Description 4 port 4 port w/ time delay 10 port 10 port w/time delay Type 1 Enclosure Type12 Enclosure Type 4 Painted Enclosure Type 4X Stainless Steel Enclosure 2030-EUAF 2030-EUJF 2030-EUFF 2030-EUCF 2030-EUAF-1TDA 2030-EUJF-1TDA 2030-EUFF-1TDA 2030-EUCF-1TDA 2030-EUAT 2030-EUJT 2030-EUFT 2030-EUCT 2030-EUAT-1TDA 2030-EUJT-1TDA 2030-EUFT-1TDA 2030-EUCT-1TDA To order the optional enclosed Expansion Module for field addition for outside of North America: Catalogue Number ➌ Description 4 port 4 port w/ time delay 10 port 10 port w/time delay 12-16 IP30 Enclosure IP54 Enclosure 2030-EUPF 2030-EUHF IP65 Enclosure 2030-EUWF 2030-EUPF-1TDA 2030-EUHF-1TDA 2030-EUWF-1TDA 2030-EUPT 2030-EUHT 2030-EUWT 2030-EUPT-1TDA 2030-EUHT-1TDA 2030-EUWT-1TDA Safety Isolation System ElectroGuard Optional Features (continued) Status Communication to a remote PLC (Should be ordered with Safety Isolation System) This option provides Remote I/O via “Flex” modules. Communication can be via: • The DeviceNet communication platform, or • The Remote I/O communication platform. Note: The status communication option allows a remote PLC to receive status signals from the ElectroGuard Safety Isolation System. The ElectroGuard does not accept input signals through these communication platforms. Status communication capabilities: • • • • Overall system status, Status of each Remote Lockout Station, Status of the Pneumatic Isolation Module (if used), Status of other optional Safety Input devices. Note: Each communication module provides sixteen (16) data points. In determining which Catalogue Number String to specify from the table below, please keep the following in mind: • • • • Overall system status information requires one (1) data point. The Pneumatic Isolation Module (if used) requires one (1) data point. Each Remote Lockout Station used in the application requires one (1) data point. Each optional Rockwell Automation Safety Input device (i.e. Safety Mat, Light Curtain, E-Stop Station, Proximity Switch, Photo Switch) requires one (1) data point. To order the Status Communication to a remote PLC option, add one of the following Catalogue Strings to the Safety Isolation System Catalogue Number: Communication Platform Number of I/O points Catalogue Number String ➊ 16 points -1COM Remote I/O DeviceNet 32 points -2COM 48 points -3COM" 64 points -4COM! 16 points -1DNET 32 points -2DNET 48 points -3DNET" 64 points -4DNET! " Maximum available for units from 23A through 85A. ! Only available on units from 110A through 1200A. ➊ e.g. Catalogue Number 2031-A0085JB becomes Catalogue Number 2031-A0085JB-1COM to indicate an 85A Safety Isolation System that includes 16 points of Remote I/O for status communication to a remote PLC. Cover Mounted Metering (Must be ordered with Safety Isolation System): Cover mounted ammeters and/or voltmeters are available as factory installed options in order to provide visual indication of line side system current and/or voltage. To order metering, add one or more of the following Catalogue Strings to the Safety Isolation System Catalogue Number: Type of Metering Required Catalogue Number String ➋ Single-phase Ammeter -1AM Three-phase Ammeter -3AM Single-phase Voltmeter -1VM Three-phase Voltmeter -3VM ➋ e.g. Catalogue Number 2031-A0085JB becomes Catalogue Number 2031-A0085JB-1AM to indicate an 85A Safety Isolation System that includes a cover mounted single-phase Ammeter. 12-17 Safety Isolation System ElectroGuard Typical Wiring Diagram/Wire Length Considerations Typical Wiring Diagram Safety Isolation System with Optional Fusible Disconnecting Means Total Wire Length for Expansion Modules For North America Max. Total Wire Gauge Wire Length 14AWG 40,000 feet 16AWG 23,000 feet 18AWG 11,700 feet GC 1IC 2IC L1 Sample Calculation: An application for a 630A Safety Isolation System will require 8 Remote Lockout Stations (RLS): T1 T2 To Motor Starters T3 L2 L3 Designates field connection points To Loads Remote Lockout Station(s) The wire length from RLS # 1 to the Control Module (in the ElectroGuard Power Panel) will be 50ft. The wire length from RLS # 2 to the Control Module will be 200ft. The wire length from RLS # 3 to the Control Module will be 100ft. The wire length from RLS # 4 to the Control Module will be 300ft. The wire length from RLS # 5 to the Control Module will be 500ft. The wire length from RLS # 6 to the Control Module will be 1000ft. The wire length from RLS # 7 to the Control Module will be 850ft. The wire length from RLS # 8 to the Control Module will be 750ft. 14AWG wire will be used to connect the RLS to the Control Module (see illustration below). Wire Length Considerations ATTENTION: It is important not to exceed the maximum wire length values shown in this section. If the maximum values are exceeded, this may result in an unreliable signal to the Safety Isolation System. Consider using an Expansion Module if wire lengths greater than those shown for the Remote Lockout Stations are needed. 152m (500ft) RLS #5 1. Determine the distance in feet or meters from each Remote Lockout Station to the Control Module (located inside the Safety Isolation System Power Panel). 2. Sum the distances for all of the Remote Lockout Stations. 3. Double this value. 4. Compare this doubled value with the maximum values for total wire length shown in the table below: Total Wire Length for Remote Lockout Stations For Outside of North America Wire Gauge Max. Total Wire Length Wire Gauge Max. Total Wire Length 14AWG 4,600 feet 18 Gauge Metric 1,400 meters 16AWG 2,600 feet 14 Gauge Metric 800 meters 18AWG 1,300 feet If the application requires a total wire length greater than those shown in the table, one or more Expansion Modules should be used. The maximum wire length for the Expansion Modules is shown in the following table: 259m (850ft) 228m (750ft) RLS #8 Expansion Module 91m (300ft) RLS #7 30m (100ft) RLS #3 Calculate the total wire length as follows: 12-18 304m (1000ft) RLS #4 Each Remote Lockout Station is connected to the Control Module in the Power Panel of the Safety Isolation System. The total length of the wire used to connect the Remote Lockout Stations to the Control Module should not exceed the maximum values shown in the following tables. For North America For Outside North America Max. Total Wire Gauge Wire Length 18 Gauge Metric 12,200 meters 14 Gauge Metric 7,000 meters 61m (200ft) RLS #2 Control Module RLS #1 RLS #6 Power Panel 15m (50ft) Analysis: The Control Module furnished with the 630A Safety Isolation System is capable of supporting a maximum of six (6) RLS. Since this installation will require eight (8) RLS, an optional 4 port Expansion Module will also be used. The Expansion Module will be wired to the Control Module and will take the place of one of the original six RLS. We will, therefore, plan to wire five (5) of the RLS directly to the Control Module and three (3) of the RLS to the Expansion Module. Since the Expansion Module allows greater wire lengths than the Control Module, we will plan to wire the RLS to be installed furthest away from the Power Panel to the Expansion Module. For RLS # 1: wire length = 50ft x 2 = 100ft For RLS # 2: wire length = 200ft x 2 = 400ft For RLS # 3: wire length = 100ft x 2 = 200ft For RLS # 4: wire length = 300ft x 2 = 600ft For RLS # 5: wire length = 500ft x 2 = 1000ft Safety Isolation System ElectroGuard Wire Length Considerations/Ordering Instructions The total wire length for the 5 RLS to be wired to the Control Module will be: 100ft + 400ft + 200ft + 600ft + 1,000ft = 2,300ft Per the table entitled Total Wire Length for Remote Lockout Stations on page 12-18, the maximum allowable wire length for 14AWG wire is 4,600ft for the RLS to be wired to the Control Module. This portion of the installation will be within the maximum wire length permitted. Next, we need to check the wire length calculation for the RLS to be wired to the Expansion Module. For RLS # 6: wire length = 1000ft x 2 = 200ft For RLS # 7: wire length = 850ft x 2 = 1700ft For RLS # 8: wire length = 750ft x 2 = 1500ft The total wire length for the 3 RLS to be wired to the Expansion Module will be: 2000ft + 1700ft + 1500ft = 5,200ft Per the table entitled Total Wire Length for Expansion Modules on page 12-18, the maximum allowable wire length for 14AWG wire is 40,000ft for the RLS to be wired to the Expansion Module. This portion of the installation will also be within the maximum wire length permitted. Ordering Instructions 1. Determine the Catalogue 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: a. 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. 2. 3. 4. 5. b. 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.” c. 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”. d. Select the Safety Isolation System that meets or exceeds this horsepower or kilowatt rating at the required voltage and frequency. e. Sum the locked-rotor 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 locked-rotor current”. f. Find the horsepower or kilowatt rating of a single motor with a locked-rotor current value greater than or equal to the “combined load locked-rotor current” value determined in Step “e”. g. Select the Safety Isolation System that meets or exceeds this horsepower or kilowatt rating at the required voltage and frequency. h. Compare the ratings of the Safety Isolation Systems selected in Steps “d” and “g”. Select the larger of the two systems for your application. Determine how many Remote Lockout Stations are required for the application. Determine how many Expansion Modules (if any) are required for the application. Pick suitable enclosure type(s) for the Safety Isolation System Power Panel, Remote Lockout Stations and enclosed modules (e.g., Expansion Modules, Pneumatic Isolation Module). Determine what, if any, factory installed options are required for the application (e.g. Pneumatic Isolation, Status Communication to remote PLC, metering). 12-19