Allen-Bradley ElectroGuard 85...1200 A User Manual
Allen-Bradley ElectroGuard 85...1200 A is a safety isolation system (SIS) designed to enhance lockout/tagout (LOTO) procedures for machines. It isolates energy by using redundancy and operator feedback, making it easier and quicker to perform LOTO. For machines with electrical and pneumatic energy sources, the ElectroGuard 85...1200 A provides disconnection, isolation, and grounding functionality. For example, it can be used to isolate a machine's electrical energy, allowing maintenance personnel to safely work on the machine.
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USER MANUAL BULLETIN 2030 ElectroGuard® Safety Isolation System 2 Important User Information Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes, and standards. The figures, charts, sample programs, and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication. Allen-Bradley Publication SGI-1.1, Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control (available from your local Allen-Bradley distributor) describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication. Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited. Throughout this manual we use notes to make you aware of safety considerations: ATTENTION ! Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss Attention statements help you to: Identify a hazard Avoid a hazard Recognize the consequences IMPORTANT Identifies information that is critical for successful application and understanding of the product. Publication 2030-UM003A-EN-P - May 2006 3 Product Safety Labels The following Product Safety Labels identify information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Figure 0.1 Hazardous Voltage, Part Number. 31035-090-01 Figure 0.2 Hazardous Voltage Part Number. 31035-091-01 Figure 0.3 Pneumatic Energy Present Part Number. 31035-092-01 Figure 0.4 Heavy Object Part Number. 31035-093-01 Figure 0.5 Heavy Object Part Number. 31035-094-01 Publication 2030-UM003A-EN-P - May 2006 Table of Contents Chapter 1 — Product Overview Purpose of the Safety Isolation System. . . . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Requirements and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Description of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Sequence of Isolation Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Typical Safety Isolation System Layout. . . . . . . . . . . . . . . . . . . . . . . . 1-5 Chapter 2 — Installation and Wiring Pre-Installation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Power Fuses or Circuit Breaker Requirements. . . . . . . . . . . . . . . 2-2 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Approximate Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Receiving the ElectroGuard® Power Panel and Modules . . . . . . . . 2-26 Storing the ElectroGuard® Power Panel and Modules. . . . . . . 2-26 ElectroGuard® Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Remote Lockout Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Verification Module (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Expansion Module (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Pneumatic Isolation Module (Optional) . . . . . . . . . . . . . . . . . . . 2-32 Installation and Wiring of the ElectroGuard® Power Panel . . . . . . 2-34 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Installation of the Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 Incoming and Outgoing Three-phase Cable Specifications . . . 2-36 Wiring of the Power Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Installation and Wiring of the ElectroGuard® Control Module . . . 2-45 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 Wiring the Remote Lockout Stations to the Control Module (RLS1…RLS6 Connectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Wiring the Control Module with Pneumatic Ready Option . . . 2-50 Wiring the Control Module with Time Delay Option (IP1 or FB1 Drive Control Stop Connector) . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 Wiring the RLS and System Status Signals (IP2 connector) . . . 2-54 Installation and Wiring of the ElectroGuard® Remote Lockout Station(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Remote Lockout Station Cable Specifications . . . . . . . . . . . . . . 2-56 Maximum Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Wiring the Remote Lockout Station . . . . . . . . . . . . . . . . . . . . . . 2-57 Installation and Wiring of the ElectroGuard® Dual Remote Lockout Station(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Remote Lockout Station Cable Specifications . . . . . . . . . . . . . . 2-62 Maximum Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Wiring the Dual Remote Lockout Station . . . . . . . . . . . . . . . . . 2-63 1 Publication 2030-UM003A-EN-P - May 2006 2 Table of Contents Installation and Wiring of the ElectroGuard® Expansion Module 2-68 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Installation of the Expansion Module . . . . . . . . . . . . . . . . . . . . 2-68 Wiring the Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 Installation and Wiring of the ElectroGuard® Verification Module 2-71 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 Installation of the Verification Module. . . . . . . . . . . . . . . . . . . . 2-71 Wiring of the Verification Module . . . . . . . . . . . . . . . . . . . . . . . 2-71 Installation and Wiring of the ElectroGuard® Pneumatic Isolation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 Installation of the Pneumatic Isolation Module . . . . . . . . . . . . . 2-72 Wiring of the Pneumatic Isolation Module . . . . . . . . . . . . . . . . 2-72 Installation and Wiring of the Status Communication Modules . . . 2-73 Installation of the Communication Modules . . . . . . . . . . . . . . . 2-73 Wiring of the Communication Module. . . . . . . . . . . . . . . . . . . . 2-74 Final Steps for Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . 2-81 Chapter 3 — Commissioning of the Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ElectroGuard® Safety Isolation ElectroGuard® Power Panel Verification . . . . . . . . . . . . . . . . . . . . . 3-2 System (Dual) Remote Lockout Station Verification . . . . . . . . . . . . . . . . . . . 3-7 Expansion Module Verification 4-Port or 10-Port With or Without Time Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Communication Module Verification . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Pneumatic Isolation Module Verification . . . . . . . . . . . . . . . . . . . . . 3-12 Control Module with Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Incoming Power Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Commissioning the Safety Isolation System Without Time Delay Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Remote Lockout Station Sequence Tests (23... 85 A) . . . . . . . . . . . 3-17 Remote Lockout Station Sequence Tests (110…1200 A) . . . . . . . . 3-19 Commissioning Expansion Module (4-Port or 10-Port With or Without Time Delay) (23…1200 A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Commissioning Verification Module (with Gate Locks) . . . . . . . . . 3-23 Commissioning Pneumatic Isolation Module Operation. . . . . . . . . 3-25 Commissioning the Communication Modules . . . . . . . . . . . . . . . . . 3-27 Final Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Chapter 4 — Troubleshooting Publication 2030-UM003A-EN-P - May 2006 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Field Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Troubleshooting Flowchart and Tables . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Operational Troubleshooting of the ElectroGuard® Power Panel with all Remote Lockout Stations in the ON position . . . . . . . 4-33 Table of Contents 3 Safety Isolation System (Time Delay Option) . . . . . . . . . . . . . . 4-37 Safety Isolation System (Pneumatic Isolation Option) . . . . . . . 4-37 Operational Troubleshooting of the ElectroGuard® Power Panel with all Remote Lockout Stations in the OFF Position. . . . . . . 4-38 Safety Isolation System Control Module (Time Delay Option) 4-39 Safety Isolation System (Pneumatic Isolation Option) . . . . . . . 4-39 Operational Troubleshooting of the ElectroGuard® Power Panel (110… 1200 A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Operational Troubleshooting of the ElectroGuard® Power Panel with All Remote Lockout Stations in the ON Position . . . . . . . 4-40 Safety Isolation System (Time Delay Option) . . . . . . . . . . . . . . 4-45 Safety Isolation System (Pneumatic Isolation Option) . . . . . . . 4-46 Operational Troubleshooting of the ElectroGuard® Power Panel with all Remote Lockout Stations in the OFF Position. . . . . . . 4-46 Operational Troubleshooting of the Verification Module . . . . . . . . 4-47 Operational Troubleshooting of the Pneumatic Isolation Module . 4-49 Operational Troubleshooting of the Expansion Module. . . . . . . . . 4-56 Operational Troubleshooting of the Expansion Module with All Remote Lockout Stations in the ON Position . . . . . . . . . . . . . . 4-56 Operational Troubleshooting of Series Connected Expansion Module (with all Remote Lockout Stations in the ON Position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64 Operational Troubleshooting of the Expansion Module (Switching a Remote Lockout Station to the OFF Position). . . 4-65 Chapter 5 Preventive Maintenance General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 ElectroGuard® Power Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Door Operated Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 ElectroGuard® Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Disconnect Switch (if Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Thermal-Magnetic Circuit Breaker (Option) . . . . . . . . . . . . . . . . 5-6 (Non-Combination System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Isolation and Grounding Contactors Wiring Connections . . . . . . . . 5-8 Cooling Fans and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Control Transformer and Circuit Protection . . . . . . . . . . . . . . . . . . 5-12 Equipment Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Isolated Ground Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Product Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Remote Lockout Station(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Pneumatic Isolation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Publication 2030-UM003A-EN-P - May 2006 4 Table of Contents Final Preventive Maintenance Steps . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Chapter 6 — Replacement Procedures Publication 2030-UM003A-EN-P - May 2006 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Remote Lockout Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Remote Lockout Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Remote Lockout Station Load Switch Assembly . . . . . . . . . . . . . . . . 6-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Remote Lockout Station System Isolated LED . . . . . . . . . . . . . . . . 6-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Remote Lockout Station Light Assembly . . . . . . . . . . . . . . . . . . . . . 6-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25 Power Contactor and/or Mechanical Interlock (23…85 A) . . . . . . 6-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Power Contactor and/or Mechanical Interlock (110…1200 A) . . . 6-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Control Circuit Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Push Buttons/Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Energy Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52 Table of Contents 5 Pneumatic Isolation Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57 Power Restoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58 Appendix A — Cat. No. Explanation Bulletin 2031 Non-Combination Systems (23…85 A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (110…1200 A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2032 Combination Systems with Fusible Disconnect (23…85 A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2032 Combination Systems with Fusible Disconnect (110…1200 A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2033 Combination Systems with Thermal-Magnetic Circuit Breaker (23…85 A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2033 Combination Systems with Thermal-Magnetic Circuit Breaker (110…1200 A). . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2030 Remote Lockout Station . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2030 Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2030 Pneumatic Isolation Module. . . . . . . . . . . . . . . . . . . . Bulletin 2030 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulletin 2030 Verification Module . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-8 A-9 A-9 A-9 Appendix B — Specifications Standards and Certifications - Conformity to Industry Standards. . . B-3 Appendix C — Sample Calculations of Remote Lockout Station Total Cable Length Scenario 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 Scenario 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Appendix D — Expansion Module Target Table:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 Target Table Appendix E — Replacement Parts General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Replacement Parts for the ElectroGuard® Power Panel. . . . . . . . . . E-2 Replacement Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9 Replacement Remote Lockout Station System Isolated Light LED Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10 Replacement Remote Lockout Station Load Switch Assemblies . . E-10 Appendix F — Glossary Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1 Appendix G — Product Information Labels Product Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 Product Information Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Publication 2030-UM003A-EN-P - May 2006 6 Table of Contents Publication 2030-UM003A-EN-P - May 2006 Chapter 1 Product Overview Section Page Purpose of the Safety Isolation System 1-1 Safety Requirements and Guidelines 1-1 Description of Use 1-2 Application 1-2 Operation 1-3 Sequence of Isolation Operation 1-4 Typical Safety Isolation System Layout 1-5 Purpose of the Safety Isolation System The Bulletin 2030 ElectroGuard® Safety Isolation System (SIS) enhances the ability of the machine operator or maintenance personnel to perform lockout/ tagout (LOTO) procedures, making it easier and quicker to perform LOTO. This may provide a higher level of compliance to LOTO procedures while minimizing lost productivity. Safety Requirements and Guidelines The ElectroGuard® is one subsystem of a machine control system. When installing any machine control system, it is necessary to follow the accompanying instructions and the requirements of the appropriate regulatory agencies. This may include, but is not limited to, the following: NFPA 70 (The National Electrical Code) (USA) NFPA 70E (USA) NFPA 79 (USA) Relevant OSHA (Occupational Safety Hazards Administration) requirements (USA) Relevant National, State, Provincial, and Local Codes CSA Publication C22.1-02 (The Canadian Electrical Code) Relevant OH&S (Occupational Health and Safety) Act requirements (Canada) Requirements of EN 60204 (EU) 1 Publication 2030-UM003A-EN-P - May 2006 1-2 Product Overview Description of Use The Bulletin 2030 ElectroGuard® system is designed to act like an energy disconnect for a machine. The ElectroGuard® system isolates the energy by use of redundancy and operator feedback. The Remote Lockout Stations provide the input signal to the power panel. When a Remote Lockout Station is switched off, components in the power panel and, if installed, the Pneumatic Module, remove the hazardous energy. Once this is done, a signal is sent back to the Remote Lockout Station and a light is illuminated. This gives indication to personnel that the system has been isolated. IMPORTANT Application Publication 2030-UM003A-EN-P - May 2006 The ElectroGuard® SIS must not be used for the starting or stopping of the machine. The normal machine starting and stopping means must be used. The ElectroGuard® SIS provides disconnection, isolation, and grounding functionality. It provides the necessary isolation of energy to allow work on, or access to, machine elements that are normally electrically or pneumatically powered. Product Overview Operation 1-3 The ElectroGuard® system is placed in series with the energy source of the machine. The Control Module performs the function of controling and verifying the ElectroGuard® system function. Every function is commanded and monitored for completion. The Control Module sends and receives signals from the ElectroGuard® Power Panel, the Pneumatic Isolation Module, and the Remote Lockout Stations. At any time, if either of the ElectroGuard® Power Panel’s ground is broken, the ElectroGuard® system will shutdown. Under a fault or shutdown condition of the ElectroGuard® system, the “System Isolated” light will not be illuminated. No light means no entry. The ElectroGuard®’s Control Module is powered by a 120V control transformer in the power panel. A 24V DC power supply within the Control Module provides power for the Control Module logic and some external devices. All external modules are powered from the power panel. The RLSs operate on 24V DC, and the Pneumatic Isolation Module operates on both 120V AC and 24V DC. Figure 1.1 ElectroGuard® Safety Isolation System Block Diagram Pneumatic Isolation Air Isolated Air POWER PANEL Exhaust Isolation Contactors Isolated Pressure Sense Three Phase Grounding Contactor Isolated Ground Isolated Voltage Sense PE Ground Monitor Pneumatic Control Module Isolated Electrical MACHINE ENERGY SOURCE Electrical Isolation PE Control Power Control Module 120V AC 24V DC Remote Lockout Station Publication 2030-UM003A-EN-P - May 2006 1-4 Product Overview Sequence of Isolation Operation 1. The Remote Lockout Station initiates the isolation sequence, by an operator turning the handle from the ON to OFF position. 2. The Control Module responds by commanding the isolation module(s), electrical and pneumatic (if installed), to isolate and verify isolation. a. The electrical isolation module opens two series contactors. The voltage sense circuit monitors the isolated voltage. When it reaches a safe level, the grounding contactor connects the isolated electrical lines to the isolated ground. Electrical isolation is now completed and verified by the Control Module. b. If installed, the Pneumatic Isolation Module opens the pneumatic safety valve and redundant pressure sensors verify isolation has completed. Pneumatic isolation is now completed and verified by the Pneumatic Control Module. 3. After successful isolation, the Control Module illuminates that operator's Remote Lockout Station “System Isolated” light. 4. Authorized personnel may now apply a LOTO lock to the Remote Lockout Station. ATTENTION ! Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: The ElectroGuard® can isolate the electrical energy to a portion of the machine, or the entire machine or process as required. OSHA Lockout/Tagout (LOTO) standards require that all sources of energy must be isolated from the machine or process prior to entering or servicing the machine or process. Turning the operating handle of the RLSs to the OFF position will initiate isolation of the electrical energy to the loads connected to the ElectroGuard® only. The ElectroGuard® will not isolate external energy sources that may be feeding portions of the controllers on the load side of the ElectroGuard®. ATTENTION ! Publication 2030-UM003A-EN-P - May 2006 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: A risk analysis must be performed and LOTO procedures should be developed prior to applying an ElectroGuard® system. Product Overview Typical Safety Isolation System Layout 1-5 Figure 1.2 Typical 23…85 A Safety Isolation System Layout (85A Version Shown) Isolation Contactors and Grounding Contactor Isolation is initiated by turning an RLS to the OFF position. ElectroGuard® Power Panel Optional Branch Circuit Protection Optional Communication Modules RLSs with System Isolated Light Optional 4-port or 10-port Expansion Module Optional Pneumatic Isolation Module Publication 2030-UM003A-EN-P - May 2006 1-6 Product Overview Figure 1.3 Typical 110…1200 A Safety Isolation System Layout MCC Type Main Panel Enclosure (210 A Version Shown) Optional Disconnecting Means Optional 10-port Expansion Module (4-port Available) Control Module Remote Lockout Station with “System Isolated Light” Optional Flex I/O Modules Power Contactors (Isolation and Grounding) Status Communication to Remote PLC Optional 10-port Expansion Module (4-port Available) Publication 2030-UM003A-EN-P - May 2006 Optional Pneumatic Isolation Module Chapter 2 Installation and Wiring Pre-Installation Precautions Section Page Pre-Installation Precautions 2-1 Dimensions 2-4 Approximate Weights 2-25 Receiving the ElectroGuard® Power Panel and Modules 2-26 Installation and Wiring of the ElectroGuard® Power Panel 2-34 Installation and Wiring of the ElectroGuard® Control Module 2-45 Installation and Wiring of the ElectroGuard® Remote Lockout Station(s) 2-56 Installation and Wiring of the ElectroGuard® Dual Remote Lockout Station(s) 2-62 Installation and Wiring of the ElectroGuard® Remote Lockout Station(s) 2-56 Installation and Wiring of the ElectroGuard® Verification Module 2-71 Installation and Wiring of the ElectroGuard® Pneumatic Isolation Module 2-72 Installation and Wiring of the Status Communication Modules 2-73 Final Steps for Installation and Wiring 2-81 ATTENTION ! ATTENTION Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. ! 1 The following information is only a guide for proper installation. Rockwell Automation cannot assume responsibility for the compliance or non-compliance to any code, national, local, or otherwise for the proper installation of the ElectroGuard® or associated equipment. Publication 2030-UM003A-EN-P - May 2006 2-2 Installation and Wiring ATTENTION ! IMPORTANT ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. The ElectroGuard® is not designed to provide the start and stop functions for the machine or process. The normal starting and stopping means of the machine or process must be used. Power Fuses or Circuit Breaker Requirements Publication 2030-UM003A-EN-P - May 2006 IMPORTANT The ElectroGuard® does not provide branch circuit protection. Follow the requirements of regulatory agencies and local codes to select the circuit required for both line and load circuits. ElectroGuard® is available with branch circuit protection, either fuse or circuit breaker. IMPORTANT The Control Module “HV” terminal block must be reconfigured when the incoming power to the ElectroGuard® system is 3-Phase Delta connected using a grounded mid-point of a phase, a grounded junction of phases, or when a high resistance ground is used. If one of these power systems are used, the jumper wire supplied on the Control Module “HV” terminal block between terminals (1) and (7) must be removed and discarded. Refer to wiring diagram supplied with the equipment for location of jumper wire. Installation and Wiring 2-3 Figure 2.1 Power System Configurations (Remove HV Jumper) (Remove HV Jumper) (Remove HV Jumper) (Remove HV Jumper) (Remove HV Jumper) (Remove HV Jumper) 480V and Below 3-Phase Supplied Systems (Shown above) Remove Factory Installed Jumper Wire on “HV” Terminal Block Above 480V 3-Phase Supplied Systems (Shown above) Verify that jumper Wire is not Present from the Factory Isolated Grounding Conductor ATTENTION ! The ElectroGuard® includes the equipment grounding (P.E.) lug, and the isolated grounding conductor terminal block. Both are located on the Power Panel. The purpose of the isolated grounding conductor is to provide a direct connection from the SIS to the main power distribution earth ground. If this connection is lost during system operation, the SIS will shut down. An isolated grounding conductor must be connected between the isolated grounding conductor terminal block and the main power distribution earth ground (i.e. the point where all grounds are bonded together). Publication 2030-UM003A-EN-P - May 2006 2-4 Installation and Wiring Figure 2.2 Isolated Ground Conductor Isolated Ground PE High Resistance Ground Dimensions IMPORTANT Publication 2030-UM003A-EN-P - May 2006 All of the dimensions in this section are approximate and are not intended for manufacturing purposes. Consult your local Allen-Bradley distributor for complete dimension drawings. All dimensions are subject to change. Conduit entry holes are not provided. If conduit is used, use appropriately rated conduit and hubs. Installation and Wiring 2-5 Table 2.1 (23… 85 A) Approximate Enclosure Dimensions Bulletin Number 2031 2032 2033 Enclosure Dimensions A in. (mm) B in. (mm) C in. (mm) Type 1 36.00 (914.40) 30.00 (762.00) 36.90 (937.26) Type 12 36.00 (914.40) 30.00 (762.00) 36.90 (937.26) Type 4 36.00 (914.40) 30.00 (762.00) 36.90 (937.26) Type 4X 36.00 (914.40) 30.00 (762.00) 36.90 (937.26) Type 1 37.38 (949.45) 31.38 (797.05) 38.28 (972.31) Type 12 37.38 (949.45) 31.38 (797.05) 38.28 (972.31) Type 4 37.38 (949.45) 31.38 (797.05) 38.28 (972.31) Type 4X 37.38 (949.45) 31.38 (797.05) 38.28 (972.31) Figure 2.3 (23… 85 A) Non-Combination or Combination ElectroGuard® Power Panel Clearance holes for #3/8-16 mounting hardware C 14.20 (360.68) A 13.24 (336.30) B 12.07 (322.58) For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 49.24 (1250.70) 48.00 (1219.20) LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 2-6 Installation and Wiring Table 2.2 (110...1200 A) Approximate Enclosure Dimensions Bulletin Number Current Rating (A) Enclosure Type See Figure Width in. (mm) Sections Non-Combination (without bus) 110 180 210 300 2031 420 630 860 1200 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.5 40 (1016) 4, 4X 2.6 40 (1016) 1, 12 2.5 40 (1016) 4, 4X 2.6 40 (1016) 1, 12 2.9 75 (1905) 4, 4X 2.10 79 (2007) 1 2 Non-Combination (with bus) 2031 110 12 2.4 35 (889) 180 12 2.4 35 (889) 210 12 2.4 35 (889) 300 12 2.4 35 (889) 420 12 2.4 35 (889) 630 12 2.5 40 (1016) 860 12 2.5 40 (1016) 1200 12 2.9 75 (1905) Note: All height is 90 in.(2.286 mm); all depth is 20 in. (508 mm) Publication 2030-UM003A-EN-P - May 2006 1 2 Installation and Wiring 2-7 Table 2.2 (110...1200 A) Approximate Enclosure Dimensions (Continued) Bulletin Number Current Rating (A) Enclosure Type See Figure Width in. (mm) Sections Fusible Disconnect (without bus) 110 180 210 300 2032 420 630 860 1200 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.7 55 (1397) 4, 4X 2.10 79 (2007) 1, 12 2.8 60 (1524) 4, 4X 2.10 79 (2007) 1, 12 2.8 60 (1524) 4, 4X 2.10 79 (2007) 1, 12 2.12 110 (2794) 4, 4X 2.13 119 (3023) 1 2 3 Fusible Disconnect (with bus) 2032 110 12 2.4 35 (889) 180 12 2.4 35 (889) 210 12 2.4 35 (889) 300 12 2.4 35 (889) 420 12 2.7 55 (1397) 630 12 2.8 60 (1524) 860 12 2.8 60 (1524) 1200 12 2.12 110 (2794) 1 2 3 Note: All height is 90 in.(2.286 mm); all depth is 20 in. (508 mm) Publication 2030-UM003A-EN-P - May 2006 2-8 Installation and Wiring Table 2.2 (110...1200 A) Approximate Enclosure Dimensions (Continued) Bulletin Number Current Rating (A) Enclosure Type See Figure Width in. (mm) Sections Circuit Breaker (without bus) 110 180 210 300 2033 420 630 860 1200 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.4 35 (889) 4, 4X 2.6 40 (1016) 1, 12 2.8 55 (1397) 4, 4X 2.10 79 (2007) 1, 12 2.8 60 (1524) 4, 4X 2.10 79 (2007) 1, 12 2.8 60 (1524) 4, 4X 2.10 79 (2007) 1, 12 2.11 110 (2794) 4, 4X 2.13 119 (3023) 1 2 3 Circuit Breaker (with bus) 2033 110 12 2.4 35 (889) 110 12 2.4 35 (889) 180 12 2.4 35 (889) 210 12 2.4 35 (889) 300 12 2.4 35 (889) 420 12 2.7 55 (1397) 630 12 2.8 60 (1524) 860 12 2.8 60 (1524) 1200 12 2.11 105 Note: All height is 90 in.(2.286 mm); all depth is 20 in. (508 mm) Publication 2030-UM003A-EN-P - May 2006 1 2 3 Installation and Wiring 2-9 Figure 2.4 35 in. Wide Single-door MCC Enclosure Type 1, 12 Bulletin 2031 (110…420 A) Bulletin 2032 (110…300 A) Bulletin 2033 (110…300 A) SPLICE MT ST ANDARD SPLICE MT ST G. ANDARD HOLE G. C HOLE OVER C OVER Top View 35.00 (889.00) 20.00 (508.00) 2.50 (63.50) STANDARD SPLICE COVER MTG. HOLE For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE 90.00 (2286.00) STANDARD SPLICE COVER MTG. HOLE 34.44 Door (874.78) Front View STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 2-10 Installation and Wiring Figure 2.5 40 in. Wide Two-door MCC Enclosure, Type 1, 12 Bulletin 2031 (630…860 A) Top View 20.00 (508.00) 40.00 (1016.00) 2.50 (63.50) For units with communications, use part number 31035-090-01 For units without communications, use part 90.00 (2286.00) 19.44 (493.78) Left door 19.88 (504.95) Right door Front View Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-11 Figure 2.6 40 in. Wide Single-door MCC Enclosure, Type 4, 4X Bulletin 2031 (110…860 A) Bulletin 2032 (110…300 A) Top View 40.25 (1022.35) 20.00 (508.00) 3.19 (81.03) For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 90.12 (2289.05) 36.38 (924.05) Front View Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 2-12 Installation and Wiring Figure 2.7 55 in. Wide MCC Enclosure Type 1, 12 Bulletin 2032 (420 A) Bulletin 2033(420 A) SPLICE MT ST SPLICE MT ST ANDARD G. ANDARD G. HOLE HOLE C OVER C OVER SPLICE MT ST SPLICE MT ST ANDARD G. ANDARD G. SPLICE HOLE MT ST HOLE C ANDARD OVER C G. OVER HOLE C OVER SPLICE MT ST AND G. H Top View 20.00 (508.00) 20.00 (508.00) 35.00 (889.00) 2.50 For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE 90.00 (2286.00) STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE 19.44 (493.78) 34.44 (874.78) Left door Right door Front View Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-13 Figure 2.8 60 in. Wide MCC Enclosure Type 1, 12 Bulletin 2032 (630…860 A) Bulletin 2033 (630…860 A) SPLICE MT ST ANDARD G. HOLE C OVER SPLICE SPLICE MT MT ST ST ANDARD ANDARD G. G. HOLE HOLE C C OVER OVER Top View 40.00 (1016.00) 20.00 (508.00) 2.50 (63.50) 20.00 (508.00) For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE 90.00 (2286.00) STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE 19.44 (493.78) 19.88 (504.95) 19.44 (493.78) Left door Right door Door Front View STANDARD SPLICE COVER MTG. HOLE Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 2-14 Installation and Wiring Figure 2.9 75 in. Wide MCC Enclosure Type 1, 12 Bulletin 2031 (1200 A) Top View 40.00 (1016.00) 35.00 (889.00) width 2.50 (63.50) 20.00 (508.00) For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 90.00 (2286.00) 34.44 (874.78) DOOR 19.44 (493.78) LH DOOR Front View 19.88 (504.95) RH DOOR Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-15 Figure 2.10 79 in. Wide Two-door MCC Enclosure, Type 4, 4X Bulletin 2031 (1200 A) Bulletin 2032 (420…860 A) Top View 78.50 (1993.90) 20.00 (508.00) 3.19 (81.03) For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 90.12 (2289.05) 36.38 (924.05) Front View Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 2-16 Installation and Wiring Figure 2.11 105 in. Wide MCC Enclosure Type 1.12 Bulletin 2033 (1200 A) SPLICE MT ST SPLICE MT ST ANDARD G. ANDARD G. HOLE HOLE C OVER C OVER Top View 30.00 (762.00) 40.00 (1016.00) 35.00 (889.00) 20.00 (508.00) 2.50 (63.50) STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 90.00 (2286.00) 34.44 (874.78) 19.44 (493.78) 19.88 (504.95) 29.44 (747.76) Door Left door Right door Door Front View Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-17 Figure 2.12 110 in. Wide MCC Enclosure Type 1, 12 Bulletin 2032 (1200 A) S SPLICE MT ST SPLICE MT ST ANDARD G. ANDARD G. HOLE HOLE C OVER C OVER SPLIC MT ST AN G. Top View 35.00 (889.00) 20.00 (508.00) 35.00 (889.00) 40.00 (1016.00) 2.50 (63.50) For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE 90.00 (2286.00) 34.44 (874.78) 19.44 (493.78) 19.88 (504.95) Door Left door Right door Front View STANDARD SPLICE COVER MTG. HOLE 34.44 (874.78) STANDARD SPLICE COVER MTG. HOLE STANDARD SPLICE COVER MTG. HOLE Door Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 2-18 Installation and Wiring Figure 2.13 119 in. Wide Two-door MCC Enclosure, Type 4, 4X Bulletin 2032 (1200 A) Top View 40.25 (1022.35) 20.00 (508.00) 3.19 (81.03) For units with communications, use part number 31035-090-01 For units without communications, use part number 31035-091-01 90.12 (2289.05) 36.38 (924.05) Front View Left Side View NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-19 Figure 2.14 Single Remote Lockout Station (Type 12 Enclosure) 1.38 (35.05) DIA. HOLE FOR 1" CONDUIT - TOP. TOP HOLE PLUGGED. 2.00 (50.8) 2.00 (50.8) 1.59 (40.4) 5.38 (136.7) (4)-.31 (7.9) DIA. MOUNTING HOLES .38 (9.7) SYSTEM ISOLATED WHITE PILOT LIGHT LENS Part No. 32005-383-02 9.50 (241.3) 8.75 (222.3) 1.26 (32.0) 2.00 (50.8) 5.04 (128.0) 1.38 (35.05) DIA. HOLE FOR 1" CONDUIT - BOTTOM NOTES: 1) DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2) ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES 2.63 (66.80) 2.00 (50.8) Publication 2030-UM003A-EN-P - May 2006 2-20 Installation and Wiring Figure 2.15 Dual Remote Lockout Station (Type 12 Enclosure Shown) Top View Part No. 32005-383-02 F Front View Right Side View Bottom View Note: Dimensions are in inches. Dimensions are not intended for manufacturing purposes. Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-21 Figure 2.16 NEMA 7/9 1“ NPT Hole (Plugged) Part No. 32005-383-02 6.62 4.87 4.28 12.28 4.28 3.17 6.12 8.56 1“ NPT Hole (Plugged) 8.80 6.80 5.28 0.55 1“NPT Hole Note: Dimensions are in inches. Dimensions are not intended for manufacturing purposes. Figure 2.17 Verification Module Part No. 31035-090-01 Note: Dimensions are in inches (mm). Dimensions are not intended for manufacturing purposes. Publication 2030-UM003A-EN-P - May 2006 2-22 Installation and Wiring Figure 2.18 10-Port Expansion Module (Open Type) Mounting slots 1/4 hardware 23.00 (584.20) 22.00 (558.80) 6.69 (169.93) If seal is broken, replace with Part Number 32005-386-03 or 32005-386-04 10.56 (271.39) 8.50 (215.90) Part No. 32005-384-02 FRONT VIEW RIGHT SIDE VIEW Note: Dimensions are in inches (mm). Dimensions are not intended for manufacturing purposes. Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-23 Figure 2.19 4-Port Expansion Module (Open Type) 13.71 [348.2] 6.12 [155.4] 12.00 [304.8] If seal is broken, replace with Part Number 32005-386-03 or 32005-386-04 8.72 [221.6] 11.00 [279.4] 11.56 [293.6] Part No. 32005-384-02 4-SLOTTED HOLES FOR #10-32 MOUNTING 5" (127mm) CLEARANCE FOR WIRING AND CONNECTOR REMOVAL Note: Dimensions are in inches (mm). Dimensions are not intended for manufacturing purposes. Publication 2030-UM003A-EN-P - May 2006 2-24 Installation and Wiring Figure 2.20 Pneumatic Isolation Module (in Type 12 Enclosure) 2.00 (50.80) 2.00 (50.80) 5.00 (127.00) 28.09 (713.49) 13.34 (338.84) 25.39 (644.91) 24.00 (609.60) 5.00 (127.00) 20.00 (558.80) 18.00 (457.20) CLEARANCE HOLES FOR #3/8-16 MOUNTNING HARDWARE Part No. 32005-384-02 14.50 (368.30) 6.00 (152.40) 31.25 (793.75) WINDOW IN DOOR Part No. 31035-090-0 30.00 (762.00) Part No. 31035-083-01 32.90 (835.66) Part No. 31035-082-01 If seal is broken, replace with Part Number 32005-386-03 or 32005-386-04 2.12 (53.85) 7.81 (198.37) SEE NOTE 3 6.00 2.12 (53.85) Publication 2030-UM003A-EN-P - May 2006 Note: Dimensions are in inches (mm). Dimensions are not intended for manufacturing purposes. Installation and Wiring 2-25 ) Use flexible conduit and fittings when installing the external electrical plug provided with the module. IMPORTANT External pipe fittings are provided on the enclosure for customer connection to facility air piping. When installing air connections, the Pneumatic Module external pipe fitting must be held secure. Improper connections in internal fitting may become loose causing an air leak. IMPORTANT When making the hard-piped air connections to the air inlet and outlet fittings to the module, a clearance of 5 in. (12.5 cm) should be observed for ease of installation and module replacement, if necessary. Approximate Weights Table 2.3 Approximate Weights of ElectroGuard® Power Panels Power Panel Ampere Rating Without Disconnecting Means With Disconnecting Means Lbs. Kg. Lbs. Kg. 23- 85 A 335 152 350 159 110 A 600 272 1050 476 180 A 650 295 1100 499 210 A 680 308 1150 522 300 A 725 329 1250 567 420 A 1100 499 2200 998 630 A 1250 567 2500 1134 860 A 1500 680 2650 1202 1200 A 1750 794 2780 1261 System Component Lbs. Kg. Remote Lockout Station 6 3 RLS NEMA 7/9 16 7 4-port Expansion Module w/o encl. 15 7 10-port Expansion Module w/o encl. 25 12 Pneumatic Isolation Module 135 62 Control Module 85 40 Verification Module 25 12 Table 2.4 Approximate Weights of ElectroGuard® Modules Publication 2030-UM003A-EN-P - May 2006 2-26 Installation and Wiring Receiving the ElectroGuard® Power Panel and Modules Upon receipt, thoroughly inspect the packaging before accepting the shipment from the freight company. Any damage must be reported to the freight agent. Should any concealed damage be found during unpacking, it is the responsibility of the user to notify the freight agent. Storing the ElectroGuard® Power Panel and Modules IMPORTANT The ElectroGuard® Power Panel and modules should remain on their shipping skids or in their shipping cartons until installation. If the equipment is not to be used for a period of time, it must be stored according to the following instructions in order to maintain warranty coverage: Store in a clean, dry location Store within an ambient temperature range of –10…+60C (+14…+140F). Store within a relative humidity of 5…95%, non-condensing. Do not store equipment where it could be exposed to a corrosive atmosphere. Do not store in a construction area. ElectroGuard® Power Panel 1. Remove the ElectroGuard® SIS Power Panel from the shipping carton. 2. Visually inspect the enclosure for damage that may have occurred during shipment. 3. Open the enclosure door after loosening the door fasteners (see Figure 2.21 or 2.22). Look for damaged components, or wires that may have been disconnected during shipment. IMPORTANT Publication 2030-UM003A-EN-P - May 2006 Use caution when opening the enclosure door. The unit may tip forward when the door is opened. Installation and Wiring 2-27 Figure 2.21 23...85 A Type 12 Enclosure with Optional Disconnecting Means Power Panel Door Fasteners Figure 2.22 110...1200 A Type 12 Enclosure with Optional Disconnecting Means . Power Panel Door Fasteners Publication 2030-UM003A-EN-P - May 2006 2-28 Installation and Wiring 4. Check the ElectroGuard® Power Panel nameplate catalog no. (located on the middle right of the inside of the enclosure door) against the purchase order (see Figure 2.23). Figure 2.23 ElectroGuard® Power Panel Nameplate CATALOG NO. SERIES A-B SERIAL NO. LINE (V) CONT.(V) HP/kW WIRING DIAGRAM HZ PHASE ENCL. TYPE AMP BRANCH CIRCUIT OVERCURRENT DEVICE (kAIC) SHORT CIRCUIT CURRENT RATING (kA rms sym.] MADE IN U.S.A. (Actual Size) 5. Check the document holder on the inside of the enclosure door to verify a document envelope was provided. If not, contact your local Rockwell Automation distributor. Remote Lockout Station 1. Remove the RLS from the shipping carton. 2. Visually inspect the enclosure for damage that may have occurred during shipment. ATTENTION ! This is a safety device. Altering, defeating or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. 3. Loosen the two screws holding the enclosure cover to the enclosure base (see Figure 2.24). Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-29 Figure 2.24 Bulletin 2030-RLSJW Type 12 Remote Lockout Station Cover Clamp Screws 4. To open the RLS enclosure cover, rotate the operating handle to the OFF position. Squeeze the handle interlock lever and operating handle as in Figure 2.25. Lift the enclosure cover away from the base. Figure 2.25 Opening a Remote Lockout Station Squeeze the operating hand interlock lever together. 5. Look for damaged components or wires that may have been disconnected during shipment. 6. Verify the RLS nameplate catalog no. (located on the inside of the enclosure on the side surface) against the purchase order (see Figure 2.26). Publication 2030-UM003A-EN-P - May 2006 2-30 Installation and Wiring Figure 2.26 Remote Lockout Station Nameplate CATALOG NO. SERIES A-B SERIAL NO. CONT. VOLTS WIRING DIAGRAM MADE IN U.S.A. (Actual Size) 7. Refer to the documentation inside the RLS for the applicable wiring diagram. 8. Close the enclosure cover. With the operating handle in the OFF position, rotate the handle interlock lever clockwise and push the enclosure cover toward the enclosure base while holding the handle interlock lever. Release the handle interlock lever. Verification Module (Optional) 1. Remove the Verification Module from the shipping carton 2. Visually inspect the enclosure for damage that may have occurred during shipping. 3. Open the enclosure door after loosening the door fasteners. Look for damaged components or wires that may have been disconnected during shipment. 4. Verify the nameplate catalog no. (located inside right of the enclosure door) against the purchase order (see Figure 2.28). Figure 2.27 Verification Module Nameplate CATALOG NO. SERIES A-B SERIAL NO. CONT.(V) WIRING DIAGRAM LINE (V) HP/kW HZ PHASE ENCL. TYPE AMP BRANCH CIRCUIT OVERCURRENT DEVICE (kAIC) SHORT CIRCUIT CURRENT RATING (kA rms sym.] MADE IN U.S.A. (Actual Size) Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-31 Expansion Module (Optional) 1. Remove the Expansion Module from the shipping carton. 2. Visually inspect the enclosure for damage that may have occurred during shipping. 3. Open the enclosure door after loosening the door fasteners. Look for damaged components or wires that may have been disconnected during shipment. 4. Remove the protective paper from the Expansion Module viewing window. 5. Verify the nameplate catalog no. (located on the front or right side of the equipment) against the purchase order (see Figure 2.28). Figure 2.28 Expansion Module Nameplate CATALOG NO. SERIES A-B SERIAL NO. CONT.(V) LINE (V) HP/kW WIRING DIAGRAM HZ PHASE ENCL. TYPE AMP BRANCH CIRCUIT OVERCURRENT DEVICE (kAIC) SHORT CIRCUIT CURRENT RATING (kA rms sym.] MADE IN U.S.A. (Actual Size) ATTENTION ! ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Publication 2030-UM003A-EN-P - May 2006 2-32 Installation and Wiring Figure 2.29 Factory Seals on Expansion Module (Open Type) Factory seal Factory seal Pneumatic Isolation Module (Optional) 1. Remove the Pneumatic Isolation Module from the shipping carton. 2. Visually inspect the enclosure for damage that may have occurred during shipment. 3. Remove the adhesive protective paper from the enclosure viewing window. 4. Look through the module viewing window for damaged components or wires that may have been disconnected during shipment. 5. Check the nameplate catalog no. (located on the right side of the enclosure) against the purchase order (see Figure 2.30). Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-33 Figure 2.30 Pneumatic Isolation Module Nameplate CATALOG NO. SERIES A-B SERIAL NO. VALVE PORT SIZE MINIMUM 2 BAR (30 P.S.I.) MAXIMUM 7 BAR (120 P.S.I.) Y - DIAGRAM CONT. VOLTS TYPE INLET AIR PRESSURE MADE IN U.S.A. (Actual Size) ATTENTION ! ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Figure 2.31 Factory Seal on Pneumatic Isolation Module Tamper-Indicating Seal Publication 2030-UM003A-EN-P - May 2006 2-34 Installation and Wiring Installation and Wiring of the ElectroGuard® Power Panel Overview The ElectroGuard® Power Panel houses the Control Module, the isolation and grounding contactors, the control circuit transformer, and the system on/ off push button operators, as well as the optional branch circuit protection and communications modules. Installation of the Power Panel ATTENTION ! IMPORTANT In order to help avoid serious injury or death, proper lifting techniques and equipment must be used when moving and installing the ElectroGuard®. The lifting means must be capable of lifting the weight of the panel. The ElectroGuard® Safety Isolation System must be protected upstream by fuses or a thermal-magnetic circuit breaker. (The ElectroGuard® is available with fuse or circuit breaker branch circuit protection.) Size the upstream branch circuit short circuit protective device per applicable local codes 1. Verify that the power panel door is closed and fasteners securely tightened. 2. Secure the enclosure properly in its final location by using the enclosure mounting slots (see Figures 2.32, 2.33, and 2.34). Figure 2.32 ElectroGuard® Power Panel External Mounting Feet (23…85 A) ElectroGuard® Power Panel Upper Mounting Feet (Lower Mounting Feet Not Shown) Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-35 Figure 2.33 Floor Mounting of ElectroGuard® Single-door Power Panel (110…1200 A) (Top View) 2.62 (57) A MCC Style Enclosures Floor Mounting Hole Location (Front of Enclosure shown) 20.00 (508) 1.69 (43) 9.13 (232) 0.25 (6) 16.56 (421) 7.38 (187) 3.25 (83) B B (2) Mounting Slots 56 x 1.13 slot (14) x (29) slot Horizontal Ground Bus Front of Enclosure 20 in. Deep 30 in. 35 in. 20 in. 25 in. Dim. Wide Wide Wide Wide A 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889) B 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445) Figure 2.34 Floor Mounting of ElectroGuard® Two-door Power Panel (110…1200 A) 40.00 10.00 (254) 10.00 (254) 16.56 20.00 (421) (508) 0.25 (6) 7.38 (187) (4) Mounting Slots 56 x 1.13 slot (14) x (29) slot Ground Bus 20.00 (508) Note: Dimensions are in inches (mm). Dimensions are not intended for manufacturing purposes. Publication 2030-UM003A-EN-P - May 2006 2-36 Installation and Wiring MCC Type enclosures wider than 40 in. consist of MCC section widths necessary to obtain the overall ElectroGuard® Power Panel width (see Table 2.5). The mounting dimensions will be as shown for the various MCC section widths in Figures 2.33 and 2.34. Table 2.5 ElectroGuard® Power Panel Section Dimensions . Total Required Power Panel Width 55 in. 60 in. 75 in. 105 in. 110 in. Left Hand Section 35 in. Wide 40 in. Wide 35 in. Wide 35 in. Wide 35 in. Wide Center Section — — — 40 in. Wide 40 in. Wide Right Hand Section 20 in. Wide 20 in. Wide 40 in. Wide 30 in. Wide 35 in. Wide Incoming and Outgoing Three-phase Cable Specifications IMPORTANT Refer to applicable local codes and standards when selecting incoming and outgoing three phase power cables. Cable must have 75C copper wire only. Cable with 600V insulation is required (or as specified by local codes). Oil-resistant cable is recommended. Wiring of the Power Panel IMPORTANT The ElectroGuard® does not provide branch circuit protection unless ordered with the optional fused disconnect switch or circuit breaker. It is necessary to follow the requirements of regulatory agencies and local codes to select the circuit required for both line and load circuits. The enclosure is not provided with conduit entry holes. Use conduit and applicable environmentally-rated hub. After properly mounting the enclosure, then open the enclosure door. Follow the wiring diagram supplied. Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-37 For Bulletin 2031 Non-Combination Systems 1. Connect the incoming power wires to the L1-L2-L3 terminals of the 1IC Contactor or factory-supplied power block (see Figures 2.35 and 2.36). For units with a BUS, refer to the schematic. Figure 2.35 Incoming Power Connections on Power Block (23…85 A) L1 L2 L3 Figure 2.36 Incoming Power Connections on Power Block (110…860 A, Optional) L3 L2 L1 2. Connect the load to terminals T1-T2-T3 of the ElectroGuard® isolation contactor 2IC (see Figures 2.37 and 2.38). Publication 2030-UM003A-EN-P - May 2006 2-38 Installation and Wiring Figure 2.37 Outgoing Power Connections to 2IC Contactor (110…1200 A) 1IC GC 2IC T1 T2 T3 Figure 2.38 Outgoing Power Connections to 2IC Contactor (23…85 A) T3 T2 T1 3. Connect a properly sized ground conductor to the Protective Earth (P.E.) terminal (see Figures 2.39 and 2.40, and Table 2.6). Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-39 Figure 2.39 Equipment Ground Conductor (P.E.) Lug (110…1200 A) Figure 2.40 Equipment Ground Conductor (P.E.) Lug (23…85 A) 4. Connect a properly sized ground conductor to the isolated ground terminal block (see Figures 2.41 and 2.42, and Table 2.6). Figure 2.41 Isolated Ground Terminal Block (110…1200 A) Publication 2030-UM003A-EN-P - May 2006 2-40 Installation and Wiring Figure 2.42 Isolated Ground Terminal Block (23…85 A) IMPORTANT Publication 2030-UM003A-EN-P - May 2006 The Isolated Ground Conductor must not be connected to conduit on any panel board it passes through and must be connected directly to distribution earth ground at the point where all grounds are bonded together. Installation and Wiring 2-41 For Bulletin 2032 or 2033 Combination Systems 1. Connect the incoming power wires to terminals L1-L2-L3 of the disconnect switch (or circuit breaker) (see Figures 2.43, 2.44, and Table 2.6). Figure 2.43 Incoming Power Connections on Fusible Disconnect Switch (Bulletin 2032) L3 L2 L1 Figure 2.44 Incoming Power Connections to Circuit Breaker (Bulletin 2033) L3 L2 L1 Publication 2030-UM003A-EN-P - May 2006 2-42 Installation and Wiring 2. Connect the load to terminals T1-T2-T3 of the ElectroGuard® isolation contactor 2IC (see Figures 2.45 and 2.46, and Table 2.6). For units using a BUS, refer to the schematic. Figure 2.45 Outgoing Power Connection Points on 2IC Isolation Contactor (110… 1200 A, without BUS) 1IC GC 2IC T1 T2 T3 Figure 2.46 Outgoing Power Connections to 2IC Contactor (23… 85 A) T3 T2 T1 3. Torque the incoming and outgoing power wire terminals to the values shown on the torque label located inside the enclosure 4. Connect the applicable-sized ground conductor to the P.E. (Protective Earth) ground lug (see Figures 2.39 …2.40). IMPORTANT Publication 2030-UM003A-EN-P - May 2006 The Isolated Ground Conductor must not be connected to conduit on any panel board it passes through and must be connected directly to distribution earth ground at the point where all grounds are bonded together. Installation and Wiring 2-43 Table 2.6 Power Connection Specifications for Torque (see Table on Power Panel Door) Field Cable Connections (Torque -75C Copper Wire Only) Connection Point 1IC Isolation Contactor or 2IC Isolation Contactor Function Incoming Power Connection or Outgoing Power Connection to Machine Connection Point Designator L1, L2, L3 or T1, T2, T3 Cable Size Circuit Breaker Line Current Rating Voltage* Rating* 23 A 43 A 85 A 110 A 180 A 210 A 300 A 420 A 630 A 860 A 1200 A 23 A 43 A 85 A 110 A 630 A 860 A 1200 A 23 A 43 A 85 A 110 A #6-250 MCM 180 A (2X) 1/0-250 MCM 210 A 300 A 420 A 630 A 860 A 1200 A (2X) 1/0-250 MCM (2X) 1/0-250 MCM (2X) #4-600 MCM (2X) #6-350 MCM (4X) #6-350 MCM (4X) #4-600 MCM 180 A Incoming Power Terminal Block Bulletin 2031 Incoming Power Connection L1, L2, L3 210 A 300 A 420 A Fusible Disconnect Bulletin 2032 Branch Circuit Protection L1, L2, L3 AWG #16-10 #14-4 #14-1 #6-300 MCM #6-300 MCM (2) #4-350 MCM (2X) #4-350 MCM (2X) #4-350 MCM (2X) 2/0-500 MCM (4X) 2/0-500 MCM (4X) 3/0-750 MCM #14-2/0 #14-2/0 #14-2/0 #14-2/0 (optional) #6-350 MCM (optional) #6-350 MCM (optional) (2X) #4-500 MCM (optional) (2X) #4-500 MCM (optional) (4X) #4-600 MCM (4X) #4-600 MCM (4X) 3/0-750 MCM #14-8 #14-4 #8-1/0 Publication 2030-UM003A-EN-P - May 2006 2-44 Installation and Wiring Field Cable Connections (Torque -75C Copper Wire Only) Connection Point Function Cable Size Circuit Breaker Line Current Rating Voltage* Rating* Connection Point Designator 23 A 43 A 85 A 110 A 180 A 210 A Circuit Breaker Bulletin 2033 Branch Circuit Protection 300 A L1, L2, L3 420 A 630 A 860 A 1200 A Equipment Ground Lug (P.E.) Isolated Ground Conductor Terminal Block 23…85 A 39-42 40-45 42 43-45 46 47 48 46-47 45, 46, 49, 50 47, 48 50-52 48 49, 53-54 49 50-51 53-54 56 56 57 51, 52, 57-59 53 53 54 54 56 59-60 61 60 61 62 56, 57, 62, 63 57-60, 66 AWG #14-1/0 #14-1/0 #14-1/0 #4-4/0 #14-1/0 #4-4/0 #4-350 MCM #14-1/0 #4-350 MCM #4-350 MCM #4-350 MCM 250-500 MCM 250-500 MCM (2X) 400-500 MCM 250-500 MCM (2X) 400-500 MCM 250-500 MCM (2X) 400-500 MCM (2X) 400-500 MCM (2X) 2/0-500 MCM (2X) 2/0-500 MCM (3X) 3/0-500 MCM (2X) 2/0-500 MCM (3X) 3/0-500 MCM (2X) 2/0-500 MCM (3X) 3/0-500 MCM (2X) 400-500 MCM (2X) 2/0-500 MCM (3X) 3/0-500 MCM (3X) 3/0-500 MCM (4X) #1-600 MCM #14–4 #8-1/0 Chassis Ground/Protective EartH P.E. 110…420 A Isolated Ground Conductor Connection Isolated Ground Terminal Block 23 – 210 A #6 – 250 MCM #14 – 2 300 – 1200 A #6 – 250kcmil 630…1200 A Control Module Connector Plugs Input and Output Connections RLS1 – RLS6, IP1 – IP4, ZB, HP1 & HP2, FB1 & FB2 for Control Module Communication Modules: 1COM-3COM 1DNET-3DNET 1CNET-3CNET Control Voltage Source Interface with Control Module Publication 2030-UM003A-EN-P - May 2006 L #14 – 6 N #22 – 10 0 – 15 #22 – 10 . #12 Max External Connector Plug HC #14 Max. 1FU, 2FU #14-6 RLS Internal Terminal Block NOTE: For installation instructions see Publication No. 2030-UM002A-EN-P. * See Appendix A for catalog explanations. #18 – 14 G Input Module Pneumatic Module Connector Interface with Control Plug Module Communication Module 1492-FB1 Fuse Holders Power Supply Protection Remote Lockout Station H, A, B, C H, A, B, C, H H, A B B B, C C H, A, B, C H, A, B, C H A, C H H, A B B C C H, A, B, C A H H A A B B C C C H, A, B, C H, A, B, C #18 -14 Installation and Wiring 2-45 Installation and Wiring of Overview the ElectroGuard® Control The ElectroGuard® Control Module is an essential sub-assembly of the Module ElectroGuard® Safety Isolation System. This module contains the relay logic necessary for the operation of the system, and provides the connectors for the Remote Lockout Stations, the Pneumatic Isolation Module (optional), the time delay option, and the system status signals for customer wiring to a remote PLC. See Table 2.7 for Control Module connector information. ATTENTION ! ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Table 2.7 Control Module Table of Connectors Connector Description RLS1 Remote Lockout Station #1 connection RLS2 Remote Lockout Station #2 connection RLS3 Remote Lockout Station #3 connection RLS4 Remote Lockout Station #4 connection RLS5 Remote Lockout Station #5 connection RLS6 Remote Lockout Station #6 connection HP1, HP2 Pneumatic Module HV High Voltage IP1 On/Off IP1 Control Stop IP2 PLC IP3 Interconnect Function Connects Remote Lockout Station to Control Module Connects Remote Lockout Station to Control Module Connects Remote Lockout Station to Control Module Connects Remote Lockout Station to Control Module Connects Remote Lockout Station to Control Module Connects Remote Lockout Station to Control Module Control and status interface with optional Pneumatic Isolation Module Line, load, and ground (P.E.) inputs for Control Module Interface with door mounted push buttons and pilot lights Optional Control Stop (control module with Time Delay) Provide system status output signals to customer PLC or optional Remote I/O Contactor coils and auxiliary contact input and outputs 23…85 A 110…1200 A X X X X X X X X — X — X X X X X — X X — X X X X Publication 2030-UM003A-EN-P - May 2006 2-46 Installation and Wiring Table 2.7 Control Module Table of Connectors IP4 Control stop ZB Power contactor auxiliary contact status interface FB1, FB2 Control Stop Optional control stop (Expansion Module with time delay) Connects mirror contacts on contactors for safety relay monitoring of contactor status Optional Control Stop (Control Module with Time Delay and Expansion Modules with Time Delay) X — — X — X Connectors RLS1 through RLS6, IP1,IP2, HP1, HP2 and IP4 and ZB will require field wiring. Connectors IP3, HV, FB1, and FB2 are wired at the factory (see Figures 2.47 and 2.48). Figure 2.47 Location of 23...85 A Connectors in Control Module (bottom view) RLS1 RLS2 RLS3 RLS4 IP1 IP2 HP1 HP2 IP3 IP4 HV Figure 2.48 Location of 110...1200 A Connectors in Control Module (bottom view) RLS1 RLS2 RLS3 RLS4 RLS5 RLS6 IP1 IP2 IP3 ZB HP1 HP2 FB1 FB2 HV With the exception of the HV connector, all other connectors at the Control Module are “keyed” in order to uniquely identify each connector, in the event they will be removed and re-inserted. (See Figure 2.49). Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-47 Figure 2.49 Keying of the Connectors at the Control Module (23…1200 A) (110…1200 A only in gray) RLS #1 1 2 3 4 5 6 7 8 9 10 G N D T B IP1 RLS #3 RLS #5 1 2 3 4 5 6 7 8 9 10 G N D 1 2 3 4 5 6 7 8 9 10 G N D RLS #4 RLS #6 1 2 3 4 5 6 7 8 9 10 G N D 1 2 3 4 5 6 7 8 9 10 G N D IP4 ZB 1 2 3 4 5 6 7 8 9 10 11 12 P l u g RLS #2 1 2 3 4 5 6 7 8 9 10 G N D T B IP2 1 2 3 4 5 6 7 8 9 10 11 12 P l u g IP3 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 HV 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 G N D 1 2 3 4 5 6 7 8 T B P l u g (No keying on HV) HP1 T B 1 2 3 4 5 6 FB1 7 8 9 10 T B P l u g 1 2 3 4 P l u g 6 7 8 9 10 11 12 8 9 10 11 12 P l u g FB2 HP2 T B 5 1 2 3 4 5 6 7 8 9 10 T B 1 2 3 4 5 6 7 P l u g Publication 2030-UM003A-EN-P - May 2006 2-48 Installation and Wiring Figure 2.50 Control Module Factory Seals (23…85 A) Tamper-indicating seal Factory seal #32005-386-02 OR Rockwell field seal #32005-386-03 OR customer seal #32005-386-04 Part number 32005-384-02 Control Module Factory Seals Figure 2.51 Control Module Factory Seals (110…1200 A) Tamper-indicating seal Factory seal #32005-386-02 OR Rockwell field seal #32005-386-03 OR customer seal #32005-386-04 Part number 32005-384-02 Control Module Factory Seals Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-49 Wiring the Remote Lockout Stations to the Control Module (RLS1…RLS6 Connectors) The four (23… 85 A) or six (110… 1200 A) Remote Lockout Stations supported by the ElectroGuard® must be wired to the RLS1…RLS6 connector plugs in the Control Module (see Figure 2.52). Figure 2.52 Remote Lockout Station Wiring to the Control Module RLS1 through RLS6 6 7 8 1 2 3 4 5 6 7 8 9 10 G N D Gr ee n 5 Yellow 9 G 1 N 0 D 4 Brown Viole t Gra y Remote Lockout Station Connector Plug in Control Module 1 2 3 ck Bla Red e Blu e ng Ora Remote Lockout Station Terminal Block in Control Module Drain Wire Terminal Block Inside Remote Lockout Station IMPORTANT 1 2 3 4 6 G 7 8 9 N D The Control Module in the ElectroGuard® Power Panel has connectors to accommodate six (110… 1200 A) Remote Lockout Stations (four in the 23... 85 A models). The unused Remote Lockout Station connectors must have jumper wires installed. Jumper wire plugs are factory installed. If removing a Remote Lockout Station after it is installed, the jumpers in Figure 2.53 must be installed. Publication 2030-UM003A-EN-P - May 2006 2-50 Installation and Wiring Figure 2.53 Jumper Wire Installation for Unused Remote Lockout Station Connection Plug RLS (any #) 1 2 IMPORTANT 3 4 5 6 7 8 9 10 11 If an installation requires more than four (23… 85 A) or six (110… 1200 A) Remote Lockout Stations, Expansion Module(s) can be used to increase the total number of the Remote Lockout Stations to a maximum of 40 on 23… 85 A or 60 on 110… 1200 A. (See Appendix D of this manual for maximum cable length and number of Remote Lockout Stations. Wiring the Control Module with Pneumatic Ready Option The ElectroGuard® can be ordered with the Pneumatic ready option. The HP1 and HP2 connectors interface the Control Module to the Pneumatic Isolation Module. When the connection to the Pneumatic Isolation Module is not needed, jumper wires must be installed on the HP1 connector in the Control Module. See Table 2.8 and Figure 2.54 for jumper information: Figure 2.54 Jumper Wire Installation on Connector “HP1” When the Optional Pneumatic Isolation Module is Not Used HP1 1 2 Publication 2030-UM003A-EN-P - May 2006 3 4 5 6 7 8 9 10 Installation and Wiring 2-51 Table 2.8 Pneumatic Isolation Module Jumper Connector HP1 Connection Points 5 and 6 Recommended Wire #16 AWG/1.3 mm2 red 7 and 8 #16 AWG/1.3 mm2 blue 9 and 10 #16 AWG/1.3 mm2 blue For wiring the Pneumatic Isolation Module, see Installation and Wiring of the ElectroGuard® Pneumatic Isolation Module on page 2-72 Wiring the Control Module with Time Delay Option (IP1 or FB1 Drive Control Stop Connector) IMPORTANT The optional status Communication Modules allow a remote PLC to monitor the ElectroGuard® Safety Isolation System. The Control Module with time delay feature may be used in applications where the machine or process requires a controlled stop. The time delay feature provides a set of contacts, which can be wired in series with the 2-wire or 3-wire control of a drive or system. After the operating handle of the RLS has been moved to the OFF position, the “DRIVE CONTROL STOP” contacts open, and 1…30 seconds later, isolation of the power bus occurs. Adjustment of this time delay is accomplished by adjusting 2TR and 3TR in the Control Module of the 110… 1200 A units and on 1IC and 2IC of the 23… 85 A units. IMPORTANT The adjustment on two timers must be within two seconds of each other. If not, the system isolated light will not come on when the RLS is switched. If the machine or process is not shut down before switching the RLS to the OFF position, this option provides a redundant means of performing the controlled stop function. In the 23... 85 A models, the drive control stop connector is labeled IP1. In the 110... 1200 A models, the drive control stop connector is labeled FB1. See Figure 2.55 for a typical two-wire control scheme and Figure 2.56 for a typical three-wire control scheme. See Figure 2.57 or 2.58 for wiring to the Drive Control Stop connector. Publication 2030-UM003A-EN-P - May 2006 2-52 Installation and Wiring Figure 2.55 Typical 2-Wire Control Scheme with “DRIVE CONTROL STOP” Function from Control Module with Optional Time Delay 2 Wire Control Start / Stop 1CR 2CR Drive Stop / Run Input From Control Module Figure 2.56 Typical 3-Wire Control Scheme with “DRIVE CONTROL STOP” Function from Control Module with Optional Time Delay 3 Wire Control SR K1 K2 Stop Drive Stop Start From Expansion Module with Time Delay Publication 2030-UM003A-EN-P - May 2006 Start Installation and Wiring 2-53 Figure 2.57 (23…85 A) Wiring to the IP1 Control Stop Connector IP1 Terminal Block in Control Module 1 2 3 4 5 6 7 8 9 10 11 12 IP1 Connector Plug in Control Module For Factory Wiring Drive Control Stop Figure 2.58 (110…1200 A) Wiring to Connector FB1 for a Drive Control Stop Connector FB1 Terminal Block in Control Module 1 2 3 4 5 6 7 8 9 10 1112 FB1 Connector Plug in Control Module Drive Control Stop without Expansion Module N.O. Output Publication 2030-UM003A-EN-P - May 2006 2-54 Installation and Wiring Wiring the RLS and System Status Signals (IP2 connector) The Control Module provides status signals for the Safety Isolation System and for each of the Remote Lockout Stations (RLS) connected to the module. The RLS status signals are provided via auxiliary contacts from the RLS. When the RLS switch is in the OFF position, the auxiliary contact will be open. Conversely, when the RLS switch is in the ON position, the auxiliary contact will be closed. The Safety Isolation System status signal is provided via a series connection of an auxiliary contact from 1IC and 2IC. When the RLS switch is in the OFF position, the auxiliary contacts for 1IC and 2IC will be open. When the RLS switch is in the ON position, the auxiliary contacts for 1IC and 2IC will be closed. These status signals can be wired to a customer-supplied control, or to the optional Communication Modules installed in the ElectroGuard® Power Panel. IMPORTANT The optional status Communication Modules allow a remote PLC to monitor the ElectroGuard® Safety Isolation System. ATTENTION Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! The Communication Module can be powered from a source external to the ElectroGuard®. See Figure 2.59 or 2.60 for wiring to the IP2 connector in the Control Module. See Installation and Wiring of Status Communication Modules on page 2-73. Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-55 Figure 2.59 (23…85 A) ElectroGuard® Status Signals/Wiring to the IP2 Connector IP2 Terminal Block in Control Module 1 2 3 4 5 6 7 8 9 10 11 12 IP2 Connector Plug in Control Module RLS1 For factory use RLS2 System Status RLS3 RLS4 (24VDC MAX.) Figure 2.60 110…1200 A ElectroGuard® Status Signals/Wiring to the IP2 Connector IP2 Terminal Block in Control Module 1 2 3 4 5 6 7 8 9 10 11 12 IP2 Connector Plug in Control Module RLS1 RLS6 RLS2 RLS5 RLS3 RLS4 (24VDC MAX.) Publication 2030-UM003A-EN-P - May 2006 2-56 Installation and Wiring Installation and Wiring of Overview the ElectroGuard® Remote The Remote Lockout Station (RLS) is a rotary operated, enclosed switch with Lockout Station(s) a System Isolated verification light and operating handle that can be locked in the OFF position to provide Lockout/Tagout. The Remote Lockout Station is used to initiate the isolation sequence simultaneously in two separate ElectroGuard® units by sending a signal to the Control Module. Remote Lockout Station Cable Specifications IMPORTANT Cable must have copper conductors only. Cable with 600V insulation is required. Oil-resistant cable is recommended. Individual conductors within the cable should be color-coded or otherwise clearly marked (see Table 2.9). Cable must have a shield with a drain wire similar to Alpha wire XTRA-GUARD® 2: – Part No. 25450/9 for #14 AWG, 0.64 in. O.D. – Part No. 25440/9 for #16 AWG, 0.61 in. O.D. – Part No. 25430/9 for #18 AWG, 0.55 in. O.D. Table 2.9 Suggested Color Scheme for Remote Lockout Station Cable Publication 2030-UM003A-EN-P - May 2006 RLS Terminal Block No. Wire Color 1 Black 2 Red 3 Blue 4 Orange 6 Yellow 7 Brown 8 Violet 9 Gray GND Green Installation and Wiring 2-57 Maximum Cable Length IMPORTANT Table 2.10 Maximum Allowable Cable Lengths . In North America Outside of North America Maximum Total Cable Length (ft.) Wire Gauge Control Module Connector RLS1, RLS2, RLS3 19,500 14 AWG RLS4, RLS5, RLS6 19,500 RLS1, RLS2, RLS3, RLS4 RLS1, RLS2, RLS3 16 AWG 18 AWG The maximum total cable length between all of the RLSs and the Control Module in the ElectroGuard® Power Panel shown in Table 2.10 must not be exceeded. This may affect the reliable operation of the ElectroGuard®. Consider using an optional Expansion Module if cable lengths greater than those shown are needed (see Installation and Wiring of the ElectroGuard® Expansion Module on page 2-68). Wire Gauge (mm2) Maximum Total Wire Length (m) 23…85 A 110…1200 A 5,900 — X 5,900 — X 19,500 5,900 X — 12,250 3,735 — X 2.1 RLS4, RLS5, RLS6 12,250 3,735 — X RLS1, RLS2, RLS3, RLS4 12,500 1.3 3,735 X — RLS1, RLS2, RLS3 7,650 2.330 — X RLS4, RLS5, RLS6 7,650 2,330 — X RLS1, RLS2, RLS3, RLS4 7,650 2,330 X — 0.8 The cable lengths in Table 2.10 represent the total wire impedance allowed to help ensure proper operation of the safety monitoring relays used in the isolation system. See Appendix C of this manual regarding length calculation, conductor sizing and installation scenarios. Wiring the Remote Lockout Station 1. Open the RLS enclosure by loosening the two cover clamp screws (see Figure 2.24). With the operating handle held in the OFF position, squeeze the handle and interlock lever and operation handle as in Figure 2.25. Lift the cover away from the base. Publication 2030-UM003A-EN-P - May 2006 2-58 Installation and Wiring 2. Use appropriate environmentally-rated hubs or conduit fittings to connect cables to the RLS enclosure. Each RLS is furnished with two 1.38 in. (35 mm) diameter openings (one on the top and one on the bottom) designed to accept 1 in. (25.4 mm) conduit fittings or hubs. The top openings have closing plugs to maintain the integrity of the enclosure environmental rating. Red plastic cap plugs are inserted in the bottom openings to keep debris out of the enclosure during shipment and storage. IMPORTANT When installing and wiring the RLS, remove and discard the red plastic cap plug. If wiring the RLS using one top opening, remove the corresponding closing plug from the top and install in the open bottom hole to maintain the integrity of the enclosure environmental rating. IMPORTANT The cables to the RLS must not be run in a line voltage wireway or run adjacent to power conductors. The cables must be protected from physical damage. This requires the appropriate conduit outside of the RLS. IMPORTANT Connector plugs provided on ElectroGuard® Control Modules and Expansion Modules are factory shipped with two jumper wires installed (see Figure 2.61). These two jumper wires must be removed and discarded when wiring is performed to connect a Remote Lockout Station to the connector plug. Failure to remove the two jumper wires on the connector plug will prevent proper operation of the RLS “System Isolated” indicator light. Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-59 Figure 2.61 RLS Connector Plug Jumper Wire RLS Connector Plug 1 2 3 4 5 6 7 8 9 10 11 Factory installed jumper wires. These two wires MUST be removed when wiring an RLS to the connector plug. 3. Select an RLS port and connector plug on the ElectroGuard® unit to be dedicated to the RLS being installed. Remove these plugs by firmly grasping their strain relief tabs and pulling straight out from the port. IMPORTANT Control Module and Expansion Module connector plugs and ports, with the exclusion of the HV connector in the Control Module, are factory keyed. This is done to help ensure correct plug installation after maintenance or servicing, which may have required the removal of any of the connector plugs. Installing an RLS connector plug into a port with non-matching keying may damage the connector as well as the Control Module or Expansion Module port. Publication 2030-UM003A-EN-P - May 2006 2-60 Installation and Wiring Figure 2.62 Wiring from the RLS Terminal Block to a Connector Plug on a Control Module or Expansion Module To Control or Expansion Module (RLS1 to RLS4/RLS6) or (RLS_A to RLS_J) 1 2 3 4 5 6 7 8 9 G 1 N 0 D RLS Connector port Terminals in Control Module or Expansion Module RLS Connector Plug for connecting RLS to Control Module or Expansion Module The fifth terminal of the Connector Plug is not used for RLS connection Drain Wire Color Coded Cable Recommended 1 2 3 Publication 2030-UM003A-EN-P - May 2006 Green Gray Violet Brown Yellow Orange Red Blue Black Terminal Block Inside Remote Lockout Station Braided Cable Shield G 4 6 7 8 9 N D Installation and Wiring 2-61 Table 2.11 Continuity Check Table Remote Lockout Station Status ON ON ON ON OFF OFF OFF OFF Control Module/Expansion Module Connector Plug Connection Point Numbers 2&7 3&8 4&9 1&6 2&7 3&8 4&9 1&6 Continuity Yes Yes Yes No No No No Yes ➊ ❶ The “SYSTEM ISOLATED” light on the front of the Remote Lockout Station has an impedance of about 2k Ohms. 4. Wire each terminal block to its corresponding plug using appropriate cable (see Figure 2.62, also use Table 2.9, if using recommended cable). All wires from the first connected ElectroGuard® System should go to one terminal block, and all of the wires from the second system should go to the remaining terminal block. 5. Have one technician operate the RLS while a second technician checks the continuity between connection points on the RLS connector plug for the Control Module or Expansion Module of the ElectroGuard® System (per Table 2.11). If continuity check is unsatisfactory, review wiring done in step 4 for errors and then re-check continuity. 6. When the continuity checks are successfully completed, close the RLS enclosure cover, place the cover clamps over the lip on the edge of the cover, and tighten the two cover clamp screws. 7. Commission the unit per Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System. Publication 2030-UM003A-EN-P - May 2006 2-62 Installation and Wiring Installation and Wiring of the ElectroGuard® Dual Remote Lockout Station(s) Overview The Dual Remote Lockout Station (RLS) is a rotary operated, enclosed switch with two System Isolated verification lights and an operating handle that can be locked in the OFF position to provide Lockout/Tagout. The Dual Remote lockout Station is used to initiate the isolation sequence simultaneously in two separate ElectroGuard® units by sending signals to each Control Module. Remote Lockout Station Cable Specifications IMPORTANT Cable must have copper conductors only. Cable with 600V insulation is required. Oil-resistant cable is recommended. Individual conductors within the cable should be color-coded or otherwise clearly marked (see Table 2.12). Cable must have a shield with a drain wire similar to Alpha wire XTRA-GUARD® 2: – Part No. 25450/9 for #14 AWG, 0.64 in. O.D. – Part No. 25440/9 for #16 AWG, 0.61 in. O.D. – Part No. 25430/9 for #18 AWG, 0.55 in. O.D. Table 2.12 Suggested Color Scheme for Remote Lockout Station Cable Publication 2030-UM003A-EN-P - May 2006 RLS Terminal Block No. Wire Color 1 Black 2 Red 3 Blue 4 Orange 6 Yellow 7 Brown 8 Violet 9 Gray GND Green Installation and Wiring 2-63 Maximum Cable Length IMPORTANT The maximum total cable length between all of the RLSs and the Control Module in the ElectroGuard® Power Panel shown in Table 2.13 must not be exceeded. This may affect the reliable operation of the ElectroGuard®. Consider using an optional Expansion Module if cable lengths greater than those shown are needed (see Installation and Wiring of the ElectroGuard® Expansion Module on page 2-56). . Table 2.13 Maximum Allowable Cable Lengths In North America Wire Gauge 14 AWG 16 AWG 18 AWG Outside of North America Control Module Connector Maximum Total Cable Length (ft.) RLS1, RLS2, RLS3 19,500 Wire Gauge (mm2) 2.1 Maximum Total Wire Length (m) 23…85 A 5,900 — 110…1200 A X RLS4, RLS5, RLS6 19,500 5,900 — X RLS1, RLS2, RLS3, RLS4 19,500 5,900 X — RLS1, RLS2, RLS3 12,250 3,735 — X RLS4, RLS5, RLS6 12,250 3,735 — X RLS1, RLS2, RLS3, RLS4 12,500 3,735 X — RLS1, RLS2, RLS3 7,650 2.330 — X RLS4, RLS5, RLS6 7,650 2,330 — X RLS1, RLS2, RLS3, RLS4 7,650 2,330 X — 1.3 0.8 The cable lengths in Table 2.13 represent the total wire impedance allowed to help ensure proper operation of the safety monitoring relays used in the isolation system. See Appendix C in this manual regarding length calculation, conductor sizing and installation scenarios. Note that each Dual RLS is connected to two separate ElectroGuard® units, and a cable length calculation must be done for both systems separately. When doing individual calculations, use only the length of the cable connected directly to that unit. Wiring the Dual Remote Lockout Station 1. Open the Dual RLS enclosure by loosening the two cover clamp screws (see Figure 2.24). With the operating handle held in the OFF position, squeeze the handle and interlock lever and operation handle as in Figure 2.25. Lift the cover away from the base. Publication 2030-UM003A-EN-P - May 2006 2-64 Installation and Wiring 2. Use appropriate environmentally-rated hubs or conduit fittings to connect cables to the Dual RLS enclosure. Each Dual RLS is furnished with four 1.38 in. (35 mm) diameter openings (two on the top and two on the bottom) designed to accept 1 in. (25.4 mm) conduit fittings or hubs. The top openings have closing plugs to maintain the integrity of the enclosure environmental rating. Red plastic cap plugs are inserted in the bottom openings to keep debris out of the enclosure during shipment and storage. IMPORTANT When installing and wiring the Dual RLS, remove and discard both red plastic cap plugs. If wiring the Dual RLS using one or both top openings, remove the corresponding closing plug(s) from the top and install in the open bottom hole(s) to maintain the integrity of the enclosure environmental rating. IMPORTANT The cables to the Dual RLS must not be run in a line voltage wireway or run adjacent to power conductors. The cables must be protected from physical damage. This requires the appropriate conduit outside of the Dual RLS. IMPORTANT Connector plugs provided on ElectroGuard® Control Modules and Expansion Modules are factory shipped with two jumper wires installed (see Figure 2.63). These two jumper wires must be removed and discarded when wiring is performed to connect a Remote Lockout Station to the connector plug. Failure to remove the two jumper wires prevents proper operation of the RLS “System Isolated” indicator light. Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-65 Figure 2.63 RLS Connector Plug Jumper Wire RLS Connector Plug 1 2 3 4 5 6 7 8 9 10 11 Factory installed jumper wires. These two wires MUST be removed when wiring an RLS to the connector plug. 3. Select an RLS port and connector plug on both ElectroGuard® units to be dedicated to the Dual RLS being installed. Remove these plugs by firmly grasping their strain relief tabs and pulling straight out from the port. IMPORTANT Control Module and Expansion Module connector plugs and ports, with the exclusion of the HV connector in the Control Module, are factory keyed. This is done to help ensure correct plug installation after maintenance or servicing, which may have required the removal of any of the connector plugs. Installing an RLS connector plug into a port with non-matching keying may damage the connector as well as the Control Module or Expansion Module port. Publication 2030-UM003A-EN-P - May 2006 2-66 Installation and Wiring Figure 2.64 Wiring from the RLS Terminal Block to a Connector Plug on a Control Module or Expansion Module To Control or Expansion Module (RLS1 to RLS4/RLS6) or (RLS_A to RLS_J) 1 2 3 4 5 6 7 8 9 G 1 N 0 D RLS Connector port Terminals in Control Module or Expansion Module RLS Connector Plug for connecting RLS to Control Module or Expansion Module The fifth terminal of the Connector Plug is not used for RLS connection Drain Wire Color Coded Cable Recommended 1 2 3 Publication 2030-UM003A-EN-P - May 2006 Green Gray Violet Brown Yellow Orange Red Blue Black Terminal Block Inside Remote Lockout Station Braided Cable Shield G 4 6 7 8 9 N D Installation and Wiring 2-67 Table 2.14 Continuity Check Table Remote Lockout Station Status ON ON ON ON OFF OFF OFF OFF Control Module/Expansion Module Connector Plug Connection Point Numbers 2&7 3&8 4&9 1&6 2&7 3&8 4&9 1&6 Continuity Yes Yes Yes No No No No Yes ❶ ❶ The “SYSTEM ISOLATED” light on the front of the Remote Lockout Station has an impedance of about 2k Ohms. 4. Wire each terminal block to its corresponding plug using appropriate cable (see Figure 2.64, also use Table 2.12 if using recommended cable). All wires from the first connected ElectroGuard® System should go to one terminal block, and all of the wires from the second system should go to the remaining terminal block. 5. Have one technician operate the Dual RLS while a second technician checks the continuity between connection points on the RLS connector plug for the Control Module or Expansion Module of the first ElectroGuard® System (per Table 2.14). If continuity check is unsatisfactory, review wiring done in Step 4 for errors and then re-check continuity. When all of the connections between the Dual RLS and the first ElectroGuard® System are satisfactory, repeat for all connections between the Dual RLS and the second ElectroGuard® System. 6. When both continuity checks are successfully completed, close the Dual RLS enclosure cover, place the cover clamps over the lip on the edge of the cover and tighten the two cover clamp screws. 7. Commission the unit per Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System, of this manual. Publication 2030-UM003A-EN-P - May 2006 2-68 Installation and Wiring Installation and Wiring of the ElectroGuard® Expansion Module Overview The ElectroGuard® Expansion Modules are used when there is a need to increase the number of Remote Lockout Stations, or the maximum total wire length for the four or six Remote Lockout Stations supported by the Control Module in the ElectroGuard® Power Panel. Expansion modules are available in four-port or ten-port constructions with or without an adjustable 30-second time delay for the drive control stop (optional Expansion Module with time delay) (see Figure 2.65). Figure 2.65 10-port Expansion Module (Open Type) The Expansion Modules provide the connectors for the additional Remote Lockout Stations, the Remote Lockout Stations’ status signals, the drive control stop (optional Expansion Module with time delay), and the connector to interface the Expansion Module to the Control Module in the ElectroGuard® Power Panel or the series connection of the Expansion Modules.(see Figure 2.66). Note: Four-port Expansion Module is not pictured. Installation of the Expansion Module See the Expansion Module Installation Instruction Sheet (Revision 2 or later). Wiring the Expansion Module See the Expansion Module Installation Instruction Sheet (Revision 2 or later). Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring 2-69 Figure 2.66 Connectors in 10-port Expansion Modules RLS_A RLS_B RLS_C RLS_D RLS_E RLS_F RLS_I RLS_J RLS_G RLS_H PLC1 EXB PLC2 EXB EXB Figure 2.67 Connection of Expansion Modules to the Control Module Expansion Module EXB Connector Expansion Module EXB ElectroGuard Power Panel RLS Expansion Module EXB RLS Control Module Expansion Module EXB RLS RLS RLS Expansion Module EXB RLS Connector RLS Remote Lockout Station Remote Lockout Station Remote Lockout Station Remote Lockout Station Publication 2030-UM003A-EN-P - May 2006 2-70 Installation and Wiring Figure 2.68 Series Connected Expansion Modules Any Expansion Module RLS Connector Expansion Module EXB Connector Expansion Module RLS EXB ElectroGuard Power Panel Expansion Module Control Module RLS EXB RLS Remote Lockout Station Expansion Module RLS Publication 2030-UM003A-EN-P - May 2006 EXB Installation and Wiring Installation and Wiring of the ElectroGuard® Verification Module 2-71 Overview The Verification Module is an optional add-on module for the ElectroGuard® Safety Isolation System that links a customer-supplied remote device to the ElectroGuard® Control Module. The Verification Module provides a set of redundant contacts to a remote device that close when the ElectroGuard® system has safely isolated energy to the machine or process; the Verification Module can also monitor the state of the remote device and not re-apply energy until the remote device is in the proper state. The Verification Module uses a standard RLS port on a Control Module or Expansion Module and its safety outputs are analogous to an RLS 'System isolated' light. Installation of the Verification Module See the Verification Module Installation Instruction Sheet (Revision 2 or later). Wiring of the Verification Module See the Verification Module Installation Instruction Sheet (Revision 2 or later). Publication 2030-UM003A-EN-P - May 2006 2-72 Installation and Wiring Installation and Wiring of the ElectroGuard® Pneumatic Isolation Module Overview The optional Pneumatic Isolation Module provides isolation of the pneumatic energy to the machine or process. When an RLS is switched to the OFF position, the pneumatic energy supplied to the machine is turned off and the residual energy between the machine and pneumatic isolation module will be exhausted through the air exhaust muffler on the pneumatic module. Installation of the Pneumatic Isolation Module See the Pneumatic Isolation Module Installation Instruction Sheet (Revision 2 or later). Wiring of the Pneumatic Isolation Module See the Pneumatic Isolation Module Installation Instruction Sheet (Revision 2 or later). Publication 2030-UM003A-EN-P - May 2006 Installation and Wiring Installation and Wiring of the Status Communication Modules 2-73 Installation of the Communication Modules ATTENTION ! Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. The optional status Communication Modules provided by Rockwell Automation are via “Flex I/O” modules. Note: The optional status communication allows access to the status signals from the ElectroGuard® Safety Isolation System. The Safety Isolation System status communication capabilities are: One data point for status indication of the ElectroGuard® Power Panel. N.O. auxiliary contacts from 1IC and 2IC are wired in series to provide the status of the isolation contactor in the ElectroGuard® Power Panel. Three data points for status indication of the Pneumatic Isolation Module (if applicable). One data point provides the status of the Pneumatic Valve, and two data points provide pressure status of PS1 and PS2 pressure switches in the Pneumatic Isolation Module. One data point for status indication of each Remote Lockout Station used in the application. An auxiliary contact from the Remote Lockout Station provides switch status indication. When the Remote Lockout Station switch is in the OFF position, the auxiliary contact is open. Conversely, when the Remote Lockout Station switch is in the ON position, the auxiliary contact is closed. Note: The optional status Communication Modules are installed at the factory in the ElectroGuard® Power Panel enclosure when ordered with the Safety Isolation System. Each input communication module provides 16 data points. A maximum of three input communication modules (1794-IB16) can be installed within the ElectroGuard® Power Panel enclosure. The optional status Communication Modules are installed at the factory in the Expansion Module enclosure when ordered with an enclosed Expansion Module. A maximum of one input Communication Module (1794-IB16) can be installed within the enclosed Expansion Module. If additional input communication modules (1794-IB16) need to be installed at a later time either in the ElectroGuard® Power Panel enclosure or a customer enclosure, follow the 1794-IB16 and 1794-TB3 installation instructions. See reference publications 1794-5.4 and 1794-5.2. Publication 2030-UM003A-EN-P - May 2006 2-74 Installation and Wiring Wiring of the Communication Module The data point for the 1IC and 2IC isolation contactors status, and the data points for the status of the Remote Lockout Stations connected to the Control Module and Expansion Module in the ElectroGuard® Power Panel are factory wired to the Communication Module. The data points from the Pneumatic Isolation Module and/or any open style Expansion Modules installed in a customer’s enclosure will be wired to the 1794-IB16 by the user. If additional input communication modules (1794-IB16) are installed by the user at a later time either in the ElectroGuard® Power Panel enclosure or a customer supplied enclosure, follow the 1794-IB16 and 1794-TB3 wiring instructions. See reference publications 1794-5.4 and 1794-5.2. (See Tables 2.15, 2.16, and Figures 2.69…2.71 for typical wiring to the Communication Modules The power for the Input Modules (separate control source #2) is factory wired when the optional Communication Module is ordered with the Safety Isolation System. The power for the Communication Adapter (separate control source #1) is wired by the customer. To meet CE requirements, three ferrite cores and six wire ties are provided to the customer for use when wiring the Communication Module. Two of the ferrite cores must be placed around the wire’s end feeding the power supplies of the Communication Module inside the enclosure. The first ferrite core is attached where the wires exit the enclosure and the second ferrite core is attached where the wires attach to the power supplies. The third ferrite core must be placed around the communication cable attached to the Communication Adapter Module inside the enclosure, where the wires exit the enclosure. Publication 2030-UM003A-EN-P - May 2006 2-75 Installation and Wiring Table 2.15 Safety Isolation System Status Signals Com Port 1 COM 1 CNET 1 DNET 1 ENET 1 PNET (Input Module) Module ElectroGuard® Power Panel Connector IP2 FB2 Connection Point No. 9 and 10 7 and 8 8 and 16 Pneumatic Isolation Module HC 17 and 18 19 and 20 Control Module IP2 PLC1EXB 10-Port or 4-Port Expansion Module (Optional) 2 COM 2 CNET 2 DNET 2 ENET 2 PNET (Input Module) PLC2EXB Status Indication System Pneumatic Valve Pressure Switch 1 Pressure Switch 2 1 and 2 RLS1 3 and 4 RLS2 5 and 6 RLS3 7 and 8 RLS4 9 and 10 RLS5 11 and 12 RLS6 1 and 2 RLS1A 3 and 4 RLS1B 5 and 6 RLS1C 7 and 8 RLS1D 9 and 10 RLS1E 1 and 2 RLS1F 3 and 4 RLS1G 5 and 6 RLS1H 7 and 8 RLS1I 9 and 10 RLS1J RLS Status Closed with all RLS “ON” Open with any RLS “OFF” Open Air Closed No Value Pressure or Fault Valve Fault Closed with all Open with any RLS “ON” RLS “OFF” Closed with all Open with any RLS “ON” RLS “OFF” Closed with RLS1 Open with RLS1 “ON” “OFF” Closed with RLS2 Open with RLS2 “ON” “OFF” Closed with RLS3 Open with RLS3 “OFF” “ON” Closed with RLS4 Open with RLS4 “ON” “OFF” Closed with RLS5 Open with RLS5 “ON” “OFF” Closed with RLS6 Open with RLS6 “OFF” “ON” Open with Closed with RLS1A “OFF” RLS1A “ON” Open with Closed with RLS1B “OFF” RLS1B “ON” Closed with Open with RLS1C “ON” RLS1C “OFF” Open with Closed with RLS1D “OFF” RLS1D “ON” Open with RLS1E Closed with RLS1E “ON” “OFF” Closed with Open with RLS1F RLS1F “ON” “OFF” Open with Closed with RLS1G “OFF” RLS1G “ON” Open with Closed with RLS1H “OFF” RLS1H “ON” Closed with Open with RLS1I RLS1I “ON” “OFF” Closed with RLS1J “ON” Open with RLS1J “OFF” 23…85 A X N/A 110…1200 A N/A X Input No./Bit 0 X X 1 X X 2 X X 3 X X 4 X X 5 X X 6 X X 7 N/A X 8 N/A X 9 N/A X 9 N/A X 10 N/A X 11 N/A X 12 N/A X 13 N/A X 14 N/A X 15 N/A X 0 N/A X 1 N/A X 2 Publication 2030-UM003A-EN-P - May 2006 2-76 Installation and Wiring Table 2.15 Safety Isolation System Status Signals (Continued) Com Port 2 COM 2 CNET 2 DNET 2 ENET 2 PNET (Input Module) Module Connector PLC1EXB 10-Port Expansion Module (Optional) PLC2EXB Connection Point No. Status Indication 1 and 2 RLS2A 3 and 4 RLS2B 5 and 6 RLS2C 7 and 8 RLS2D 9 and 10 RLS2E 1 and 2 RLS2F 3 and 4 RLS2G 5 and 6 RLS2H 7 and 8 RLS2I 9 and 10 RLS2J RLS Status 23…85 A Closed with Open with N/A RLS2A “ON” RLS2A “OFF” Open with Closed with N/A RLS2B “OFF” RLS2B “ON” Open with Closed with N/A RLS2C “OFF” RLS2C “ON” Closed with Open with RL2D N/A RLS2D “ON” “OFF” Open with RLS2E Closed with N/A “OFF” RLS2E“ON” Open with RLS2F Closed with N/A RLS2F “ON” “OFF” Closed with Open with N/A RLS2G “ON” RLS2G “OFF” Open with Closed with N/A RLS2H “OFF” RLS2H “ON” Open with RLS2I Closed with N/A RLS2I“ON” “OFF” Closed with Open with RLS2J N/A RLS2J “ON” “OFF” N/A N/A N/A N/A 110…1200 A Input No./Bit X 2 X 3 X 4 X 5 X 6 X 7 X 8 X 9 X 10 X 11 X X X X 12 13 14 15 Note: If one Expansion Module is used, RLS6 is not used. Note: If two Expansion Modules (available only on 55 in. enclosures or larger) are used, RLS5 and RLS 6 are not used. Also, reduce Expansion Module Input No./Bit by one (1). The 24V DC, 1794-PS13 power supplies, for the Communication Module must be powered by separate control sources. Field connection points for 120V/230V AC separate control voltage sources are provided as part of the Communication Module. (See Figure 2.69 and Table 2.16) Table 2.16 Communication Modules Power Supply Connections Connection Point AC Ground Terminal Block 120/230V AC Common/ Neutral 120/230V AC Power Publication 2030-UM003A-EN-P - May 2006 Designator G To 1794-PS13 Terminal A L2/N B L1/L C FUSE I G J +24V COM H #14 MTW, Green / Yellow C F B E A D C F B E A D G J +24V I E G +24V #16 MTW Blue -V LW D HI +V 3 #16 MTW Blue w/ White Stripe H COM Communication Adaptors 1794-ACN15 1794-APB 1794-ACNR15 1794-ASB 1794-ACN15K 1794-ASBK 1794-ACNR15K 1794-ASB2 1794-ADN 1794-APB 1794-ADNK COM 1794-AENT D F 1794-FLA If a 1794-IB16 and 1794-TB3 Input Module and base are customer installed at a later time, connect a jumper from terminal (51) +24V DC to terminal (34) on the next base. Connect a jumper from terminal (33) Common to terminal (16) on the next base. 2 WHT wire CAN* = Controller Area Network +V Drain CAN* High Bare wire RED wire -V CAN* Low BLU wire TO BLK wire CONNECT 3 (L1) (L2) (GND) 1794-PS13 24VDC POWER SUPPLY #2 Connect the Device Net cable to the removable connector as shown: #14 MTW, Yellow #14 MTW, White w/ Yellow (L1) (L2) (GND) 1794-PS13 24VDC POWER SUPPLY #1 1 G Customer connection points for 120V/230V AC separate control sources. NOTES: N Separate Control Source #1 FUSE 1 G Separate Control Source #2 N 1 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 V 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 COM 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1794-IB16 #1 COM 2 COM 2 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 V 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1794-IB16 #3 Factory or Customer Installed Input Modules and terminal bases (see typical Connection Diagram) (24VDC PLC Wiring to IO#16 Blue MTW) 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 V 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1794-IB16 #2 (3) 1794-IB16 & 1794-TB3 Maximum in Electroguard Power Panel (24VDC, 16 Sink Input Modules) Installation and Wiring 2-77 Figure 2.69 Communication Module Publication 2030-UM003A-EN-P - May 2006 2-78 Installation and Wiring Figure 2.70 Typical Wiring for 23… 85 A Safety Isolation System with Pneumatic Isolation Module and No Expansion Modules V COM _ + 16 24V DC 34 IP2 Input Terminal IP2 2IC 1IC 35 0 (9) (10) HC System Status HC VLV PLC 36 1 (8) (16) HC HC PS1 PLC 2 37 (17) (18) HC Pneumatic Module Status HC PS2 PLC 3 38 (19) (20) IP2 RLS1 (1) (2) IP2 RLS2 RLS1 AUX 4 RLS1 IP2 (7) (2) RLS2 IP2 39 4 RLS2 AUX 4 5 40 (3) (2) IP2 RLS3 (5) (2) IP2 RLS4 (7) (2) RLS3 AUX 4 (7) (4) RLS3 IP2 (7) (6) RLS4 IP2 (7) (8) 41 6 RLS4 AUX 42 7 Red Customer Wiring #16 Blue MTW Publication 2030-UM003A-EN-P - May 2006 Brown Customer Wiring #16 Blue MTW Status of Remote Lockou Stations from Control Module Installation and Wiring 2-79 Figure 2.71 Typical Wiring for 110...1200 A, Safety Isolation System with Pneumatic Isolation Module and One (1) Expansion Module V 34 COM + _ 24V DC 2IC 1IC FB2 Input Terminal 16 FB2 0 35 (8) (7) HC HC VLV PLC 36 1 (8) (16) HC HC PS1 PLC 37 2 (17) (18) Status of Pneumatic Module HC PS2 PLC HC 3 38 (20) (19) IP2 RLS1 (1) (2) IP2 RLS2 (3) (2) IP2 RLS3 (5) (2) IP2 RLS4 (3) (2) IP2 RLS5 (5) (2) RLS1 AUX 4 RLS1 IP2 (7) (2) RLS2 IP2 (7) (4) RLS3 IP2 (7) (6) RLS4 IP2 (7) (4) RLS5 IP2 (7) (6) 4 39 RLS2 AUX 4 15 40 RLS3 AUX 4 6 41 RLS4 AUX 4 42 Status of Remote Lockout Stations from Control Module 7 RLS5 AUX 4 43 To Sheet 4 Status of Isolation Contactors 8 Customer Wiring #16 Blue MTW Red Brown Customer Wiring #16 Blue MTW Publication 2030-UM003A-EN-P - May 2006 2-80 Installation and Wiring Figure 2.72 Typical Wiring for 110...1200 A, Safety Isolation System with Pneumatic Isolation Module and One (1) Expansion Module [Continued] From Sheet 3 PLC1 EXB RLS1A (1) (2) PLC1 EXB RLS1B (3) (2) PLC1 EXB RLS1C (5) (2) RLS1A 4 AUX RLS1A PLC1 EXB (7) (2) RLS1B PLC1 EXB (7) (4) RLS1C PLC1 EXB (7) (6) RLS1D PLC1 EXB (7) (8) RLS1E PLC2 EXB (7) (10) RLS1F PLC2 EXB (7) (2) RLS1G PLC2 EXB (7) (4) RLS1H PLC2 EXB (7) (6) RLS1I PLC2 EXB 44 9 RLS1B 4 AUX 45 10 RLS1C 4 AUX 46 11 PLC1 EXB RLS1D (7) (2) PLC1 EXB RLS1E (9) (2) PLC2 EXB RLS1F (1) (2) PLC2 EXB RLS1G (3) (2) PLC2 EXB RLS1H (5) (2) PLC2 EXB RLS1I RLS1D 4 AUX 47 12 RLS1E 4 AUX 13 48 RLS1F 4 AUX 14 49 RLS1G 4 AUX 15 50 RLS1H 4 AUX 1 35 RLS1I AUX 4 36 Status of Remote Lockout Stations from Expansion Module (1794-IB16#2) 2 (7) (2) PLC2 EXB RLS1J (7) (2) RLS1J 4 AUX (7) (8) RLS1J PLC2 EXB (7) (8) 37 3 Customer Wiring #16 Blue MTW Red Brown 4 Notes: Remote Device. 5 Terminal Screw tightening torque: 5…7 lb-in. (0.565…0.791 N•m) 6 Status of Remote Lockout Stations from Expansion Module (1794-IB16#1) Customer Wiring #16 Blue MTW If an additional open type (4) or (10) port Expansion Modules are added by the customer at a later time, additional 194-TB3 and 1794-IB16 will be required for the status indication of the Remote Lockout Stations connected to these Expansion Modules. A maximum of (3) 1794-IB16 and 1794-TB3 Input Modules and bases can be installed within the ElectroGuard® Power Panel. Publication 2030-UM003A-EN-P - May 2006 6 Installation and Wiring Final Steps for Installation and Wiring 2-81 At this point in the installation/wiring process, all of the Safety Isolation System components should be installed and wired. Close all RLS enclosure covers and tighten the two cover clamp screws. All RLSs should be in the OFF position. Proceed to Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System. Publication 2030-UM003A-EN-P - May 2006 2-82 Installation and Wiring Publication 2030-UM003A-EN-P - May 2006 Chapter 3 Commissioning of the ElectroGuard® Safety Isolation System Purpose Section Page Purpose 3-1 Required Equipment 3-2 ElectroGuard® Power Panel Verification 3-2 (Dual) Remote Lockout Station Verification 3-7 Expansion Module Verification 4-Port or 10-Port With or Without Time Delay 3-10 Communication Module Verification 3-11 Pneumatic Isolation Module Verification 3-12 Control Module with Time Delay 3-13 Incoming Power Verification 3-14 Commissioning the Safety Isolation System Without Time Delay Option 3-15 Remote Lockout Station Sequence Tests (23... 85 A) 3-17 Remote Lockout Station Sequence Tests (110…1200 A) 3-19 Commissioning Expansion Module (4-Port or 10-Port With or Without Time Delay) (23…1200 A) 3-21 Commissioning Verification Module (with Gate Locks) 3-23 Commissioning Pneumatic Isolation Module Operation 3-25 Commissioning the Communication Modules 3-27 Final Steps 3-29 ATTENTION ! Commissioning of the ElectroGuard® must be performed by a qualified technician familiar with the Safety Isolation System, who then seals the Remote Lockout Station(s). The Safety Isolation System Control Module, and optional Expansion and Pneumatic Isolation Modules are factory sealed. The technician responsible for the commissioning process should record the commissioning and all subsequent servicing of the system. The purpose of Commissioning the system is to verify that the Safety Isolation System was correctly installed and operates properly. 1 Publication 2030-UM003A-EN-P - May2006 3-2 Commissioning of the ElectroGuard® Safety Isolation System Commissioning is necessary in order to verify: System hardware is operating as intended, Proper operation of each Remote Lockout Station, Proper operation of the Isolation and Grounding Contactors. Required Equipment ElectroGuard® Power Panel Verification One multi-meter with lead assortment Field Connection Diagrams (supplied with the unit) for the ElectroGuard® Power Panel, Control Module, Remote Lockout Station, and, if applicable, Expansion Module, Communication Module, Verification Module, and Pneumatic Isolation Module. Proper personal protective equipment. ATTENTION ! Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. 1. With the power to the Safety Isolation System turned OFF and locked out at the upstream customer supplied disconnect (or locked out at the optional disconnecting means in the ElectroGuard® Power Panel), loosen the door fasteners and open the enclosure door (see Figure Chapter 3 for 23...85 A or Figure Chapter 3 for 110...1200 A). ATTENTION ! Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® must be performed by a qualified technician familiar with the Safety Isolation System, who then seals the Remote Lockout Station(s). The Safety Isolation System Control Module, and optional Expansion and Pneumatic Isolation Modules are factory sealed. The technician responsible for the commissioning process should record the commissioning and all subsequent servicing of the system. ATTENTION Hazardous voltage could be present. To avoid serious injury or death: ! Personal protective equipment may be required for the commissioning process. Commissioning of the ElectroGuard® Safety Isolation System 3-3 Figure 3.1 23…85 A ElectroGuard® in Type 12 Enclosure with Optional Branch Circuit Protection Cover Fasteners Figure 3.2 110…1200 A ElectroGuard® in MCC Enclosure . Power Panel Door Fasteners 2. Verify that voltage is not present phase-to-phase and phase-to-ground on either the load side of the optional disconnecting means (if provided) or the terminals of the power distribution block (if optional disconnecting means not provided (See Figures Chapter 3 and Chapter 3 for disconnecting means, or Figures Chapter 3 and Chapter 3 for power distribution block). Publication 2030-UM003A-EN-P - May2006 3-4 Commissioning of the ElectroGuard® Safety Isolation System Figure 3.3 Load Side of Fusible Disconnect Switch (Shown Without Fuses) T1 T2 T3 Figure 3.4 Load-side of Circuit Breaker T1 T2 T3 Publication 2030-UM003A-EN-P - May2006 3-5 Commissioning of the ElectroGuard® Safety Isolation System Figure 3.5 Line Side of Typical Power Distribution Block (23… 85 A) L1 L2 L3 Figure 3.6 Line Side of Typical Power Distribution Block (110… 1200 A) L1 L2 L3 3. Verify that all the power connections inside of the ElectroGuard® Power Panel are tight. Refer to the torque label affixed to the enclosure door. (See Figure Chapter 3 for location of label on enclosure door.) Publication 2030-UM003A-EN-P - May2006 3-6 Commissioning of the ElectroGuard® Safety Isolation System Figure 3.7 Torque Label Location 4. If the customer-supplied or factory-installed upstream disconnecting means is a fusible disconnect, verify that applicable sized power fuses are in place to allow commissioning and start up of the system. 5. Verify the Isolated Ground conductor is present and secured at the “Isolated Ground” terminal block. The isolated Grounding conductor must have a direct connection to Earth Ground. 6. Verify the Equipment Ground conductor is present and secured at the (P.E.) terminal lug. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Check the wiring from each of the Remote Lockout Stations to verify that wiring matches Figure Chapter 3 for each Remote Lockout Station. Figure 3.8 Wiring the Remote Lockout Station to the Control Module or Expansion Module To Control or Expansion Module Color coded cable recommended BLACK RED BLUE ORANGE YELLOW BROWN VIOLET GREY GREEN (Dual) Remote Lockout Station Verification 3-7 G 1 2 3 4 6 7 8 9 N D Terminal Block inside Remote Lockout Station Check each Remote Lockout Station for proper wiring and operation as follows: 1. At the power panel, remove the Remote Lockout Station connector plug from the terminal block in the Control Module or the Expansion Module (see Figure Chapter 3). Publication 2030-UM003A-EN-P - May2006 3-8 Commissioning of the ElectroGuard® Safety Isolation System Figure 3.9 Remote Lockout Stations Connector Plugs 2. Have a qualified technician operate the Remote Lockout Station while another technician checks continuity between connection points on the Remote Lockout Station connector plug in the Control Module or the Expansion Module as outlined in Table Chapter 3, “Continuity Check Table”. If continuity check is unsatisfactory, see Chapter 4, Troubleshooting. Note: When all of the connections between the Dual RLS and the first ElectroGuard® system are satisfactory, repeat for all connections between the Dual RLS and the second ElectroGuard® system. Table 3.1 Continuity Check Table Remote Lockout Station Status Control Module / Expansion Module Connector Plug Connection Point Numbers Continuity On 2&7 Yes On 3&8 Yes On 4&9 Yes On 1&6 No Off 2&7 No Off 3&8 No Off 4&9 No Off 1&6 Yes ❶ ❶ The “SYSTEM ISOLATED” light on the front of the Remote Lockout Station has an impedance of about 2k Ohms. If a Remote Lockout Station connector plug is not used, grip the strain relief pad holding the Remote Lockout Station connector, and remove the connector by pulling it away from the Control Module or Expansion Module. Verify that jumper wires have been installed at connection points (3) and (8) and (4) and (9). (See Table Chapter 3 and Figure Chapter 3 for jumper information.) Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System 3-9 Table 3.2 Jumpering Out an Unused Remote Lockout Station PortStation Connector Plug Connection Points Recommended Wire RLS1 through RLS6 (3) & (8) # 16 AWG MTW, blue/1.3 mm2 blue (4) & (9) # 16 AWG MTW, blue/1.3 mm2 blue Figure 3.10 Jumper Wire Installation on a Connector Plug for an Unused Remote Lockout Station. RLS (any #) 1 2 IMPORTANT 3 4 5 6 7 8 9 10 11 For proper operation of the Safety Isolation System: When a Remote Lockout Station is installed, the two jumper wires must be removed from the plug that will be used to connect it. 3. Ensure that the connection points do not have continuity with any other connection point or ground when the Remote Lockout Station operating handle is in the ON position, except as stated in Table Chapter 3. 4. Ensure that the connection points do not have continuity with any other connection point or ground when the Remote Lockout Station operating handle is in the OFF position, except as stated in Table Chapter 3. 5. If a Remote Lockout Station fails any of the above continuity checks troubleshoot the point-to-point wiring between the terminal block in the Remote Lockout Station and the Remote Lockout Station connector plug in the Control Module or the Expansion Module. IMPORTANT For proper operation of the Safety Isolation System: The five-step procedure outlined above should be repeated for each Remote Lockout Station. Note: If any Remote Lockout Station fails the continuity check and if the wiring between the Remote Lockout Station terminal block and the Remote Publication 2030-UM003A-EN-P - May2006 3-10 Commissioning of the ElectroGuard® Safety Isolation System Lockout Station connector plug in the Control Module or the Expansion Module is correct, replace the Remote Lockout Station. Expansion Module Verification 4-Port or 10-Port With or Without Time Delay Verify that the open type Expansion Module has been securely attached to the mounting plate of the enclosure. Verify that the tamper-indicating seal has not been broken. Check that there is proper clearance for the connector plugs and wires. A clearance of 6 in. (152 mm) should be observed for ease of installation and removal of connector plugs. Check that all connectors are secure and inserted into the proper ports on the Expansion Module. There are four or ten Remote Lockout Station ports, one or two PLCEXB ports, and one EXB port. The EXB connector plug from the Expansion Module must be securely attached to a Remote Lockout Station port in the Control Module, or another Expansion Module. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Communication Module Verification 3-11 The Communication Module is for ElectroGuard® status and does not affect the operation of the ElectroGuard® system. The communications can be verified after the system is commissioned by cycling each component of the system. Publication 2030-UM003A-EN-P - May2006 3-12 Commissioning of the ElectroGuard® Safety Isolation System Pneumatic Isolation Module Verification IMPORTANT When installing air connections, the Pneumatic Module external pipe fitting needs to be held secure. If this is not done, internal fitting may become loose, causing an air leak. When making the hard-piped air connections to the air inlet and outlet fittings to the module, a clearance of 5 in. (127 mm) should be observed for ease of installation and module replacement, if necessary. 1. Verify that an air filter and moisture trap for the incoming air line and a moisture trap for the outgoing air line have been installed. 2. Verify the Pneumatic Isolation Module has been securely attached to a wall or other form of permanent mount. 3. Check for a minimum of 6 in. (152 mm) of clearance for access to inlet and outlet piping connections. 4. Verify that the area in front of the pressure relief valve, protruding from the enclosure bottom is clear of obstructions. 5. Verify that inlet and outlet air line fittings have been tightened to prevent air line leakage. 6. Verify the electrical connector on the side of the Pneumatic Isolation Module is inserted and properly latched to the bulkhead connector. 7. Check connector plugs HP1 and HP2 inside the ElectroGuard® Power Panel to verify they are correctly installed and firmly inserted to the corresponding terminal blocks in the Control Module. 8. Verify the indicator Light Status Chart is affixed to the enclosure door. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Control Module with Time Delay 3-13 If the Safety Isolation System has been purchased with the Time Delay Option, the Control Module will provide two connection points for the Drive Control Stop. For more information, see Wiring the Control Module with Time Delay Option (IP1 or FB1 Drive Control Stop Connector) on page 2-51. Publication 2030-UM003A-EN-P - May2006 3-14 Commissioning of the ElectroGuard® Safety Isolation System Incoming Power Verification ATTENTION Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Personal protective equipment may be required for this portion of the commissioning process. 1. With the power to the Safety Isolation System still turned OFF and locked out at the customer-supplied upstream disconnect (or locked out at the optional disconnecting means in the ElectroGuard® Power Panel), verify the disconnect that feeds electrical energy to the ElectroGuard® Power Panel does not feed any other panel or device on the machine. 2. Verify the Motor Starters or Drives located downstream of the Safety Isolation System are OFF and can not start automatically when power is applied. 3. Turn the operating handles of all of the RLSs to the OFF position. A padlock(s) can be inserted into the locking tab of the RLS operating handles (if it is in the OFF position) in order to keep the electrical energy feeding the loads isolated. ATTENTION In this test, the disconnecting means supplying electrical energy to the Safety Isolation System will be turned ON. ! Other panels or devices on portions of the machine not controlled by the SIS may also be fed through the branch circuit protection supplying the electrical energy. It is the responsibility of personnel commissioning this system to take the necessary measures to protect the operators. 4. Remove the padlock and move the handle of the upstream customer supplied disconnecting means supplying power to the Safety Isolation System to the ON position, OR 5. Remove the padlock and move the handle of the optional disconnecting means in the ElectroGuard® Power Panel to the ON position. 6. Open the ElectroGuard® Power Panel enclosure door and measure between phases to verify that proper input voltage is available. 7. Verify there is no power at the load side of the main contactors 1IC and 2IC (With the RLSs in the OFF position, the power contactors 1IC and 2IC should be de-energized.) 8. Verify that proper input voltage is available to the Safety Isolation System Control Circuit Transformer primary and 120V AC ±10% is present on the secondary. The Safety Isolation System control transformer will be energized. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Commissioning the Safety Isolation System Without Time Delay Option ATTENTION 3-15 During this process, the machine could inadvertently start. ! ATTENTION Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION Commissioning of the ElectroGuard® must be performed by a qualified technician familiar with the Safety Isolation System, who then seals the Remote Lockout Station(s). The Safety Isolation System Control Module, and optional Expansion and Pneumatic Isolation Modules are factory sealed. The technician responsible for the commissioning process should record the commissioning and all subsequent servicing of the system. ! 1. Turn all the Remote Lockout Station operating handles to the ON position and continue with the following commissioning process to confirm the proper operation of all system functions. Note: Air will be exhausting out the muffler of the Pneumatic Isolation Module until the “SYSTEM ON” push button is pressed. 2. Energize the power bus to the motor starters (or drives) fed from the Safety Isolation System by pressing the “SYSTEM ON” push button. (Pilot lights “SYSTEM CONTROL ON” and “ISOLATED GROUND CONNECTED” will illuminate.) 3. Check motor operation using the machine or process normal “START” and “STOP” functions. Keep the machine in the stopped mode. If the Pneumatic Module is attached, verify that air is being supplied to the process from the Pneumatic Isolation Module. 4. Observe the indicating lights in the Safety Isolation system Control Module after the “SYSTEM ON” push button has been depressed. (Refer to the indicator Light Explanation sheet for the Control Module, included in the document holder on the inside of the Power Panel enclosure door.) Publication 2030-UM003A-EN-P - May2006 3-16 Commissioning of the ElectroGuard® Safety Isolation System Pilot lights “ISOLATED GROUND CONNECTED” (or “SYSTEM GROUND CONNECTED”) and “SYSTEM CONTROL ON” should be illuminated. Safety relay 1SR - (Power), (K1) and (K2) LEDs should be “On”. (23...85 A only) LED for terminal blocks 1 and 2 should be On”. (23…85 A only) Safety relay 2SR- (Power), (CH1), and (CH2) LEDs should be “On”. (110...1200 A only) NEON terminal blocks (1), (1B) and (2) should be illuminated. (110...1200 A only) Safety relays 2SR, 2ASR, 5SR - (Power), (CH1), and (CH2) LEDs should be “On”. (110...1200 A only) Safety relays 3SR and 4SR - (Power) LED should be “On”, (CH1), and (CH2) should be “Off ”. DC power supply LED should be “On”. LED for terminal blocks (100) and (103) will be “On” indicating 24V DC power is present. The ML pilot light should not be illuminated. Contactors 1IC and 2IC will energize. (23...85 A only) LEDs for terminal blocks 142…151 should be ON. (23...85 A only) All blown fuse indicating lights 1FU…10FU should be OFF. (23...85 A only) LED terminal block (128 and 129) should be dimly lit. (110...1200 A only) LED terminal blocks (141) through (178) should be “On”. (110...1200 A only) Blown fuse indicating lights on fuseholders for 1FU through 16FU should be “Off ”. Confirm all Remote Lockout Station “SYSTEM ISOLATED” lights are “Off ”. 5. Check system operation by individually using each Remote Lockout Station to conduct the sequence tests that follow. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Remote Lockout Station Sequence Tests (23... 85 A) 3-17 IMPORTANT If the System Isolated light does not illuminate, stop commissioning at this point and go to Chapter 4, Troubleshooting. Do not continue commissioning until the problem has been resolved and the System Isolated light illuminates again. ATTENTION Commissioning of the ElectroGuard® must be performed by a qualified technician familiar with the Safety Isolation System, who then seals the Remote Lockout Station(s). The Safety Isolation System Control Module, and optional Expansion and Pneumatic Isolation Modules are factory sealed. The technician responsible for the commissioning process should record the commissioning and all subsequent servicing of the system. ! One at a time, check the operation of each Remote Lockout Station by conducting the following sequence test: Turn the operating handle of the Remote Lockout Station to the OFF position. (Time delay option only) Two N.O. auxiliary contacts from pilot control relays 1CR’ and 2CR’ are wired in series to connection points IP1 (11) and IP1 (12). These connection points, when wired to the customer’s drive start/stop circuit, will provide an instantaneous signal to initiate a controlled stop. (Time delay option only) Pilot relays 1CR’ and 2CR’ will de-energize, removing power from off delay timing relays 2TR and 3TR. (Time delay option only) After 30 seconds, contactors 1IC and 2IC de-energize. (Standard Module) 1IC and 2IC will be de-energized. GC will be energized. The “SYSTEM ISOLATED” light should go “On” Voltage sensing relays ACR, BCR, and CCR will be de-energized. Safety relays 2SR - (Power) LED remains “On”, and (CH1), and (CH2) LEDs will go “Off ”. Refer to the Indicator Light Explanation Sheet for LED terminal blocks (142) through (151) indicating status. The ML pilot light should be illuminated. LED terminal blocks (128) and (129) should be illuminated. See the indicator lights explanation sheet for LED terminal blocks 142…151 indicating status. (Time delay option only) Resistance between terminals 11 and 12 at connector IP1 of the Control Module should be high or infinite ohms. Publication 2030-UM003A-EN-P - May2006 3-18 Commissioning of the ElectroGuard® Safety Isolation System Turn the Remote Lockout Station operating handle back to the ON position, and continue the check by moving on to the next Remote Lockout Station and completing the sequence test again. Note: For the Remote Lockout Station connected to an Expansion Module, see Commissioning Expansion Module (4-Port or 10-Port With or Without Time Delay) (23…1200 A) on page 3-21. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Remote Lockout Station Sequence Tests (110…1200 A) 3-19 RLS1…RLS3 Turn the operating handle of Remote Lockout Station “RLS1” to the OFF position. (Time delay option only) Two N.O. auxiliary contacts from 1CR’ and 2CR’ are wired in series between terminals 11 and 12 on connector plug FB1 of the Control Module. (these connection points, when wired to a customer’s drive start/stop circuit, will provide an instantaneous signal to the drive to initiate a controlled stop.) (Time delay option only) Pilot relays 1CR’ and 2CR’ will de-energize, removing power from off delay timing relays 2TR and 3TR. (Time delay option only) Resistance between terminals 11 and 12 at connector FB1 of the Control Module should be high or infinite ohms. (Time delay option only) After 30 seconds, contactor 1IC and 2IC de-energize. (Standard module) 1IC and 2IC will be de-energized. GC will be energized. The “SYSTEM ISOLATED” light should go “On” Voltage sensing relays ACR, BCR, and CCR will be de-energized. Safety relays 2SR and 5SR - (Power) LED remains “On”, and (CH1), and (CH2) LEDs will go “Off ”. Safety relays 2ASR, 3SR and 4SR - (Power), (CH1), and (CH2) LEDs will be “On”. Refer to the Indicator Light Explanation Sheet for LED terminal blocks (141) through (178) indicating status. The ML pilot light should be illuminated. LED terminal block (129) should be “On”. Return the RLS1 operating handle back to the ON position. Continue by completing the above sequence test using Remote Lockout Station RLS2 followed by RLS3. RLS4…RLS6 Turn the operating handle of Remote Lockout Station “RLS4” to the OFF position. (Time delay option only) Pilot relays 1CR; and 2CR’ will de-energize, removing power from off delay timing relays 2TR and 3TR. (Time delay option only) Resistance between terminals 11 and 12 at connector FB1 of the Control Module should be high or infinite ohms. (time delay option only) After 30 seconds, contactors 1IC and 2IC are de-energized. (Standard module) 1IC and 2IC will be de-energized. Publication 2030-UM003A-EN-P - May2006 3-20 Commissioning of the ElectroGuard® Safety Isolation System GC will be energized. The “SYSTEM ISOLATED” light will go “On” Voltage sensing relays ACR, BCR, and CCR will be de-energized. Safety relays 2ASR and 5SR - (Power) LED remains “On”, and (CH1) and (CH2) LEDs will go “Off ”. Safety relays 2SR, 3SR and 4SR - (Power), (CH1) and (CH2) LEDs will be “On”. The ML pilot light should be illuminated. LED terminal block (129) should be “On”. Refer to the Indicator Light Explanation Sheet for LED terminal blocks (141) through (178) indicating status. Return the RLS4 operating handle back to the ON position. Continue by completing the above sequence test using Remote Lockout Station RLS5 followed by RLS6. Note: For Communication Module option, refer to Chapter 2. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Commissioning Expansion Module (4-Port or 10-Port With or Without Time Delay) (23…1200 A) ATTENTION ! 3-21 Commissioning of the ElectroGuard® must be performed by a qualified technician familiar with the Safety Isolation System, who then seals the Remote Lockout Station(s). The Safety Isolation System Control Module, and optional Expansion and Pneumatic Isolation Modules are factory sealed. The technician responsible for the commissioning process should record the commissioning and all subsequent servicing of the system. 1. Turn on the power to the ElectroGuard® Power Panel. 2. All the Remote Lockout Station switches must be in the ON position. Observe the indicating lights in the Expansion Module(s). (See the indicating lights explanation sheet in the document folder for the Expansion Module.) Safety relay SR in the Expansion Module is energized. The red LED (Power) and the two green output LEDs (K1 and K2) will illuminate. LED terminal blocks (–), (+), 41, 42 (dimly), 63…88, and 91 (dimly) for the 10-port Expansion Module will be illuminated. LED terminal blocks (–), (+), 41, 42 (dimly), 63…66, 73, 74…77, 84, 85…88, and 91 (dimly) for the 4-port Expansion Module will be illuminated. 3. One at a time, check the operation of each Remote Lockout Station connected to the Expansion Module(s) by conducting the following sequence test. For 23…85 A units, perform RLS test as defined in Commissioning the Safety Isolation System on Page 3-15. For 110…1200 A units, perform RLS test as defined in Commissioning the Safety Isolation system. When Expansion Module is plugged into RLS1 to RLS3 on Page 3-19 and RLS4 to RLS6 on Page 3-19. Expansion Module(s) Without Time Delay See the indicator light explanation sheet for LED terminal blocks 63…88 for the 10-port Expansion Module and 63…66, 73, 77, 84, 88 indicating status for the 4-port expansion. (23…85 A only) LED terminal blocks 128 and 129 in the Control Module should be illuminated. (110…1200 A only) LED terminal block 129 in the Control Module should be illuminated. LED terminal blocks 42 and 91 in the Expansion Module should be illuminated. Publication 2030-UM003A-EN-P - May2006 3-22 Commissioning of the ElectroGuard® Safety Isolation System Expansion Module(s) With Time Delay When all the Remote Lockout Station switches connected to the time delay Expansion Module are ON, the green LED (Power) and the two green output LEDs (CH1, CH2) for the instantaneous safety outputs and the two green outputs LEDs (CH1T, CH2T) for the timed safety outputs will be illuminated. Turn the operating handle of the Remote Lockout Station to the OFF position. The System Isolated light should be “On” after the appropriate time delay. Verify that 1IC and 2IC de-energize after the appropriate time delay. N.O. auxiliary contacts from safety relay SR are wired to connection points PLC1 EXB(11) and PLC1 EXB(12). These connection points, when wired in the customer’s drive start/stop circuit, will provide an instantaneous signal to initiate a controlled stop. 4. Turn the Remote Lockout Station operating handle back to the ON position and continue the check by moving on to the next Remote Lockout Station connected to the Expansion Modules and complete the sequence test again. 5. Verify all RLSs are in the ON position, the System Isolated lights are “Off ” and 1IC and 2IC are energized. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Commissioning Verification Module (with Gate Locks) ATTENTION 3-23 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION Commissioning of the ElectroGuard® must be performed by a qualified technician familiar with the Safety Isolation System, who then seals the Remote Lockout Station(s). The Safety Isolation System Control Module, and optional Expansion and Pneumatic Isolation Modules are factory sealed. The technician responsible for the commissioning process should record the commissioning and all subsequent servicing of the system. ! 1. Turn on the power to the ElectroGuard® Power Panel and the solenoid gate. 2. Confirm that all Remote Lockout Stations switches are in the ON position. 3. Press the “SYSTEM ON” push button (located on the ElectroGuard® Power Panel). 4. Verify power LED of safety relays SR1 and SR2 are “On”. 5. Verify Gate Locks are “Locked”. 6. Turn any Remote Lockout Station switch to the OFF position 7. Verify the following LEDs are “On”: CR1 and CR2 SR1-Power, CH1, CH2, CHT1 and CHT2 SR2-Power, CH1 and CH2 8. Remove tongue from Gate Lock. 9. Verify that LEDs CH1 and CH2 of SR2 turn “Off ”. 10. Replace the tongue from the Gate Lock. 11. Verify that LEDs CH1 and CH2 of SR2 turn “On”. 12. Repeat steps 8–11 if a second Gate Lock is attached to the Verification Module. Publication 2030-UM003A-EN-P - May2006 3-24 Commissioning of the ElectroGuard® Safety Isolation System 13. Confirm that all Remote Lockout Stations switches are in the ON position. 14. Verify the following LEDs are “Off ”: CR1 and CR2 SR1 — CH1, CH2, CHT1, and CHT2. 15. Repeat the sequence for any additional Verification Modules connected to the system. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Commissioning Pneumatic Isolation Module Operation ATTENTION 3-25 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION Commissioning of the ElectroGuard® must be performed by a qualified technician familiar with the Safety Isolation System, who then seals the Remote Lockout Station(s). The Safety Isolation System Control Module, and optional Expansion and Pneumatic Isolation Modules are factory sealed. The technician responsible for the commissioning process should record the commissioning and all subsequent servicing of the system. ! 1. Verify that air is being supplied to the inlet of the Pneumatic Isolation Module. 2. Turn on the power to the ElectroGuard® Power Panel. 3. Confirm that all Remote Lockout Station switches are in the ON position. 4. Verify that the “System On” light is illuminated (located on the Power Panel). If not, press the “System On” push button. If the “System On” light does not illuminate, refer to Chapter 4, Troubleshooting. 5. Air will exhaust from the muffler of the Pneumatic Isolation Module until its internal air safety valve is reset. 6. Confirm that the Pneumatic Isolation Module has been reset. Refer to Indicator Light Status Chart on module door and that air is not being exhausted out the muffler. 7. Confirm that compressed air is going to the pneumatic machine components connected to the air outlet of the Pneumatic Isolation Module. 8. With the compressed air supply on and the Safety Isolation System in the “RUN” mode, turn any Remote Lockout Station switch to the OFF position. 9. Observe that contactors “1IC” and “2IC” in the ElectroGuard® Power Panel de-energize. This initiates the air isolation cycle of the Pneumatic Isolation Module. Publication 2030-UM003A-EN-P - May2006 3-26 Commissioning of the ElectroGuard® Safety Isolation System 10. As isolation of the outlet air begins, the safety valve in the Pneumatic Isolation Module will de-energize and prevent air from flowing to its outlet port. After this, any residual back pressure in the air lines from the machine pneumatics will be relieved through the exhaust muffler to the atmosphere. 11. When outlet residual air pressure decreases to 5 psi or less, the Pneumatic Isolation Module will signal the Control Module in the Power Panel that the compressed air is isolated. 12. After the Control Module receives the proper signal from the Pneumatic Isolation Module, the Control Module circuit logic (with all other input signals being correct) will enable the grounding contactor “GC” to energize. 13. Verify that the “System Isolated” light has illuminated on the Remote Lockout Station that was switched to OFF. IMPORTANT If “System Isolated” light does not illuminate, STOP commissioning at this point and see Chapter 4, Troubleshooting of this manual. Do not continue commissioning until the problem is resolved and the “System Isolated” light will illuminate. 14. Move the Remote Lockout Station switch operator to the ON position. 15. Confirm the “System Isolated” light on the Remote Lockout Station is no longer illuminated 16. Again use the door mounted Indicator Light Status Chart and the viewing window to confirm operational status of the Pneumatic Isolation Module. 17. Confirm that compressed air has been restored to the pneumatic machine components connected to the air outlet of the Pneumatic Isolation Module. 18. If air pressure has not been restored by the Pneumatic Isolation Module, go to the troubleshooting section of this manual. 19. If air pressure has been successfully restored, commissioning of the Pneumatic Isolation Module is complete. 20. At this point during commissioning, test the machine pneumatics for proper operation. This is to confirm the Pneumatic Isolation Module will pass enough compressed air flow to enable proper pneumatics operation. If a problem occurs, re-verify the Pneumatic Isolation Module installation. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Commissioning the Communication Modules ATTENTION ! ATTENTION ! 3-27 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: In this test the disconnect supplying electrical energy to the Safety Isolation System will be turned ON. Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. Verify separate control voltage source is present (120/230V AC to the Communication Module). Turn all the Remote Lockout Station operating handles to the ON position. Turn ON the Safety Isolation System and confirm I/O terminal indicator LED status as follows: 1. Safety Isolation Systems without the optional Pneumatic Isolation or Expansion Modules: I/O LEDs (0), (4), (5), (6), (7), (8), and (9) will be “On”. Note: (8) and (9) are for 110… 1200 A only. When the operating handle of a Remote Lockout Station is turned to OFF and then ON, the following I/O LEDs will go “Off ” and then “On”: LED (0), and the LED of the Remote Lockout Station that was turned “Off ” and then back “On” as follows: Remote Lockout Station I/O LED Terminal RLS1 4 RLS2 5 RLS3 6 RLS4 7 RLS5 (110…1200 A only) 8 RLS6 (110…1200 A only) 9 2. For Safety Isolation Systems with the optional Pneumatic Isolation Module, I/O LEDs (1), (2), and (3) should illuminate under the following conditions: Publication 2030-UM003A-EN-P - May2006 3-28 Commissioning of the ElectroGuard® Safety Isolation System I/O LED LED Status Valve Status 1 On Normal operation 1 Off Fault State/No Air Pressure I/O LED LED Status Pressure Switch #1 Status 2 On High Pressure 2 Off Low Pressure I/O LED LED Status Pressure Switch #2 Status 3 On High Pressure 3 Off Low Pressure For Safety Isolation Systems with a single 10-Port Expansion Module, I/O LEDs (4) to (15) will go “On”. When the operating handle of a Remote Lockout Station is turned to the OFF position and then ON, the following I/O LEDs will go “Off ” and then “On”: LED (0) and the LED of the Remote Lockout Station that was turned “Off ” and then back “On” as shown in Table Chapter 2, Safety Isolation System Status Signals. If additional Expansion Modules are added, the number of Communication input modules must be increased to obtain the Remote Lockout Station status signals from these Expansion Modules. A maximum of three communication modules can be installed within the ElectroGuard® Power Panel. Each module provides an additional sixteen inputs. Publication 2030-UM003A-EN-P - May2006 Commissioning of the ElectroGuard® Safety Isolation System Final Steps 3-29 To prevent tampering, reseal the Remote Lockout Stations and Power Panel doors with a tamper-indicating seal. There are holes on the right-hand side of the Remote Lockout Station enclosure to accommodate a wire seal (see Figure Chapter 3). The Power Panel enclosure doors have a hasp (23…85 A), a locking door handle (bays without fusible disconnects or circuit breaker), or a locking quarter-turn latch that will accommodate a tamper-indicating wire seal or lock. An alternative is to use the tamper-indicating seal (Part No. 32005-386-04). Figure 3.11 Remote Lockout Station Sealing Points RLS seal should be located here Follow your facility's procedures for sealing the Remote Lockout Stations. Close the ElectroGuard® Power Panel enclosure door(s) and tighten all fasteners securely. IMPORTANT A service log, with the following data, should be maintained for each Safety Isolation System: Serial Number of the unit Date of system commissioning Name of the commissioning technician Name of the service technician Description of the service performed Date of the service Publication 2030-UM003A-EN-P - May2006 3-30 Commissioning of the ElectroGuard® Safety Isolation System Notes: Publication 2030-UM003A-EN-P - May2006 Chapter 4 Troubleshooting General Section Page General 4-1 Field Repairs 4-3 Troubleshooting Flowchart and Tables 4-3 Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) 4-33 Operational Troubleshooting of the ElectroGuard® Power Panel (110… 1200 A) 4-40 Operational Troubleshooting of the Verification Module 4-47 Operational Troubleshooting of the Pneumatic Isolation Module 4-49 Operational Troubleshooting of the Expansion Module 4-56 The information in the following sections is provided to the user as a diagnostic tool to aid in the troubleshooting of the ElectroGuard® SIS. The assumption has been made that the SIS had been properly installed and operating prior to the occurrence of a fault. ATTENTION ! ATTENTION ! 1 ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. Publication 2030-UM003A-EN-P -May 2006 4-2 Troubleshooting ATTENTION Hazardous voltage and other forms of energy could be present. To avoid serious injury or death: ! Local facility safety procedures and maintenance guidelines must always be followed when troubleshooting the ElectroGuard® equipment. ATTENTION Hazardous energy could be present while troubleshooting the ElectroGuard® system. Proper personal protective equipment must be used and any precautions determined by your facility. ! ATTENTION ! Severe injury, death, property damage, or economic loss could occur if the system is not recommissioned after repair. Refer to Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System, of this manual for proper commissioning. Troubleshooting requires clear definition of the problem based upon the system fault symptoms. Clear problem definition and knowing the system status or operating conditions prior to the problem will narrow the scope of the troubleshooting. (i.e., Was the system in the normal running mode? Were Remote Lockout Stations being turned ON or OFF? Was there a power source problem?) The Control Module, optional Expansion Module, and Pneumatic Isolation Module include indicator light status charts to assist in troubleshooting. The use of the following documentation is highly recommended when troubleshooting the ElectroGuard® System: Troubleshooting Flowchart (Figure 4.1). Troubleshooting Tables (Tables 4.2…4.11). Indicator Light Status Charts supplied with the equipment. Electrical schematics supplied with the equipment. Operational Troubleshooting included in this chapter. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting Field Repairs ATTENTION ! Troubleshooting Flowchart and Tables 4-3 ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. It is recommended that troubleshooting of the SIS begin with the use of the following troubleshooting flowchart for a more systematic and modular approach. If additional information on the SIS mode of operation is needed, refer to the operational troubleshooting sections in this chapter. Publication 2030-UM003A-EN-P - May 2006 4-4 Troubleshooting Table 4.1 Troubleshooting Flowchart Define Operating Conditions Prior to Fault No Was System Operating Properly Prior to Fault? Review System Components for proper installation Yes Define Nature of Trouble No Was an RLS Switch being Operated? See Table 4.1 A & B, 4.2, 4.3, 4.4 (Pneumatic option) No Power to the Machine fed through the ElectroGuard Suspect Expansion Module Yes RLS Switched to “On” RLS Switched to “Off” Grounding Contactor “GC” will not pick up “System Isolated” light will not illuminate See Table 4.6 See Table 4.5 A & B See Table 4.7 A & B Suspect Expansion Module fault See Table 4.8 Publication 2030-UM003A-EN-P - May 2006 Suspect Pneumatic Module fault See Table 4.9 (Pneumatic option) Suspect RLS fault See Table 4.10 (Pneumatic option) Troubleshooting 4-5 Table 4.2 A (23…85 A) Was a Remote Lockout Station Switch Being Operated? (No) Problem Component Possible Cause Pushed In No Power to System the machine coast-to-stop fed through the push-pull Loose Wire ElectroGuard® operator Check Action System coast-to-stop push-pull operator status. Pull or twist to reset the system coast-to-stop operator. System Coast-to-Stop operator wiring. Secure wiring. Shorted transformer Verify status of blown fuse indicator lights for 5FU, 6FU, and 7FU on the fuse holders. Check control transformer terminals X1 and X2 for 120V AC. Replace control transformer install appropriate size fuse(s). (see Chapter 6 — Replacement Procedures and Appendix E — Replacement Parts). Control transformer fuses (5FU, 6FU, 7FU) blown Verify status of blown fuse indicator lights for 5FU, 6FU, and 7FU on the fuse holders. Check for loose wires or wire strands that may have shorted. Replace and install appropriate size fuse(s). See the fuse label affixed on the ElectroGuard® Power Panel door. Loose connections in transformer circuit Check transformer wiring. Secure transformer wiring. Voltage feeding the transformer is OFF Neon voltage indicator terminal blocks Check that incoming power to the 1 and 2 ON when 120V AC is present. ElectroGuard® Power Panel is present. Isolated ground conductor Loose connection Verify the isolated ground conductor is Connect isolated ground conductor to connected to the isolated ground the isolated ground terminal block. See terminal block. the torque label affixed on the ElectroGuard® Power Panel door Fuse 4FU 4FU fuse blown Verify status of blown fuse indicator light for 4FU on the fuse holder. Replace 4FU with correct size fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Measure resistance between connection points IP1 (4) and HV(1). A resistance reading of less than 1,000 would indicate a shorted relay coil for 1GCR or 2GCR. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E — Replacement Parts). 1SR power LED and the two green output LEDs (K1 and K2) should be illuminated (see Figure 4.2) Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and appendix E—Replacement Parts). Control transformer 1SR safety relay Defective 1SR safety relay If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33. Publication 2030-UM003A-EN-P - May 2006 4-6 Troubleshooting Table 4.1A (23…85 A) Was a Remote Lockout Station Switch Being Operated? (No) (Continued) Problem Component Fuse 8FU No Power to the machine fed through the ElectroGuard® (Continued) Fuse 9FU Possible Cause Check Action 8FU fuse blown Verify status of blown fuse indicator light for 8FU on the fuse holder. Replace 8FU fuse with appropriate size fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Measure resistance between connection points IP3(5) and HP1(2). A resistance reading of less than 150 would indicate a short circuit has occurred. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). 9FU fuse blown Verify status of blown fuse indicator light for 9FU on the fuse holder. Replace 9FU fuse with appropriate size fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel Door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Short on DC side of power supply Disconnect an RLS connector plug in the Control Module and measure the resistance between connection points RLS(5) and RLS(10). A resistance reading of less than 1,000 would indicate a short circuit has occurred. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). HV connector Loose connection plug Check for loose connections on the HV Secure wire connections on the HV connector plug. connector plug in the Control Module. See the torque label affixed on the ElectoGuard power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures and Appendix E—Replacement parts). If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-7 Table 4.1B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (No) (Continued) Problem Component Check Action No Power to the machine fed through the ElectroGuard® Pushed In System coast-to-stop push-pull Loose Wire operator System coast-to-stop push-pull operator status. Pull or twist to reset the system coast-to-stop operator. System coast-to-stop operator wiring. Secure wiring. Shorted transformer Verify status of blown fuse indicator lights for 4FU, 21FU, and 22FU on the fuse holders Check control transformer terminals X1 and X2 for 120V AC. Replace control transformer install appropriate size fuse(s). (See Chapter 6–Replacement Procedures and Appendix E—Replacement parts.) Control transformer fuses (4FU, 21FU, or 22FU) blown Verify status of blown fuse indicator lights for 4FU, 21FU, and 22FU on the fuse holders Replace and install appropriate size fuse(s). See the fuse label affixed on the ElectroGuard® Power Panel door. Loose connections in transformer circuit Check transformer wiring. Secure transformer wiring. Voltage feeding the transformer is OFF. Neon voltage indicator terminal blocks Check that incoming power to the 1 and 2 ON when 120V AC is present. ElectroGuard® Power Panel is present. Isolated ground conductor Loose connection Verify the isolated ground conductor is connected to the isolated ground terminal block. Connect isolated ground conductor to the isolated ground terminal block. See the torque label affixed on the ElectroGuard® Power Panel door. Fuse 4FU 4FU fuse blown Verify status of blown fuse indicator light for 4FU on the fuse holder. Replace 4FU with appropriate size fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control module and return for repairs (see Filed Repairs on page 4-3, Chapter 6— Replacement Procedures, and appendix E—Replacement parts). Coil for relay 1GCR or 2GCR may be shorted. This cannot be verified without breaking the tamper-indicating seal on the Control Module. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts). Control transformer Possible Cause If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel on page 4-40. Publication 2030-UM003A-EN-P - May 2006 4-8 Troubleshooting 4.1B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (No) (Continued) Problem Component Possible Cause Check Action No Power to the machine fed through the ElectoGuard (Continued) Fuse 5FU 5FU fuse blown Verify status of blown fuse indicator light for 5FU on the fuse holder. Replace 5FU with appropriate size fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts). Measure resistance between connection points HV(5) and IP1(4). A resistance reading of less than 1,000 would indicate a shorted relay coil for 1MCR or 2MCR. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts) Measure resistance between connection points IP1(3) and HV(6). A resistance reading of less than 100 would indicate a shorted relay coil for 1SR or 4CR. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts) 1SR safety relay Defective 1SR safety relay 1SR power LED and the two green output LEDs (K1 and K2) should be illuminated (see Figure 4.2) Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts) Fuse 6FU 6FU fuse blown Verify status of blown fuse indicator light for 6FU on the fuse holder. Replace 6FU with appropriate size fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts) Coil for relay DCCR, 1CR1, 2CR1, 1CR, 2CR, or 3CR may be shorted. This cannot be verified without breaking the tamper-indicating seal on the Control Module. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts) Verify status of blown fuse indicator light for 7FU on the fuse holder. Replace 7FU with appropriate size fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts) Coil for relay 5CR, 6CR, 7CR, 8CR, 11CR, or 12CR may be shorted. This cannot be verified without breaking the tamper-indicating seal Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts) Fuse 7FU 7FU fuse blown If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (110…1200 A) on page 4-40. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting Problem Component Fuse 8FU No power to the machine fed through the ElectroGuard® (Continued) Fuse 9FU Fuse 12FU 4-9 Table 4.1B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (No) (Continued) Possible Cause Check Action 8FU fuse blown Verify status of blown fuse indicator Replace 8FU with appropriate size light for 8FU on the fuse holder. fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Coil for relay 9CR, 10CR, VTCR, or Replace Control Module and return for GC1CR may be shorted. This cannot be repairs (see Field Repairs on page 4-3, verified without breaking the Chapter 6 — Replacement Procedures, tamper-indicating seal and Appendix E — Replacement Parts). 9FU fuse blown Verify status of blown fuse indicator Replace 9FU with appropriate size light for 9FU on the fuse holder. fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Measure resistance between Replace power contactor (see Field connection points IP3(9) and HV(6) for Repairs on page 4-3, Chapter 6 — 1IC; between IP3(10)and HV(6) for 2IC; Replacement Procedures, and Appendix E — Replacement Parts). between IP3(11) and HV(6) for GC. A resistance reading of less than 5 would indicate a shorted contactor coil. Visually check for loose, jammed or Replace mechanical interlock (see Field broken mechanical interlock between Repairs on page 4-3, Chapter 6 — contactors 1IC, GC, and 2IC. Replacement Procedures, and Appendix E — Replacement Parts). 12FU fuse blown Verify status of the blown fuse indicator Replace 12FU with appropriate size light for 12FU on the fuse holder. fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Short on input side of Measure resistance between Replace Control Module (see Field DC power supply connection points HP1(4) and HV(6). A Repairs on page 4-3, Chapter 6 — resistance reading of less than 150 Replacement Procedures, and Appendix E — Replacement Parts). would indicate a short circuit has occurred. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (110…1200 A) on page 4-40. Publication 2030-UM003A-EN-P - May 2006 4-10 Troubleshooting Table 4.1B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (No) (Continued) Problem Component No power to the Fuse 13FU machine fed through the ElectroGuard® (Continued) Fuse 14FU Possible Cause Check 13FU fuse blown Verify status of the blown fuse Replace 13FU with appropriate size indicator light for 13FU on the fuse fuse (replace only once). See the holder. fuse label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Short on DC side of power supply Disconnect an RLS connector plug in the Control Module and measure the resistance between connection points RLS(5) and RLS(10). A resistance reading of less than 1,000 would indicate a short circuit has occurred. 14FU fuse blown Verify status of the blown fuse Replace 14FU with appropriate size fuse indicator light for 14FU on the fuse (replace only once). See the fuse label holder. affixed on the ElectroGuard® Power Panel door. Coil for relay 3SR, 4SR, or 5SR shorted. This can not be verified without breaking the tamper-indicating seal. Fuse 16FU 16FU fuse blown Loose connection Replace Control Module (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Replace Control Module (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Verify status of the blown fuse Replace 16FU with appropriate size fuse indicator light for 16FU on the fuse (replace only once). See the fuse label holder. affixed on the ElectroGuard® Power Panel door. Coil for relay 2SR or 2ASR shorted. This can not be verified without breaking the tamper-indicating seal. HV connector plug Action Replace power contactor (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). Check for loose connections on the Secure wire connections on the HV HV connector plug. connector plug in the Control Module. See the torque label affixed on the ElectroGuard® Power Panel door. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E — Replacement Parts). If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (110…1200 A) on page 4-40. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-11 Table 4.3 (23… 85 A) & (110…1200 A) with Pneumatic Option Was an RLS Switch Being Operated? (No) Problem Component Possible Cause AC PWR neon Loose or open Pneumatic Isolation Module indicator light in connection between Control Module and will not reset and pneumatic module is ON Pneumatic Isolation prevents compressed air (see Figure 4.1 Module from reaching the and Table 4.4) outgoing air line but module does Pneumatic Isolation connection after not operate Module not providing ElectroGuard® contact input system ON push information. button has been pressed. Power Panel Control Module is not providing correct contact input information. AC PWR neon Loose connection at indicator light in HP1 or HP2 Control Module connector Pneumatic plugs. Isolation Module is OFF Loose wire on HP1 (see Figure 4.1 connector plug and Table 4.4) connection points 1 or 2. 120V AC is missing between connector plug HP1 connection points 1 and 2. Check Action Check wiring on connector plug Repair or tighten connector plugs or plug HC on the Pneumatic Isolation wiring as needed and retest Module ElectroGuard® for proper operation and Check wiring on connector isolation. See the torque label affixed on plugs HP1 and HP2 in the the ElectroGuard® Power Panel door. Control Module. Install temporary test jumper wires Test operate ElectroGuard® and if on connector plug HP1 connector electrical isolation is achieved, replace points as indicated below ❷: Pneumatic Isolation Module and return 5 to 6 for repairs (see Field Repairs on page 7 to 8 4-3, Chapter 6—Replacement 9 to 10 Procedures, and Appendix E— (see Figure 4.12) Replacement Parts). With the ElectroGuard® powered Repair per Table 4.2 up, but in OFF mode, check continuity at connector plug HP2 connection points (see Table 4.2) Check connector plugs HP1 and HP2 Push connector plugs firmly into the are completely inserted. terminal blocks to secure connections. Check that all wires on connector plug HP1 are securely attached. Tighten or reconnect any loose connector plug wires. See the torque label affixed on the ElectroGuard® Power Panel door. Measure voltage between connector plug HP1 connection points 1 and 2. Replace Control Module if 120V AC control voltage is not present, and return for repairs (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). Replace Pneumatic Isolation Module and return for repairs Defective neon — indicator light or internal wiring in Pneumatic Isolation module. Restart compressor to restore air Incoming source Compressed air source Check whether source air compressor is still ON. pressure to Pneumatic Isolation Module. air pressure to is OFF. Pneumatic Upstream air valve is Check status of all upstream air Reopen lockout valves in upstream air Isolation turned OFF. lockout valves. line feeding the Pneumatic Isolation Module inlet Module. fitting is Broken or Check for broken air line or open air Repair or reconnect compressed air line missing. disconnected fitting. to restore air pressure to Pneumatic upstream air line. Isolation Module. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33 and (110…1200 A) on page 4-40. ❷ When finished testing, remove all temporary jumper wires and re-install unplugged connector plugs. Publication 2030-UM003A-EN-P - May 2006 4-12 Troubleshooting Figure 4.1 Pneumatic Isolation Module Status Light Explanation Chart P S 1 L R P S 2 L R 12 13 V A L V E P L C 11 P S 1 P S 2 P L C P L C 12 1PSSR 2PSSR 8 8 9 13 A C P W R PS1 PS2 V A L V E P W R O K 5 3 TR RTR 4 2 10 1 Publication 2030-UM003A-EN-P - May 2006 7 V A L V E 6 Troubleshooting 4-13 Table 4.4 (23… 85 A) & (110… 1200 A) with Pneumatic Option Pneumatic Isolation Module Status Light Explanation Chart INITIAL MODE (Power and Air Pressure Applied) ITEM COMPONENT LABEL LIGHT TYPE LIGHT STATUS DESCRIPTION 1 AC PWR NEON TB ON Indicates 120V AC is being supplied by the ElectroGuard® Power Panel control circuit transformer RUN MODE (After the “SYSTEM ON” PB pushed, all RLS ON) 2 RTR (One shot) LED (Green) ON For one second, timer enabled by Control Module, energizes safety valve reset solenoid 11 VALVE PLC LED (Green) ON On for one second while timer RTR energizes safety valve reset solenoid 3 VALVE OK NEON TB ON The valve resets after safety valve reset solenoid is operated while inlet air pressure is present 4 TR LED (Green) ON Three second flash, then steady, timer energizes valve solenoids A and B which opens safety valve 5 VALVE PWR NEON TB ON Indicates 120V AC is being supplied to operate safety valve solenoids A and B 6 PS1 NEON (Red) ON When pressure switch senses outlet air pressure above 20 psi and relay PS1LR is OFF 7 PS2 NEON (Red) ON When pressure switch senses outlet air pressure above 20 psi and relay PS2LR is OFF LOCKOUT MODE (After a Remoter Lockout Station is turned OFF) 5 VALVE PWR NEON TB OFF After contactor “GC” in ElectroGuard® Power Panel is energized, an auxiliary contact removes 120V AC from solenoids A and B 3 VALVE OK NEON TB ON While solenoids A and B are de-energized and safety valve fault mechanism does not sense a fault 8 1PSSR, 2PSSR (POWER) LED (Red) ON When 120V AC is supplied by PSCR relay contact after PSCR is energized by Control Module input 9 1PSSR (OUTPUT) LED (Green) ON When 120V AC is supplied and relay circuit S13 to S14 is closed and circuit S21 to S22 is opened after PS1 senses outlet air pressure 5 psi or less 10 1PSSR (OUTPUT) LED (Green) ON When 120V AC is supplied and relay circuit S13 to S14 is closed and circuit S21 to S22 is opened after PS2 senses outlet air pressure 5 psi or less 12 PS1LR, PS1 PLC LED (Green) ON When relays are energized by pressure switch PS1 contact closing 13 PS2LR, PS2 PLC LED (Green) ON When relays are energized by pressure switch PS2 contact closing 6 PS1 NEON (Red) OFF When pressure switch senses outlet air pressure 5 psi or less and relay PS1LR is ON 7 PS2 NEON (Red) OFF When pressure switch senses outlet air pressure 5 psi or less and relay PS2LR is ON ON When safety valve fault mechanism senses an air pressure or valve fault and prevents valve reset FAULT MODE (Safety Valve not reset) 11 VALVE PLC LED (Green) Publication 2030-UM003A-EN-P - May 2006 4-14 Troubleshooting Table 4.5 (23…85 A) & (110…1200 A) with Pneumatic Option Connector Plugs HP1 and HP2 with all Remote Lockout Stations ON System Status for Continuity Checking Check Connector Plugs between Connection Points Continuity Check Must Read as Listed Action ElectroGuard® in OFF mode, connector plug HP1 should be unplugged and connector plug HP2 should remain plugged in to the Control Module terminal block assembly Plug HP2 terminals OPEN (Infinite Resistance) If closed, check for shorted wire strands between HP2 plug terminals 1 and 2. If wire connections are correct, the pneumatic module needs to be replaced (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E — Replacement Parts). ElectroGuard® in OFF mode, connector plug HP1 should be unplugged and connector plug HP2 should now be unplugged for this check Plug HP1 terminals 1 and 2 Plug HP2 terminals 3 and 4 1 and 2 Plug HP1 terminals 3 and 4 Plug HP1 terminals 5 and 6 Plug HP1 terminals 7 and 8 Plug HP1 terminals 9 and 10 When finished testing, re-install unplugged connector plugs. Publication 2030-UM003A-EN-P - May 2006 OPEN (Infinite Resistance) OPEN (Infinite Resistance) If closed, check for shorted wire strands between HP1 plug terminals 1 and 2. If wire connections are correct and resistance measured is above the given limit, the pneumatic module needs to be replaced (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E — Replacement Parts). OPEN (Infinite Resistance) If closed, check for shorted wire strands between HP1 plug terminals 3 and 4. If wire connections are correct, the pneumatic module needs to be replaced (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E — Replacement Parts). Measure resistance between terminals 5 and 6. It should be less than 10 . If resistance is incorrect, check wire connections at HP1 terminals 5 and 6. If wire connections are correct, the pneumatic module needs to be replaced (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E— Replacement Parts). OPEN (Infinite Resistance) If closed, check for shorted wire strands between HP1 plug terminals 7 and 8. If wire connections are correct, the pneumatic module needs to be replaced (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E— Replacement Parts). OPEN (Infinite Resistance) If closed, check for shorted wire strands between HP1 plug terminals 9 and 10. If wire connections are correct, the pneumatic module needs to be replaced (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E— Replacement Parts). Troubleshooting 4-15 Table 4.6 A (23…85 A) Was a Remote Lockout Station Switch Being Operated? (Yes – to ON) Problem Component RLS No power to the machine fed connector plug through the ElectroGuard® (RLS switched to ON) 1IC, 2IC Possible Cause Check Action Loose wire in RLS or RLS connector plug Check that RLS connector plugs are completely inserted. Push RLS connector plugs firmly into the terminal blocks to secure connections. Check wiring to the RLS connector plugs in the Control Module. Check wiring in the RLS. Use RLS connector plug with connection points 3 and 8, 4 and 9 jumpered to isolate the incorrectly wired RLS. See Figure 4.11. Once the incorrectly wired RLS has been isolated, check for continuity between connection points 3 and 8, 4 and 9, and 2 and 7 at the terminal block in the RLS. See RLS schematic to secure any loose wires. Replace RLS load switch assembly. see Chapter 6 — Replacement Procedures and Appendix E– Replacement Parts). Check wiring at the 1IC and 2IC contactor coils Secure wiring to the 1IC and 2IC contactor coils. See Figure 4.13 (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E— Replacement Parts). Open connection in the coil circuitry Check wiring on the IP3 connector plug Secure wiring to the connector plug connection points 5 and 6. IP3 connection points 5 and 6. 2TR, 3TR timers (time delay option) Pneumatic module connector (if applicable) Loose wire on timer circuits Check wiring to the 2TR and 3TR timer Secure wiring to the 2TR or 3TR timer modules. modules. See Figure 4.13. (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E— Replacement Parts). Faulty timer Check wiring to the IP3 connector plug Replace timer. See Figure 4.13. (see connection points 5 and 6. Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E— Replacement Parts). Faulty or open connection between Control Module and pneumatic module (if applicable) Check wiring on the HC connector on the pneumatic module. Check wiring on the HP1 and the HP2 connector plugs in the Control Module. Use the HP1 connector plug in the Control Module with connection points 5 and 6, 7 and 8, 9 and 10 jumpered to help isolate the pneumatic module. See Figure 4.12. See (23…85 A) on page 4-32. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33. Publication 2030-UM003A-EN-P - May 2006 4-16 Troubleshooting Table 4.5A (23…85 A) Was a Remote Lockout Station Switch Being Operated? (Yes – to ON) (Continued) Problem Component Possible Cause Check Action 9FU fuse blown Verify status of blown fuse indicator light for 9FU on the fuse holder. Replace 9FU with appropriate size fuse (only 0nce) Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Short on DC Side of Power Supply Disconnect an RLS connector plug in the Control Module and measure the resistance between connection points RLS 5 and RLS 10. A resistance reading of less than 1,000 would indicate a short circuit has occurred. Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 24V DC 24V DC not available power supply Check 24V DC indicating light on power supply. Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 2SR safety relay Faulty 2SR safety relay 2SR Power LED and CH1, and CH2, should be ON (see Figure 4.2) Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Mechanical Interlock Loose or broken interlock Visually check interlock for physical damage The mechanical interlock may need to be replaced. See Figure 4.13. See Field Repairs on page 4-3, Chapter 6— Replacement procedures, and Appendix E—Replacement parts.) Fuse 9FU No power to the machine fed through the ElectroGuard® (RLS switched to ON) (Continued) Defective rectifier Rectifier A, Rectifier B, or Rectifier C Verify status of blown fuse indicator Replace Control Module and return for light for 1FU, 2 FU, or 3 FU on the fuse repairs. (See Field Repairs on page 4-3, holder Chapter 6—Replacement Procedures, and Appendix E—Replacement Parts.) Expansion Module Connector plug at the Control Module Faulty Expansion Module or RLS connected to Expansion Module Use RLS connector plug with connection points 3 and 8, and 4 and 9 to isolate the faulty Expansion Module. See Expansion Module: Was a Remote Lockout Station Switch being operated? (Yes–to ON) on page 4-20. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-17 Table 4.5B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (Yes – to ON) (Continued) Problem Component Possible Cause Check RLS connector No power to the machine fed through plug the ElectroGuard® (RLS switched to ON) (Continued) Loose wire in RLS or RLS connector plug Check that RLS connector plugs Push RLS connector plugs firmly into are completely inserted. the terminal blocks to secure connections. 1IC, 2IC Action Check wiring to the RLS connector plugs in the Control Module. Check wiring in the RLS. Use RLS connector plug with connection points 3 and 8, and 4 and 9 jumpered to isolate the incorrectly wired RLS ❷. See Figure 4.11. Once the incorrectly wired RLS has been isolated, check for continuity between connection points 3 and 8, 4 and 9, and 2 and 7 at the terminal block in the RLS. See RLS schematic to secure any loose wires. Replace RLS load switch assembly. (see Chapter 6— Replacement Procedures and Appendix E—Replacement Parts.) Open connection Check wiring at the 1IC and 2IC Secure wiring to the 1IC and 2IC in the coil circuitry contactor coils Contactor coils. See Figure 4.13. (see Field Repairs on page 4-3, Chapter 6—Replacement procedures, and Appendix E—Replacement parts). Check wiring on the IP3 Secure wiring to the connector plug connector plug connection pints IP3 connection pints 5 and 6. 5 and 6. 2TR, 3TR timers Loose wire on (time delay option) timer circuits Faulty timer Check wiring to the 2TR and 3TR timer modules. Secure wiring to the 2TR or 3TR timer modules. See Figure 4.13. (see Filed Repairs on page 4-3, Chapter 6— Replacement procedures, and Appendix E—Replacement Parts). — Replace timer. See Figure 4.13 (see Field Repairs on page 4-3, Chapter 6—Replacement procedures, and Appendix E—Replacement Parts). Pneumatic Module Faulty or open Check wiring on the HC connector (if connection connector on the pneumatic between Control applicable) module. Check wiring on the HP1 Module and and the HP2 connector pneumatic module plugs in the Control Module. (if applicable) Use the HP1 connector plug in the Control Module with connection points 5 and 6, 7 and 8, 9 and 10 jumpered to help isolate the pneumatic module. See Figure 4.13. See Operational Troubleshooting of the Pneumatic Isolation Module on page 4-32. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33 and (110…1200 A) on page 4-40. ❷ When finished testing, remove all temporary jumper wires and re-install unplugged connector plugs. Publication 2030-UM003A-EN-P - May 2006 4-18 Troubleshooting Table 4.5B (110… 1200 A) Was a Remote Lockout Station Switch Being Operated? (Yes–to ON) (Continued) Problem Component Possible Cause Check Action No power to the machine fed through the ElectroGuard® (RLS switched to ON) (continued) Fuse 13FU 13FU fuse blown Verify status of blown fuse indicator light for 13FU on the fuse holder. Replace 13FU with appropriate size fuse (replace only once). Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). Short on DC side of power supply Disconnect an RLS connector plug in the Control Module and measure the resistance between connection points RLS5 and RLS10. A resistance reading of less than 1,000 would indicate a short circuit has occurred. ❷ Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). 24V DC power supply 24V DC not available Check 24V DC LED indicator on power supply. Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). 2SR safety relay Faulty 2SR safety relay 2SR power LED and CH1 and CH2 should be ON (see Figure 4.3). Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). 2ASR safety relay Faulty 2ASR safety relay 2ASR power LED and CH1 and CH2 should be ON (see Figure 4.3) Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). 3SR safety relay Faulty 3SR safety relay 3SR power LED should be ON (see Figure 4.4) Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). 4SR safety relay Faulty 4SR safety relay 4SR power LED should be ON (see Figure 4.4) Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33 and (110…1200 A) on page 4-40. ❷ When finished testing, remove all temporary jumper wires and re-install unplugged connector plugs. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-19 Table 4.5B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (Yes–to ON) (Continued) Problem Component Possible Cause Check Action No power to the machine fed through the ElectroGuard® (RLS switched to ON) (Continued) 5SR safety relay Faulty 5SR safety relay 5SR power LED and CH1 and CH2 should be ON (see Figure 4.5) Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). Faulty mirror auxiliary contactor GC Check for welded or broken auxiliary contact Replace mirror auxiliary contact on power contactor GC. (see Field Repairs on page 4-3, Chapter 6— Replacement Procedures, and Appendix E—Replacement Parts). Mechanical Interlock Loose or broken interlock Visually check interlock for physical damage The mechanical interlock may need to be replaced. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). Rectifier A, Rectifier B, or Rectifier C Defective rectifier Verify status of blown fuse indicator light for 1FU, 2FU, or 3FU on the fuse holder. Replace Control Module and return for repairs. (see Field Repairs on page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement Parts). Connector plug at the Control Module Use RLS connector plug with connection points 3 and 8, 4 and 9 jumpered to isolate the faulty Expansion Module.❷ See Figure 4.11. Refer to Table 4.7. Expansion Module Faulty Expansion Module or RLS connected to Expansion Module If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33 and (110…1200 A) on page 4-40. ❷ When finished testing, remove all temporary jumper wires and re-install unplugged connector plugs. Publication 2030-UM003A-EN-P - May 2006 4-20 Troubleshooting Table 4.7 Expansion Module: Was a Remote Lockout Station Switch Being Operated? (Yes – to ON) Problem Component 2FU No power to the machine fed through the ElectroGuard® (RLS switched to ON) SR safety relay in Expansion Module RLS connector plug(s) in Expansion Module Wiring cable between Control Module and Expansion Module or between series connected Expansion Modules Possible Cause Check Action 2FU fuse blown Verify status of blown fuse indicator light for 2FU on the fuse holder. Replace 2FU with appropriate size fuse (replace only once). Replace Expansion Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts) Faulty SR safety relay SR Power LED and CH1, CH2, K1, and K2 should be ON (see Figure 4.9). Measure the resistance between connection point EXB(10) and top of 2FU fuse holder. If the resistance is very large or infinite, the SR safety relay needs to be replaced. Replace Expansion Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 2FU fuse in Expansion Module blown Verify status of blown fuse indicator light for 2FU on the fuse holder. Replace 2FU fuse with appropriate size fuse (replace only once). Replace Expansion Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Connector plug with Verify connector plug with jumper jumper wires not wires connected from terminals 3 to 8 installed in unused RLS and 4 to 9. port(s) Wire jumpers correctly. (see Figure 4.11) RLS connector plugs not wired properly Verify all RLSs are wired properly. Wire RLS connector plugs correctly. RLS connector plug(s) not properly inserted Verify all RLS connector plugs are properly inserted. Push RLS connector plug into receptacle until properly seated. Incorrect wiring Check wire connections by performing Correct wiring. a point-to-point test on connection points. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33 or (110…1200 A) on page 4-40. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-21 Table 4.6 Expansion Module: Was a Remote Lockout Station Switch Being Operated? (Yes – to ON) Problem Component Possible Cause Check Action Control stop signal not closing (Expansion Module with time delay) Fuse 3FU 3FU fuse blown Verify status of blown fuse indicator Replace 3FU with light for 3FU on the fuse holder. appropriate size fuse (replace only once). See the fuse label affixed on the ElectroGuard® Power panel door. Replace Expansion Module and return for repairs (see Field Repairs on Page 4-3, Chapter 6—Replacement Procedures, and appendix E—Replacement Parts). Safety relay SR Faulty SR safety relay SR Power LED and CH1, CH2, K1, and K2 should be ON (see Figure 4.9). Measure the resistance between connection point EXB(10) and top of 2FU fuse holder. If the resistance is very large or infinite, the SR safety relay needs to be replaced. Replace Expansion Module and return for repairs (see Field Repairs on Page 4-3, Chapter 6—Replacement Procedures, and Appendix E— Replacement parts). Wiring cable between Control Module and Expansion Module Incorrect wiring Check wire connections by performing a point-to-point test on connection points. Correct wiring. If system problem persist after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33 or (110…1200 A) on page 4-40. Publication 2030-UM003A-EN-P - May 2006 4-22 Troubleshooting Table 4.8 A (23…85 A) Was a Remote Lockout Station Switch Being Operated? (Yes – to OFF) Problem Component Grounding 24V DC contactor GC power will not pick up supply is (RLS switched OFF to OFF) Indicating light on power supply is OFF Relays ACR, BCR, CCR, and VTCR Possible Cause Check Action Control transformer 120V AC input to power supply is missing Verify that primary and secondary voltages are present. Replace control transformer. (see Chapter 6 — Replacement Procedures and Appendix E— Replacement Parts). Verify status of blown fuse indicator light for 5FU, 6FU, or 7FU on fuse holder. Check for loose wires or wire strands that may have shorted. Replace 5FU, 6FU, or 7FU fuse with appropriate size fuse (replace only once). Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Voltage decay relays ACR, BCR, CCR, and VTCR have not dropped out Measure voltage on load side of 2IC for Wait until voltage decays to safe level low voltage (below 70V AC). for relay drop out. Relays may have welded, preventing drop out. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). GC grounding Open connection in the Check wiring at the IP3 connector plug Secure wiring to the IP3 connector plug contactor coil coil circuitry connection point 11. connection point 11. Faulty contacts Fuse 8FU Mechanical interlock 8FU fuse blown Loose or broken interlock Replace GC contactor. See Figure 4.13 and See Field Repairs page 4-3, Chapter 6 – Replacement Procedures and Appendix E– Replacement Parts. Verify status of blown fuse indicator light for 8FU on the fuse holder. Replace 8FU fuse with appropriate size fuse (replace only once). Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Measure resistance between connection points IP3(5) and HP1(2). A resistance reading of less than 150 would indicate a short circuit has occurred. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts) Visually check interlock for physical damage. Replace mechanical interlock. See Figure 4.13. See Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts) If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-23 Table 4.7A (23…85 A) Was a Remote Lockout Station Switch Being Operated? (Yes – to OFF) (Continued) Problem Component 6CR Grounding contactor GC will not pick up (RLS switched to OFF) Possible Cause Check Action Relay 6CR did not energize Contactors 1IC and 2IC did not drop out Replace 1IC or 2IC (see Field Repairs due to welded contact. on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Relay VTCR did not energize due to ACR, BCR, or CCR not picking up. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 6CR control circuit wiring defective. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 6CR coil open, or defective hold-in contact. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 3CR Relay 3CR will not drop Relay may have a welded contact out which is preventing drop out Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 11CR Relay 11CR did not energize 6CR contact did not energize. 11CR contacts did not close 11CR coil open Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 11CR contact not closing due to weld. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33. Publication 2030-UM003A-EN-P - May 2006 4-24 Troubleshooting Table 4.7B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (Yes – to OFF) Problem Component Grounding 24V DC contactor GC power will not pick up supply is (RLS switched OFF to OFF) Power LED indicator on power supply is OFF Possible Cause Check Control transformer Verify that primary and secondary 120V AC input to power voltages are present. supply is missing Verify status of blown fuse indicator light for 7FU, 21FU, or 22FU on fuse holder. Action Replace control transformer. (see Chapter 6 — Replacement Procedures and Appendix E— Replacement Parts). Replace 5FU, 6FU, 7FU, 21FU, or 22FU fuse with appropriate size fuse (replace only once). Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Voltage decay relays Measure voltage on load side of 2IC for Wait until voltage decays to safe level Relays ACR, low voltage (below 70V AC). for relay drop out. BCR, CCR, and ACR, BCR, CCR, and VTCR VTCR have not dropped Relays may have welded, preventing Replace Control Module and return for out repairs (see Field Repairs on page 4-3, drop out. Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 3SR safety Faulty 3SR safety relay 3SR power LED, and CH1 and HC2 should Replace Control Module and return for relay be ON (see Figure 4.6) repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 4SR safety Faulty 4SR safety relay 4SR power LED and CH1 and CH2 should Replace Control Module and return for relay be ON (see Figure 4.7) repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Replace Control Module and return for 5SR safety Faulty 5SR safety relay 5SR power LED should be ON and Ch1 repairs (see Field Repairs on page 4-3, relay and CH2 should be OFF (see Figure 4.8) Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Secure wiring to the IP3 connector plug GC grounding Open connection in the Check wiring at the IP3 connector plug connection point 11. connection point 11. contactor coil coil circuitry Faulty GC contactor coil Measure resistance between connection Replace GC contactor (see Field Repairs points IP3 (11) and HP1 (2). a resistance page 4-3, Chapter 6 – Replacement reading of less than approx. 5 would Procedures and Appendix E– Replacement Parts). indicate a faulty contactor coil. 9FU fuse blown Verify status of blown fuse indictor light Replace 9FU with appropriate size Fuse 9FU for 9FU on the fuse holder. fuse (replace only once). Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts) If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (110…1200 A) on page 4-40. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-25 Table 4.7B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (Yes – to OFF) (Continued) Problem Component Possible Cause Check Action Mechanical Grounding contactor GC interlock will not pick up (RLS switched to OFF) 5CR, 6CR, 7CR, or 8CR Loose or broken interlock Visually check interlock for physical damage. Replace mechanical interlock (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Relay 5CR, 6CR, 7CR, Contactors 1IC and 2IC did not drop out Replace 1IC or 2IC (see Field Repairs or 8CR did not energize due to welded contact. on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Relay VTCR did not drop out. Relay may Replace Control Module and return for repairs (see Field Repairs on page 4-3, have a welded contact that is preventing drop out. Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 3CR 5CR, 6CR, 7CR or 8CR control circuit wiring defective. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 5CR, 6CR, 7CR, or 8CR coil open, or defective hold-in contact. Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Relay 3CR will not drop Relay may have a welded contact out which is preventing drop out Replace Control Module and return for repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). 11CR or 12 CR Relay 11CR or 12CR did not energize DCCR, 5CR, 6CR, 7CR, 8CR, or GCICR Replace Control Module and return for contact did not close. Faulty 5TR timer. repairs (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, 11CR or 12CR contacts 11CR or 12CR coil open and Appendix E— Replacement Parts). did not close 11CR or 12CR contact not closing due to weld. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (110I…1200 A) on page 4-40. Table 4.9 A (23…85 A) Expansion Module: Was a Remote Lockout Station Switch Being Operated? (Yes – to OFF) Problem Component Isolation contactors 1IC and 2IC will not de-energize when all RLSs are turned to the OFF position Safety relay Time delay safety relay Check that green LEDs CHT1 and CHT2 Wait for time delay. are blinking, indicating time delay in SR output will has not timed out not process. de-energize (time delay option) Possible Cause Check Action Control stop signal not opening with all other circuitry checking OK and components functioning normally Jumper installed Jumper on IP4(3) through IP4(10) when Expansion Modules connected Check whether jumpers are present. Remove appropriate jumpers. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33. Publication 2030-UM003A-EN-P - May 2006 4-26 Troubleshooting Table 4.8B (110…1200 A) Was a Remote Lockout Station Switch Being Operated? (Yes – to OFF) Problem Component Possible Cause Isolation contactors 1IC and 2IC will not de-energize when all RLSs are turned to the OFF position Safety relay Time delay safety relay SR output will has not timed out not de-energize (time delay option) Check that green LEDs CHT1 and CHT2 Wait for time delay. are blinking, indicating time delay in process. (see Figure 4.10) Control stop signal not opening with all other circuitry checking OK and components functioning normally Jumper on FB1 or FB2 connector plug points 1…6, when Expansion Modules connected Check whether jumpers are present. Jumper installed Check Action Remove appropriate jumpers. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (110…1200 A) on page 4-40. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-27 Table 4.10 (23…85 A) & (110…1200 A) Pneumatic Option: Was a Remote Lockout Station Switch Being Operated? (Yes – to OFF) Problem Component Possible Cause When any RLS switch is switched to the OFF position, the Pneumatic Isolation Module goes to fault status, air pressure exhausts through the muffler and the RLS System Isolated indicator light(s) will not illuminate AC PWR neon indicator light in Pneumatic Isolation Module is ON but module does not operate. (see Pneumatic Isolation Module Status Light Explanation Chart Figure 4.1 on page 4-12 and Table 4.4 on page 4-13). Loose or disconnected Check that connector plugs to HP1 and Push connector plugs firmly in to the connector plug at HP1 HP2 are completely inserted. terminal blocks. or HP2 on Control Module Electrical connector plug on side of Pneumatic Isolation Module Connector plug is loose Check that connector plug is connected Push connector plug in completely and or disconnected and fully seated in bulkhead connector. secure with the latches provided. Loose wire in connector plug Inspect Connector Plug interior wires for loose connections. Pneumatic isolation module Component failure inside of Pneumatic Isolation Module Install temporary test jumper wires on Test operate ElectroGuard®. connector plug HP1 connector points as If electrical isolation is achieved, indicated below ❷: replace Pneumatic Isolation 5 to 6 Module and return for repairs (see 7 to 8 Field Repairs on page 4-3, Chapter 9 to 10 6 — Replacement Procedures, and (see Figure 4.12) Appendix E— Replacement Parts). If electrical isolation is not achieved, problem may be in ElectroGuard® Power Panel or wiring to the Pneumatic Isolation Module. Loose wire on connector plug(s) to HP1 or HP2 on Control Module Check Check that all wires on the connector plugs to HP1 and HP2 are securely attached. Action Tighten or reconnect any loose connections. Tighten or reconnect any loose connections. If system problem persists after checking the items outlined in this table, see Operational Troubleshooting of the Pneumatic Isolation Module on page 4-49 or Operational Troubleshooting the ElectroGuard® Power Panel (23…85 A) on page 4-33 or (110…1200 A) on page 4-40. ❷ When finished testing, remove all temporary jumper wires and re-install unplugged Connector Plugs. Publication 2030-UM003A-EN-P - May 2006 4-28 Troubleshooting Table 4.11 Remote Lockout Station: Was a Remote Lockout Station Switch Being Operated? (Yes – to OFF) Problem Component Possible Cause Check Action System Isolated light will not illuminate and all other components are functioning normally RLS System Loose or burned out LED cluster Isolated indicator light Check LED. Replace LED cluster (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). Loose wiring connections Check for open wiring at terminal connections. Tighten connections. RLS switch Switch contact failure With RLS switch OFF, no continuity between connection points 1 and 2, 3 and 4, 5 and 6 in the RLS switch. Replace switch in the RLS (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). RLS switch auxiliary contact Auxiliary contact Continuity and operation of the failure at connection auxiliary contact. points 21 and 22 in the RLS switch Replace switch in the RLS (see Field Repairs on page 4-3, Chapter 6 — Replacement Procedures, and Appendix E— Replacement Parts). If problem persists after checking the items outlined in this table, see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33 or (110…1200 A) on page 4-40. Figure 4.2 (23…1200 A) Safety Relay 1SR When All RLS Switches Are in the ON Position 1SR Guardmaster MINOTAUR OUTPUTS POWER UNIVERSAL SAFETY RELAY UNIT K1 DUAL CHANNEL K2 SINGLE CHANNEL Publication 2030-UM003A-EN-P - May 2006 Power (Red) K1 Relay (Green) K2 Relay (Green) Single Channel (Yellow) Always OFF Troubleshooting 4-29 Figure 4.3 (23…1200 A) Safety Relays 2SR and (110…1200 A) 2ASR When All RLS Switches Are in the ON Position SAFETY RELAY SAFETY RELAY All LEDs are ON when RLS1, RLS2 and RLS3 are ON. POWER CH 1 CH 2 All LEDs are ON when RLS4, RLS5 and RLS6 are ON. 2SR POWER CH 1 CH 2 2A S R Figure 4.4 (110...1200 A) Safety Relays 3SR and 4SR When All RLS Switches Are in the ON Position Only the “Power” LED should be ON SAFETY RELAY Only the “Power” LED should be ON SAFETY RELAY POWER POWER C H 1 C H 1 C H 2 C H 2 3S R 4S R Publication 2030-UM003A-EN-P - May 2006 4-30 Troubleshooting Figure 4.5 (110...1200 A) Safety Relay 5SR When All RLS Switches Are in the ON Position SAFETY RELAY All LEDs are ON when all Remote Lockout Stations are ON POWER C H 1 C H 2 5S R Figure 4.6 (110...1200 A) Safety Relay 3SR When Any RLS Is in the OFF Position SAFETY RELAY All LEDs are ON when any Remote Lockout Station is OFF POWER C H 1 C H 2 3S R Figure 4.7 (110...1200 A) Safety Relay 4SR When Any RLS Is in the OFF Position SAFETY RELAY All LED Indicators are ON when any Remote Lockouts Station is OFF POWER C H 1 C H 2 4S R Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-31 Figure 4.8 (110...1200 A) Safety Relay 5SR When Any RLS Is in the OFF Position Only the “Power” LED should be ON when any Remote Lockout Station is OFF SAFETY RELAY POWER C H 1 C H 2 5S R Figure 4.9 Safety Relay SR in Expansion Module without Time Delay Power (Red) “ON” SR Guardmaster K1 Relay (Green) “ON” MINOTAUR OUTPUTS POWER UNIVERSAL SAFETY RELAY UNIT K1 DUAL CHANNEL K2 Relay (Green “ON” K2 Single Channel (Yellow) Always OFF SINGLE CHANNEL These two LEDs should be on when all of the RLSs connected to the expansion module are in the ON position. Figure 4.10 Safety Relay SR in Expansion Module with Time Delay Guardmaster (Timer Adj.) MSR138.1DP These three LEDs should be ON when all the RLSs connected to the Expansion Module, are in the ON position. OR POWER These three LEDs should be ON when all RLSs connected to the Expansion Module are in the ON position. POWER CH 1 CHT 1 CH 2 CHT 2 Guardmaster (Timer Adj.) MSR138.1DP These two LEDs flash ON and OFF for the duration of the safety relay’s adjusted timing cycle INPUT 1 INPUT 2 CH 1 CHT 1 CH 2 CHT 2 These two LEDs flash ON and OFF for the duration of the safety relay’s adjusted timing cycle SR SR Publication 2030-UM003A-EN-P - May 2006 4-32 Troubleshooting Figure 4.11 Remote Lockout Station Connector Plug with Jumpers Installed RLS (any #) 1 2 3 4 5 6 7 8 9 10 11 Figure 4.12 HP1 Connector Plug with Jumpers Installed HP1 1 2 3 4 5 6 7 8 9 10 11 Figure 4.13 Contactors 1IC, 2IC, and GC 1IC L1 Publication 2030-UM003A-EN-P - May 2006 2IC GC L2 L3 T1 T2 T3 Troubleshooting Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) 4-33 Operational Troubleshooting of the ElectroGuard® Power Panel with all Remote Lockout Stations in the ON position ATTENTION ! ATTENTION ! ATTENTION ! Severe injury, death, property damage, or economic loss could occur if the system is not recommissioned after repair. Refer to Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System, of this manual for proper commissioning. ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. If the input line voltage is present, the following should occur: 1. The two neon voltage indicator terminal blocks labeled 1 and 2 will light when 120V AC control voltage is present from the secondary of the control transformer. The fan will be running. If the two neon voltage indicators, terminal blocks 1 and 2 are not illuminated: The control transformer circuit may have a blown fuse (5FU, 6FU, 7FU). The voltage feeding the transformer primary may be turned OFF. There may be a loose connection in the transformer wiring. The neon voltage indicator terminal block may be defective. 2. With all connected RLS switches in the ON position, pushing the System ON push button starts the control system logic cycle. Safety Relay 1SR is energized. If all of the 1SR input contact requirements are satisfied, the red LED (Power) and two green output LEDs (K1 and K2) will illuminate. (see Figure 4.14). Publication 2030-UM003A-EN-P - May 2006 4-34 Troubleshooting Figure 4.14 Safety Relay 1SR Guardmaster 1SR MINOTAUR UNIVERSAL SAFETY POWER RELAY UNIT DUAL CHANNEL O U K1 T P U K2 T S SINGLE CHANNEL Power (Red) K1 Relay (Green) K2 Relay (Green) Single Channel (Yellow) Always Off 3. When 1SR is energized the isolated ground monitoring Relays 1GCR and 2GCR will energize and illuminate the door-mounted System Ground Connected pilot light, and apply 120V AC to solid-state timer 1TR (mounted on Relay DCCR) and the 24V DC power supply. Any one of the following will prevent Relays 1GCR and 2GCR from energizing: Fuse 4FU is blown. The isolated ground conductor is disconnected. The connector plug labeled HV has a loose connection at connection point HV(1). If none of the above conditions are present to prevent Relays 1GCR and 2GCR from energizing, the control logic cycle proceeds. 4. The 24V DC power supply LED power indicator light should illuminate. 5. After the 1TR time delay of 1.5 seconds, 1TR energizes Relay DCCR, which then allows 24V DC to be available to the RLS circuits and Safety Relay 2SR. 6. With the 24V DC applied and all connected RLS switches in the ON position, the LED terminal blocks 100, 103, and 142…151 will be illuminated (see Figure 4.15). Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-35 Figure 4.15 23…85 A ElectroGuard® Indicating Light See Detail “B” 1 11 8 5 7 6 See Detail “A” 1 DOOR COMPONENTS PANEL COMPONENTS 3 2 DETAIL “B” 10 12 DETAIL “A” 14 13 LED TERMINAL BLOCKS Publication 2030-UM003A-EN-P - May 2006 4-36 Troubleshooting Figure 4.17 23…85 A ElectroGuard® Indicating Lights (Continued) Item Description Indicator Explanation 1 Power Supply (24V DC) LED ON when 120V is applied indicating DC available. 2 Control Transformer Sec. Fuse — 7FU LED ON when fuse is blown. Probable cause: Circuit fault or overload. Primary to secondary of control transformer is shorted. 3 Control Transformer Primary Fuses 5FU and 6FU LED ON when fuse is blown. Probable cause: Transformer shorted winding. 4 Ground Sensing Relay(s) Fuse — 4FU LED ON when fuse is blown. Probable cause: 1GCR or 2GCR coil burned out and shorted across A1 and A2. 5 Safety Monitoring Relay 1SR LED Power LED is ON when 120V is applied across A1 and A2. SYSTEM ON has been pressed. K1 ON when internal relay K1 is energized. K2 ON when internal relay K2 is energized. K1 and K2 are energized when SYSTEM ON is pressed supplying power to terminals A1 and A2, the inputs across terminals X1 and X2 are closed, DIP switch R/T in DOWN (T/Auto) position, DIP switch S/D in UP (D/Dual Channel), and the GIS coast-to-stop contacts across S13, S14, S23, and S24 are closed. Single channel is OFF when S/D switch is in the (D) dual channel position. 6 System Control On Door Device Pilot Light ON when SYSTEM ON push button has been pushed. If 1SR, 1MCR, and 2MCR have picked up and pilot light is OFF, bulb may be burnt out. Push-to-test to determine bulb failure. 7 Isolated Ground Connected Door Device Pilot Light ON when 1GCR and 2GCR relays are energized because the ground conductor is connected. Probable cause: If 1GCR and/or 2GCR have picked up and pilot light is OFF, the bulb may be burnt out. Push-to-test to determine bulb failure. 8 Safety Monitoring Relay 2SR LED Power is ON when 24V DC is applied across A1 and A 2. For 2SR: CH1 ON when internal relay K1 is energized (circuit S10 to S11 is closed because all RLS are in the ON position). CH2 ON when internal relay K2 is energized (circuit S21 to S22 is closed because all RLS are in the ON Position). CH1 and CH2 are ON when 24V DC power is supplied to terminals A1 and A2, circuit across S10 and S33 is complete and inputs across terminals S10, S11, S21, and S22 are closed. If inputs across S21 andS22 failed to close, K2 will not energize and CH2 LED will be OFF. If inputs across S10 and S11 fail to close, K1 will not energize and CH1 LED will be OFF. The safety outputs (13), (14), and (23), (24) will not close. The auxiliary output for the coil (K1 or K2) that failed to energize will not close. If either of the inputs across S10, S11, or S21, S22 were to weld, either CH1 or CH2 LEDs will remain ON. The safety relay will not re-close its safety outputs (13), (14) and (23), (24). 9 10 and 2 Terminal Block Terminal Block and 11 12 13 14 Neon 1 100 ON when 120V AC is ON. 1 is ON when 120V to GND present. 2 is ON when GND to 120V present. LED 24V DC is ON, 9FU is not blown and relay door is energized. PL ON when any RLS is OFF and system contacts are closed to energize “System Isolated” light on the RLS. LED ON when the circuit to the power supply plus is complete, 10FU is not blown, safety relay 1PSSR output is closed (Terminal 13 and 14) and one RLS station is OFF. LED ON LED On when 2SR is energized and RLS1, RLS2, RLS3, and RLS4 are ON. When RLS1 is OFF: 142 and 148…151 are ON and 143…147 are OFF. When RLS2 is OFF: 142, 143, and 149…151 are ON and 144…148 are OFF. When RLS3 is OFF: 142…144, 150, and 151 are ON and 145…149 are OFF. When RLS4 is OFF: 142…145 and 151 are ON and 146…150 are OFF. 103 ML Pilot Light 128 Terminal Block 129 Terminal Block — 151 Terminal Block 142 15 1FU, 2FU, 3FU LED ON when fuse is blown and the RLS switches are in the ON position. Probable cause: Shorted or defective ACR, BCR, or CCR coil. 16 8FU LED ON when fuse is blown and the SIS system is ON and will only be lit dimly if any RLS switch is OFF. Probable cause: 1CR, 2CR, 3CR, 6CR, 11CR, DCCR, VTCR, 1IC, 2IC, or GC coil burnt out or shorted across A1, A2. 17 9FU LED ON when fuse is blown and the SIS system is ON, the system will fault out. Probable cause: Short on DC side of power supply. 24V DC is not available to rung #68. 18 10FU LED ON when fuse is blown and the SIS system is ON. The system will not fault out. The RLS indicator will not light if turned to the OFF position. Probable cause: Shorted RLS or wiring. = Number of LED label on terminal block. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-37 7. If all connected RLS switches are in the ON position, all three green LED indicator lights on Safety Relay 2SR will illuminate (see Figure 4.13 and Figure 4.4). 8. When the safety output contacts of Safety Relays 1SR and 2SR are closed, they allow power contactors 1IC and 2IC to energize (see Figure 4.15). Safety Isolation System (Time Delay Option) When the safety output contacts of Safety Relays 1SR and 2SR are closed, they allow control Relays 1CR' and 2CR' to energize. 1CR' and 2CR' will allow off-delay timers 2TR and 3TR mounted on contactors 1IC and 2IC to energize. Power contactors 1IC and 2IC will energize. Safety Isolation System (Pneumatic Isolation Option) In addition to the normal system operation described, a contact from Relay PSCR in the Pneumatic Isolation Module must close to allow the 1IC and 2IC isolation contactors to energize. Failure of one or both isolation contactors 1IC and 2IC to energize may result from: An open connection to the 1IC, 2IC coil voltage. Safety output contacts for 1SR or 2SR not closing. Control Relays 6CR or 11CR not de-energizing. Loose 2TR or 3TR timer attachment (time delay option) 1CR' or 2CR' control relays not energizing (time delay option). An incorrect or missing input from the auxiliary contact on grounding contactor GC. Any one of the power contactors having a welded contact, preventing further normal system operation. The contactor must be replaced. The mechanical interlocks between the power contactors operating incorrectly, preventing proper contactor mechanical operation. The control contacts on the interlocks will not provide the correct logic to the circuit, preventing normal system operation. A faulty or open connection between the Control Module and the Pneumatic Isolation Module (Pneumatic Isolation Module option). Publication 2030-UM003A-EN-P - May 2006 4-38 Troubleshooting Operational Troubleshooting of the ElectroGuard® Power Panel with all Remote Lockout Stations in the OFF Position When any of the connected RLSs are switched to the OFF position, power contactors 1IC and 2IC are de-energized and contactor GC is energized. After GC is energized, the System Isolated light on the RLS will illuminate. The normal sequence of operation causing this to occur is as follows: 1. Turning an RLS OFF opens two contacts that are wired to connection points 3 and 8, and 4 and 9 on the RLS terminal block. This causes the safety output contacts of Safety Relay 2SR to open. The green Power LED on Safety Relay 2SR remains illuminated. All other LEDs on 2SR will be OFF (see Figure 4.4). 2. When the 2SR safety output contacts open, power contactors 1IC and 2IC de-energize. Control Relay 3CR will de-energize. Control Relay VTCR remains energized until the SIS loadside voltage decays to a predetermined level. This allows control relay 6CR to hold itself in and energize control relay 11CR. After the SIS loadside voltage decays to a predetermined level ACR, BCR, and CCR will de-energize. Grounding contactor GC will energize. Closing contacts on GC also complete the 24V DC circuit to illuminate the ML pilot light and the RLS System Isolated indicator light (see Figure 4.15 or 4.16). Figure 4.16 ML Light in Control Module Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-39 Safety Isolation System Control Module (Time Delay Option) When the safety output contacts of Safety Relay 2SR open, control Relays 1CR' and 2CR' will de-energize. The off-delay timers 2TR and 3TR will time out after 30 seconds, allowing contactors 1IC and 2IC to de-energize. Control Relay 3CR will de-energize. Control Relay VTCR remains energized until the SIS loadside voltage decays to a predetermined level. This allows control relay 6CR to hold itself in and energize control relay 11CR. After the SIS loadside voltage decays to a predetermined level, ACR, BCR, and CCR will de-energize. Grounding contactor GC will energize. Closing contacts on GC also completes the 24V DC circuit to illuminate the ML pilot light and the RLS System Isolated indicator light. Safety Isolation System (Pneumatic Isolation Option) In addition to the normal system operation described, redundant output contacts from Safety Relays 1PSSR and 2PSSR in the Pneumatic Isolation Module must close to complete the 24V DC circuit to illuminate the ML pilot light and the RLS System Isolated indicator light. If contactor GC is energized, the ML pilot light and LEDs 128 and 129 are ON but the RLS indicator light does not illuminate, the following faults may be possible: The System Isolated light may need to be replaced (LED cluster). The circuit through the RLS switch auxiliary contact to the LED light is defective or missing. Perform a point-to-point check between terminals 21 and 22 in the switch and terminals 1 and 6 on the terminal block in the RLS. If contactor GC does not energize, the following faults may have occurred: 24V DC may be OFF. Control Relays 6CR, 11CR, or VTCR failed to energize. Welded N.O. contact on Control Relays 1CR' or 2CR' (time delay option). Voltage Decay Relays ACR, BCR, or CCR have not de-energized. Publication 2030-UM003A-EN-P - May 2006 4-40 Troubleshooting Operational Troubleshooting of the ElectroGuard® Power Panel (110… 1200 A) Operational Troubleshooting of the ElectroGuard® Power Panel with All Remote Lockout Stations in the ON Position ATTENTION ! ATTENTION ! ATTENTION ! Severe injury, death, property damage, or economic loss could occur if the system is not recommissioned after repair. Refer to Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System, of this manual for proper commissioning protocol. ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. If the input line voltage is present, the following should occur: 1. The two neon voltage indicator terminal blocks labeled 1 and 2 will light when the 120V AC control voltage is present from the secondary of the control transformer. The enclosure cooling fan will be running. If the two neon voltage indicators, terminal blocks 1 and 2 are not illuminated: The control transformer circuit may have a blown fuse (4FU, 21FU, 22FU). The voltage feeding the transformer primary may be turned OFF. There may be a loose connection in the transformer wiring. The neon voltage indicator terminal block may be defective. 2. With all the connected RLS switches in the ON position, pushing the System ON push button (neon voltage indicator 1B will light) starts the control system logic cycle. Safety Relay 1SR is energized. If all of the 1SR input contact requirements are satisfied, the red LED (Power) and two green output LEDs (K1 and K2) will illuminate (see Figure 4.17). Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-41 Figure 4.17 Safety Relay 1SR 1SR Guardmaster Power (Red) MINOTAUR OUTPUTS POWER UNIVERSAL SAFETY RELAY UNIT K1 DUAL CHANNEL K1 Relay (Green) K2 Relay (Green) K2 SINGLE CHANNEL Single Channel (Yellow) Always OFF 3. When 1SR is energized it will energize Master Control Relays 1MCR and 2MCR which enables the isolated ground monitoring relays 1GCR and 2GCR to energize and illuminate the door-mounted System Ground Connected pilot light and apply 120V AC to solid-state timer 1TR (mounted on Relay DCCR) and the 24V DC power supply. Any one of the following will prevent Relays 1GCR and 2GCR from energizing: Fuse 5FU is blown The isolated ground conductor is disconnected The connector plug labeled HV has a loose connection at connection point HV(1) Safety relay 1SR is faulty Safety relay 4CR contact input to 1SR is faulty Master Control Relay 1MCR or 2MCR is faulty If none of the above conditions are present to prevent relays 1MCR and 2MCR from energizing, the control logic cycle proceeds. 4. The 24V DC power supply LED power indicator light should now illuminate. 5. After the 1TR time delay of 1.5 seconds, 1TR energizes relay DCCR, which then allows the 24V DC to be available to the RLS circuits and safety relays 2SR, 2ASR, 3SR, 4SR, and 5SR. 6. With the 24V DC applied and all connected RLS switches in the ON position, the LED terminal blocks 100, 103, and 141 … 178 will be illuminated (see Figure 4.18, Figure 4.19, and Table 4.12). Publication 2030-UM003A-EN-P - May 2006 4-42 Troubleshooting Figure 4.18 Control Module LED Terminal Blocks Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-43 Figure 4.19 110…1200 A Control Module See Detail “A” 21 5 22 6 23 10 1 4 20 19 14 25 24 15 16 18 17 DOOR COMPONENTS RLS1 RLS2 RLS3 RLS4 RLS5 RLS6 IP1 IP2 IP3 ZB HP1 HP2 HV FB1 FB2 PANEL COMPONENTS 3 2 LED TERMINAL BLOCKS DETAIL “B” DETAIL “A” 7 9 11 12 8 7 13 Publication 2030-UM003A-EN-P - May 2006 4-44 Troubleshooting Table 4.12 Indicator Light Explanation for 110…1200 A Control Module ( Number of LED Label on Terminal Block) Item Description Indicator Explanation 1 Power Supply (24V DC) LED ON when 120V is applied and DC available. 2 Control Transformer Sec. Fuse – 4FU NEON ON when fuse is blown; located in power panel enclosure assembly. 3 Control Transformer 21FU and 22FU NEON ON when fuse is blown; located in power panel enclosure assembly. 4 Safety Monitoring Relay 1SR LED Power LED is ON when 120V is applied across A1 and A2. SYSTEM ON has been pressed. K1 ON when internal relay K1 is energized. K2 ON when internal relay K2 is energized. K1 and K2 are energized when SYSTEM ON is pressed supplying power to terminals A1 and A2, the inputs across terminals X1 and X2 are closed, DIP switch R/T in down (T/Auto) position DIP switch S/D in up (D/Dual Channel), and the SIS coast-to-stop contacts across S13, S14, S23, and S24 are closed. Single channel is OFF when S/D switch is in the (D) dual channel position. 5 Safety Monitoring Relays 2SR, 2ASR, 3SR, 4SR, 5SR LED Power is ON when 24V DC is applied across A1and A2. For 2SR and 2ASR: CH1 ON when circuit S10 to S11 is closed because all RLS are in the ON position. CH2 ON when circuit S21 to S22 is closed because all RLS are in the ON position. For 3SR, 4SR, and 5SR: CH1 ON when circuit S10 to S11 is closed when 1IC, 2IC or GC right-hand (RH) mirror contact is closed. CH2 ON when circuit S21 to S22 is closed when 1IC, 2IC, or GC left-hand (LH) mirror contact is closed. This is normal operation when 1IC, 2IC, or GC are de-energized: CH1 ON when internal relay K1 is energized. CH2 ON when internal relay K2 is energized. CH1 and CH2 are ON when 24V DC power is supplied to terminals A1 and A2, circuit across S10 and S33 is complete and inputs across terminals S10, S11, S21, and S22 are closed. If inputs across S21 and S22 fail to close, K2 will not energize and CH2 LED will be OFF. If inputs across S10 and S11 fail to close, K1 will not energize and CH1 LED will be OFF. The safety outputs (13), (14) and (23), (24) will not close. The auxiliary output for the coil (K1 or K2) that failed to energize will not close. If either of the inputs across S10, S11 or S21, S22 were to weld, either K1 and CH1 LED or K2 and CH2 LEDs will remain ON. The safety relay will not re-close its safety outputs (13), (14) and (23), (24). 6 14FU—Fuse Block for 24V DC to 3SR, 4SR, and 5SR LED ON when fuse is blown. Probable causes: Shorted 3SR, 4SR, or 5SR. 7 8 9 10 NEON and 2 Terminal Block 1 1B Terminal Block Terminal Block 100 and 103 ML Pilot Light 11 129 Terminal Block 12 141 — 149 Terminal Blocks 12A 141 — 149 Terminal Blocks 12B 141 — 149 Terminal Blocks Publication 2030-UM003A-EN-P - May 2006 ON when 120V AC is ON. Light when GND to 120V present. 1 ON when 120V to GND present. Light 2 ON NEON ON when System ON is pushed and 1SR, 1MCR, and 2MCR are ON. LED ON when the time delay is complete and N.O. contact 1TR is closed. DCCR is on and 24V DC power is ON. PL ON when any RLS is OFF and system contacts are closed to energize “System Isolated” light on the RLS. LED ON when any RLS is OFF. LED ON when 2SR is energized and RLS 1…RLS3 are ON. When RLS1 is OFF: 141 and 147…149 are ON and 142…146 are OFF. LED When RLS2 is OFF, 141, 142, 148, and 149 are ON; 143…147 are OFF. LED When RLS3 is OFF, 141, 142, 148, and 149 are ON; 144…148 are OFF. Troubleshooting 4-45 Table 4.11 Indicator Light Explanation for 110…1200 A Control Module ( Item Description 13 170 — 178 Terminal Blocks 13A 170 — 178 Terminal Blocks 13B 170 — 178 Terminal Blocks Number of LED Label on Terminal Block) (Continued) Indicator Explanation LED ON when 2ASR is energized and RLS4…RLS6 are ON. When RLS4 is OFF: 170, 176, 177, and 178 are ON; 171…175 are OFF. LED When RLS5 is OFF: 170, 171, 177, and 178 are ON; 172…176 are OFF. LED When RLS6 is OFF; 170, 171, 172, and 178 are ON; 173…177 are OFF. 14 1FU, 2FU, 3FU ON when fuse is blown. Probable Cause: Shorted or defective ACR, BCR or CCR coil. 15 5FU ON when fuse is blown. Probable cause: 1MCR or 2MCR coils burnt out or shorted across terminals. 1 MCR and 2MCR will drop out—shutting down the system. 16 6FU ON when fuse is blown. Probable cause: 1TR, DCCR, 1CR, 2CR, 1CR’, 2CR’, 2TR, 3TR, 4CR, or 4TR defective coil. 17 7FU ON when fuse is blown. Probable cause: 11CR, 12CR, 5CR, 6CR, 7CR, or 8CR defective coil. 18 8FU ON when fuse is blown. Probable cause: 9CR, 10CR, VTCR, 5TR, or GCICR defective coil. 19 9FU ON when fuse is blown. Probable cause: 1IC, 2IC, or GC has defective coil. 20 12FU ON when fuse is blown. Probable cause: Defective or shorted power supply. 21 13FU ON when fuse is blown. Probable cause: Short on DC side of power supply. 22 15FU ON when fuse is blown. Probable cause: Shorted RLS or wiring. 23 16FU ON when fuse is blown. Probable cause: Shorted 2SR or 2ASR. Note: When optional Expansion Modules are plugged into RLS locations on the control Module, any RLS turned OFF in that Expansion Module will generate an OFF for that RLS location on the Control Module. Key: = number on terminal block for indicator light 7. If all connected RLS switches are in the ON position, all three green LED indicator lights on safety relay 2SR and 2ASR will illuminate (see Figure 4.3 and Table 4.12). 8. When the safety output contacts of safety relays 1SR, 2SR and 2ASR are closed, pilot relays 1CR and 2CR will energize and allow power contactors 1IC and 2IC to energize (see Figure 4.13). Safety Isolation System (Time Delay Option) When the safety output contacts of safety relays 1SR, 2SR, and 2ASR are closed, they allow control relays 1MCR and 2MCR to energize. 1MCR and 2MCR will allow control relays 1CR and 2CR to energize by applying voltage to off delay timers 2TR and 3TR mounted on 1CR and 2CR respectively. Power contactors 1IC and 2IC will energize. Publication 2030-UM003A-EN-P - May 2006 4-46 Troubleshooting Safety Isolation System (Pneumatic Isolation Option) In addition to the normal system operation described, a contact from relay PSCR in the Pneumatic Isolation Module must close to allow the 1IC and 2IC isolation contactors to energize. Failure of one or both isolation contactors, 1IC or 2IC to energize may result from: An open connection to the 1IC, 2IC coil voltage. Safety output contacts of 1SR, 2SR, or 2ASR not closing. Control relays DCCR, 3CR, 4CR, 5CR, 6CR, or GCICR not de-energizing. 1CR or 2CR control relays not energizing (with time delay option). 1MCR, 2MCR, 9CR, or 10CR not energizing. An incorrect or missing input from the auxiliary contact on grounding contactor GC. Any one of the power contactors having a welded contact, preventing further normal system operation. The power contactor must be replaced. The mechanical interlocks between the power contactors operating incorrectly, preventing proper contactor mechanical operation. The control contacts on interlocks will not provide the correct logic to the circuit, preventing normal system operation. A faulty or open connection between the Control Module and the Pneumatic Isolation Module (Pneumatic Isolation Module option). Operational Troubleshooting of the ElectroGuard® Power Panel with all Remote Lockout Stations in the OFF Position When any of the connected RLSs is switched to the OFF position, power contactors 1IC and 2IC are de-energized and contactor GC is energized. After GC is energized, the System Isolated light on the RLS will illuminate. The normal sequence of operation causing this to occur is as follows: 1. Turning an RLS OFF opens two contacts that are wired to connection points 3 and 8, and 4 and 9 on the RLS terminal block. This causes the safety output contacts on safety relay 2SR (monitoring RLS1, RLS2, or RLS3) or 2ASR (monitoring RLS4, RLS5 or RLS6) to open. The green power LEDs on 2SR and 2ASR remain illuminated. All other LEDs on 2SR or 2ASR will be OFF (see Figure 4.3). Publication 2030-UM003A-EN-P - May 2006 Troubleshooting Operational Troubleshooting of the Verification Module ATTENTION ! ATTENTION ! ATTENTION ! 4-47 Severe injury, death, property damage, or economic loss could occur if the system is not recommissioned after repair. Refer to Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System, of this manual for proper commissioning. ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. The Verification Module requires 24V DC, which is supplied by connecting the Verification Module RLS plug to the Control Module or Expansion Module RLS plug. The Power LEDs on SR1 and SR2 will be illuminated. When one of the Remote Lockout Station switches is turned to the OFF position, the ElectroGuard® will isolate the 3-phase power and turn on the “SYSTEM ISOLATED” light. The LEDs on CR1 and CR2 will turn “On”. If the jumpers are in place or a set of contacts are closed between SOFB1 position #9 & #10, and #11 & #12, the outputs of SR1 will close. The LEDs CH1 and CH2 of SR1 will illuminate. The outputs SO between position #1 & #2, or #3 & #4, will provide an output to drive the solenoid of a Gate Lock or other device. When the inputs SOFB1 position #1 & #2, or #3 & #4, and SOFB2 position #1 & #2, or #3 & #4, are opened, the contacts of SR2 between RLS position #3 & #8, and #4 & #9, will open. The LEDs CH1 and CH2 of SR2 will go “Off ”. When all of the Remote Lockout Station switches are turned to the ON position, the “SYSTEM ISOLATED” lights will be “Off ”. The LEDs on CR1 and CR2 will turn “Off ”. The LEDs CH1 and CH2 of SR1 will turn “Off ” and the outputs SO between position #1 & #2, or #3 & #4, will open. Publication 2030-UM003A-EN-P - May 2006 4-48 Troubleshooting The outputs of SR1 are time opening between positions #37 & #38, and #47 & #48. This will help prevent the contacts of SR2 between RLS position #3 & #8, and #4 & #9, from opening until the set time has expired. When SR1 has timed out and the inputs SOFB1 position #1 & #2, #3 & #4, #5 & #6, and #7 & #8, and SOFB2 position #1 & #2, #3 & #4, #5 & #6, and #7 & #8, are closed, the contacts of SR2 between RLS position #3 & #8, and #4 & #9, will remain closed. The LEDs CH1 and CH2 of SR2 will be “On”. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting Operational Troubleshooting of the Pneumatic Isolation Module ATTENTION ! ATTENTION ! ATTENTION ! ATTENTION ! 4-49 Severe injury, death, property damage, or economic loss could occur if the system is not recommissioned after repair. Refer to Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System, of this manual for proper commissioning. ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. Severe personal injury, death, economic loss, or equipment damage could result. Only qualified service technicians familiar with the Ross Valve and ElectroGuard® Systems should service the valve in this equipment. The Pneumatic Isolation Module requires 120V AC control voltage supplied by connecting to the ElectroGuard® Power Panel. It also requires connection to a compressed air system (minimum 30 psi). Insufficient or no air pressure to the Pneumatic Isolation Module air inlet prevents pneumatic isolation as well as illumination of the RLS System Isolated lights. The Pneumatic Isolation Module has one neon voltage indicator terminal block labeled AC PWR (see Figure 4.20). This light illuminates when 120V AC control voltage has been properly connected. Publication 2030-UM003A-EN-P - May 2006 4-50 Troubleshooting Figure 4.20 120V AC Power ON Neon Indicator Light The indicator light status chart includes an added fault mode indicator light status for the pneumatic module. The condition of the status lights can be seen through the viewing window on the front door of the Pneumatic Isolation Module. The pneumatic module provides the Control Module with contact feedback indicating the outlet air pressure is isolated. Conversely, the Control Module provides contact inputs to enable the pneumatic isolation function. If contact status output is incorrect or there is insufficient air pressure, the pneumatic module will not function and the System Isolated lights will not be allowed to illuminate. Relay PSCR will energize to start the pneumatic isolation process after it receives power via contacts on the Control Module relays 1CR and 2CR and there is enough outlet air pressure to trip pressure switches PS1 and PS2. A contact on relay PSCR also provides input to the main panel Control Module to make sure contactors 1IC and 2IC are de-energized (see Figure 4.21). Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-51 Figure 4.21 Safety Relay PSCR in the Pneumatic Isolation Module PS1 and PS2 are Allen-Bradley Bulletin 836T pressure switches that monitor the air pressure at the outlet of the pneumatic module (see Figure 4.22). They are adjusted to drop out after the safety valve has exhausted the outlet air and outlet line air pressure has decreased to 5 psi or less. The exhaust process also helps dissipate back-fed air pressure from retracting cylinders or machine pneumatic devices. Figure 4.22 Bulletin 836T Pressure Switches in the Pneumatic Isolation Module Publication 2030-UM003A-EN-P - May 2006 4-52 Troubleshooting A pair of contacts on pressure switch PS1 are connected to safety relay 1PSSR and a pair of contacts on PS2 are connected to safety relay 2PSSR. These independent safety relays monitor pressure switch status and their outputs are sent to the Control Module in the ElectroGuard® Power Panel (see Figure 4.23). If a pressure switch or safety relay fails, the control logic will not receive the necessary input from the Pneumatic Isolation Module. Outputs from both safety relays 1PSSR and 2PSSR are required to complete the Control Module circuit that illuminates the RLS System Isolated indicator lights. Figure 4.23 Safety Relays 1PSSR and 2PSSR in the Pneumatic Isolation Module Failure of a pressure switch may be indicated when its red neon trip indicator light does not illuminate. Failure of the light to illuminate may also be due to failure of the respective pressure switch light relay, PS1LR or PS2LR. A pressure switch contact failure may prevent operation of its associated safety relay, its indicator light relay or operation of the pressure switch control relay PSCR. The fault depends on which of the DPDT contacts in the pressure switch may have failed to operate correctly. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-53 Each pressure switch uses a contact to operate a pair of dedicated relays. The two relays respond to the operation of the pressure switch to illuminate the pressure switch pilot light and provide a status indication contact that can be used to communicate to a user’s external monitoring equipment (see Figure 4.24). Figure 4.24 PS1 and PS2 Status Indicator Relays Publication 2030-UM003A-EN-P - May 2006 4-54 Troubleshooting A minimum of 30 psi (2 bar) air pressure must be present at the inlet of the pneumatic module to allow the safety valve to reset and operate properly. Timer TR momentarily turns ON the safety valve reset solenoid. After approximately 3 seconds, timer TR will energize the main valve solenoids A and B (see Figure 4.25). If the safety valve resets and does not detect an internal fault, the valve opens to allow air to flow out of the pneumatic module to the machine. Figure 4.25 Timing Relay TR and RTR Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-55 Detection of an internal fault prevents the valve from opening and passing air to the outlet. This condition makes machine pneumatics connected to the outlet inoperable until the fault is corrected. A safety valve fault pressure switch is connected to relay Valve PLC to provide indication of safety valve status. During normal operation, relay Valve PLC will light the neon indicator labeled Valve OK and will provide a N.C. output status contact (for PLC, etc.). During a safety valve fault, the valve fault pressure switch will energize relay Valve PLC, which turns off the Valve OK light and opens the N.C. output status contact (see Figures 4.26 and 4.27). Figure 4.26 Valve Status Indicator Relay Figure 4.27 Valve Status Neon Indicator Light Publication 2030-UM003A-EN-P - May 2006 4-56 Troubleshooting Operational Troubleshooting of the Expansion Module Operational Troubleshooting of the Expansion Module with All Remote Lockout Stations in the ON Position ATTENTION ! ATTENTION ! ATTENTION ! Severe injury, death, property damage, or economic loss could occur if the system is not recommissioned after repair. Refer to Chapter 3, Commissioning of the ElectroGuard® Safety Isolation System, of this manual for proper commissioning. ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. The initial step in isolating the Expansion Module as the source of trouble is to verify that the Control Module is working correctly. 1. Firmly grip the strain relief pad for the RLS connector plug used to interconnect the Expansion Module (see Figure 4.28) and remove the connector by pulling it away from the Control Module. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-57 Figure 4.28 Expansion Module Connector Plug in the Control Module Expansion Module EXB Connector Expansion Module EXB ElectroGuard Power Panel RLS Expansion Module EXB RLS Control Module Expansion Module EXB RLS RLS RLS Expansion Module EXB RLS Connector RLS Remote Lockout Station Remote Lockout Station Remote Lockout Station Remote Lockout Station 2. Insert the connector plug with jumpered out connection points into the RLS port in the Control Module (see Table 4.13 and Figure 4.29 for jumper information). Table 4.13 Unused Remote Lockout Station Jumper Connector Connection Points Recommended Wire RLS1…RLS6 3 and 8 #16 AWG blue/1.3 mm2 blue 4 and 9 #16 AWG blue/1.3 mm2 blue Publication 2030-UM003A-EN-P - May 2006 4-58 Troubleshooting Figure 4.29 Jumpering Out an Unused Remote Lockout Station Port RLS (any #) 1 2 3 4 5 6 7 8 9 10 11 3. Verify the Control Module is operating properly with all the RLSs connected to this module. If the Control Module is not operating properly, see Table 4.2, 4.3, 4.6, or 4.7. If the Control Module is operating properly, remove the connector with the jumpered wires and re-insert the connector for the Expansion Module. 4. Push the System ON to start the system control logic cycle. Safety Relay SR in the Expansion Module is energized and the Red LED is on at power-up. For the non-time delay Expansion Module, if all of the Safety Relay SR input contact requirements are satisfied, the two green output LEDs (K1 and K2) will illuminate (see Figure 4.30). Figure 4.30 Safety Relay SR in Expansion Module without Time Delay GuardmasterGuardmaster SR MINOTAUR MINOTAUR SR Power (Red) UNIVERSAL UNIVERSAL SAFETY SAFETY POWER RELAY UNIT POWERK1 Relay RELAY UNIT DUAL CHANNEL O DUAL CHANNEL O (Green) U K1 U K1 T T P K2 Relay P U K2 U K2(Green) T T S S SINGLE CHANNEL Single Channel SINGLE CHANNEL(Yellow) Always Off Publication 2030-UM003A-EN-P - May 2006 Power (Red) K1 Relay (Green) K2 Relay (Green) Single Channel (Yellow) Always Off Troubleshooting 4-59 For the time delay Expansion Module, if all of the Safety Relay SR input contact requirements are satisfied, the green LED (Power) and four green output LEDs (CH1, CH2, CHT1, and CHT2) will illuminate (see Figure 4.31). Figure 4.31 Safety Relay SR in Expansion Module with Time Delay Delay Adjustment (seconds) Guardmaster 1 1.5 0.5 Guardmaster 2 1 Instantaneous Channel 1 (green) Safety Outputs Channel 2 (green) 3 POWER CH 1 CH 2 POWER CHT1 CHT2 Channel 1 (green) Channel 2 (green) Timed Safety Outputs INPUT1 INPUT2 CH 1 CH 2 SR 2 2.5 0.15 3 Power (green) 1.5 0.5 2.5 0.15 DELAY CH 1 CH 2 SR If the Safety Relay SR Power LED does not illuminate with power present at its A1 and A2 terminals, the Expansion Module needs to be replaced. With the 24V DC applied and all connected RLS switches in the ON position, the LED terminal blocks -, +, 41, 42, 63…88, and 91 for the 10-port Expansion Module will be illuminated (see Figure 4.32). With the 24V DC applied and all connected RLS switches in the ON position, the LED terminal blocks -, +, 41, 42, 63…66, 73, 74…77, 84, 85…88, and 91 for the 4-port Expansion Module will be illuminated (see Figure 4.33). The safety output contacts from Safety Relay SR are interconnected to the input channels of safety Relay 2SR or 2ASR (110…1200 A only, RLS4…RLS6 input) in the Control Module via the EXB connector plug. When all the RLSs connected to the Expansion Module are in the ON position, the input channels of safety Relay SR in the Expansion Module will be closed, and the safety output contacts from SR being interconnected to the input channels of safety Relay 2SR or 2ASR (110…1200 A only, RLS4…RLS6 input) will be closed. The system control logic cycle continues (see Operational Troubleshooting of the ElectroGuard® Power Panel (23…85 A) on page 4-33 or (110…1200 A) on page 4-40). The 1IC and 2IC contactors will be energized. Publication 2030-UM003A-EN-P - May 2006 4-60 Troubleshooting Figure 4.32 10-Port Expansion Module Indicating Lights 2 LED TERMINAL BLOCKS 7 14 12 4 6 1 5 3 Publication 2030-UM003A-EN-P - May 2006 LED Terminal Blocks 8 9 10 13 11 Troubleshooting 4-61 Figure 4.35 10-Port Expansion Module Indicating Lights (Continued) Item Description Indicator Explanation 1 #41 LED Terminal Block LED ON when 1IC, 2IC, and 3CR are OFF and GC is ON in SIS power panel. 2 1FU Fuse Blown Fuse ON when fuse is blown. 3 #42 LED Terminal Block LED ON when 1IC, 2IC, and 3CR are OFF and GC is ON in SIS power panel. 4 (–) LED Terminal Block LED ON when 24V DC supply (–V) applied through EXB connector. 5 #63…84 LED Terminal Block LED #63…73 and 74…84 terminal block ON when SR is energized and S#_A, S#_B, S#_C, S#_D, S#_E, S#_F, S#_G, S#_H, S#_I and S#_J are ON. When S#_A is OFF 64…73 and 75…84 are ON, 63 and 74 are OFF. When S#_B is OFF 65…73 and 76…84 are ON, 63…64 and 74…75 are OFF. When S#_C is OFF 66…73 and 77…84 are ON, 63…65 and 74…76 are OFF. When S#_D is OFF 67…73 and 78…84 are ON, 63…66 and 74…77 are OFF. When S#_E is OFF 68…73 and 79…84 are ON, 63…67 and 74…78 are OFF. When S#_F is OFF 69…73 and 80…84 are ON, 63…68 and 74…79 are OFF. When S#_G is OFF 70…73 and 81…84 are ON, 63…69 and 74…80 are OFF. When S#_H is OFF 71…73 and 82…84 are ON, 63…70 and 74…81 are OFF. When S#_I is OFF 72, 73, 83, and 84 are ON, 63…71 and 74…82 are OFF. When S#_J is OFF 73 and 83 are ON, 63…72 and 74…84 are OFF. 6 (+) LED Terminal Block LED ON when 24V DC applied through EXB connector. 7 2FU Fuse Blown Fuse ON when fuse is blown. 8 #85 LED Terminal Block LED ON when RLS switch string is closed in SIS Control Module. 9 #86 LED Terminal Block LED ON when RLS switch string is closed in SIS Control Module. 10 #87 LED Terminal Block LED ON when RLS switch string is closed in SIS Control Module. 11 #88 LED Terminal Block LED ON when RLS switch string is closed in SIS Control Module. Red LED POWER ON when 24V DC is applied. Green LED K1 ON when internal relay K1 is energized. Green LED K2 ON when internal relay K2 is energized. Yellow LED ON when internal switch is set to single channel (not used in this application). Green LED POWER ON when 24V DC is applied. Green LED CH1 ON when internal relay CH1 is energized. Green LED CH2 ON when internal relay CH2 is energized. Green LED CHT1 ON when internal relay CHT1 is energized. Green LED CHT2 ON when internal relay CHT2 is energized. Safety Relay SR 12 Safety Relay SR with time delay 13 #91 LED Terminal Block LED ON when 1IC, 2IC, and 3CR are OFF and GC is ON in SIS power module. 14 3FU Fuse Blown Fuse ON when fuse is blown. Publication 2030-UM003A-EN-P - May 2006 4-62 Troubleshooting Figure 4.33 4-Port Expansion Module Indicating Lights LED Terminal Blocks 7 14 2 12 4 6 1 3 5 LED TERMINAL BLOCKS Publication 2030-UM003A-EN-P - May 2006 8 9 10 13 11 Troubleshooting 4-63 Figure 4.36 4-Port Expansion Module Indicating Lights (Continued) Item Description Indicator Explanation 1 #41 LED Terminal Block LED ON when 1IC, 2IC, and 3CR are OFF and GC is ON in SIS power panel. 2 1FU Fuse Blown Fuse ON when fuse is blown. 3 #42 LED Terminal Block LED ON when 1IC, 2IC, and 3CR are OFF and GC is ON in SIS power panel. 4 (–) LED Terminal Block LED ON when 24V DC supply (–V) applied through EXB connector. 5 #63…84 LED Terminal Block LED #63…73 and 74…84 LED terminal block ON when SR is energized and S#_A, S#_B, S#_C, S#_D are ON. When S#_A is OFF 64…73 and 75…84 are ON, 63 and 74 are OFF. When S#_B is OFF 65…73 and 76…84 are ON, 63…64 and 74…75 are OFF. When S#_C is OFF 66…73 and 77…84 are ON, 63…65 and 74…76 are OFF. When S#_D is OFF 73 and 84 are ON, 63…66 and 74…77 are OFF. 6 (+) LED Terminal Block LED ON when 24V DC applied through EXB connector 7 2FU Fuse Blown Fuse ON when fuse is blown. 8 #85 LED Terminal Block LED ON when RLS switch string is closed in SIS Control Module. 9 #86 LED Terminal Block LED ON when RLS switch string is closed in SIS Control Module. 10 #87 LED Terminal Block LED ON when RLS switch string is closed in SIS Control Module. 11 #88 LED Terminal Block LED ON when RLS switch string is closed in SIS Control Module. Red LED Power ON when 24V DC is applied. Green LED K1 ON when internal relay K1 is energized. Green LED K2 ON when internal relay K2 is energized Yellow LED ON when internal switch is set to single channel (not used in this application) Green LED Power ON when 24V DC is applied. Green LED CH1 ON when internal relay CH1 is energized. Green LED CH2 ON when internal relay CH2 is energized. Green LED CHT1 ON when internal relay CHT1 is energized. Green LED CHT2 ON when internal relay CHT2 is energized. Safety Relay SR 12 Safety Relay SR with time delay 13 #91 LED Terminal Block LED ON when 1IC, 2IC, and 3CR are OFF and GC is ON in SIS power module. 14 3FU Fuse Blown Fuse ON when fuse is blown. Publication 2030-UM003A-EN-P - May 2006 4-64 Troubleshooting Operational Troubleshooting of Series Connected Expansion Module (with all Remote Lockout Stations in the ON Position) A similar process is used when Expansion Modules are connected in series as previously done with an Expansion Module connected to the Control Module. 1. Firmly grip the strain relief pad for the RLS connector plug used to interconnect the Expansion Module to the series connected Expansion Module. 2. Remove the connector by pulling it away from the Expansion Module being tested (see Figure 4.34). Figure 4.34 Series Connected Expansion Modules Any Expansion Module RLS Connector Expansion Module EXB Connector Expansion Module RLS EXB ElectroGuard Power Panel Expansion Module Control Module RLS EXB RLS Remote Lockout Station Expansion Module RLS EXB 3. Insert connector plug with jumpered out connection points into the RLS port of the Expansion Module being tested. 4. Verify the tested Expansion Module is operating properly with all the RLSs connected to this module. If the Expansion Module under test is not operating properly, refer to Table 4.7. If the tested Expansion Module is operating properly, remove the connector with the jumpered wires and re-insert the connector in the next series connected Expansion Module. Repeat this process until the Expansion Module that is not functioning properly has been isolated. Publication 2030-UM003A-EN-P - May 2006 Troubleshooting 4-65 Operational Troubleshooting of the Expansion Module (Switching a Remote Lockout Station to the OFF Position) When any of the RLSs connected to the Expansion Module is switched to the OFF position, power contactors 1IC and 2IC are de-energized and contactor GC energizes. After GC is energized, the System Isolated light on the RLS will illuminate. The normal sequence of operation causing this to occur is as follows: 1. Turning an RLS OFF opens two N.C. contacts that are wired to Connection Points 3 and 8, and 4 and 9 on the RLS terminal block. This causes the safety output contacts of safety Relay SR to open. The Power LED on safety Relay SR remains illuminated (see Figure 4.35). Figure 4.35 Safety Relay SR in Expansion Module without Time Delay Guardmaster SR MINOTAUR UNIVERSAL SAFETY POWER RELAY UNIT DUAL CHANNEL O U K1 T P U K2 T S SINGLE CHANNEL Power (Red) K1 Relay (Green) K2 Relay (Green) Single Channel (Yellow) Always Off Publication 2030-UM003A-EN-P - May 2006 4-66 Troubleshooting 2. With the time delay Expansion Module, LEDs CH1 and CH2 are OFF and LEDs CHT1 and CHT2 are blinking, indicating the timing function (see Figure 4.36). Figure 4.36 Safety Relay SR in Expansion Module with Time Delay Delay Adjustment (seconds) Guardmaster 1 1.5 0.5 Guardmaster 2 1 Instantaneous Channel 1 (green) Safety Outputs Channel 2 (green) 3 POWER CH 1 CH 2 POWER CHT1 CHT2 Channel 1 (green) Channel 2 (green) Timed Safety Outputs INPUT1 INPUT2 CH 1 CH 2 SR 2 2.5 0.15 3 Power (green) 1.5 0.5 2.5 0.15 DELAY CH 1 CH 2 SR 3. The timed safety output contacts of safety Relay SR that are interconnected to the input channels of safety Relay 2SR or 2ASR (110…1200 A only, RLS4…RLS6) in the Control Module via the EXB connector will time out and open (stop blinking). The safety output contacts for 2SR or 2ASR (110…1200 A only, RLS4…RLS6) will open. This causes power contactors 1IC and 2IC to de-energize. 4. The system control logic cycle continues (see Operational Troubleshooting of the Expansion Module on page 4-56). If contactor GC is energized, the ML pilot light and LED #41 in the Expansion Module are ON, but the RLS “System Isolated” light does not illuminate, the following faults might be possible: – The “System Isolated” light may need to be replaced (LED cluster). – The circuit through the RLS switch auxiliary contact to the LED light could be defective or missing. Perform a point-to-point check between terminals 21 and 22 in the switch and terminals 1 and 6 on the terminal block in the RLS. If contactor GC does not energize, the ML pilot light, LED #41 in the Expansion Module, and the RLS System Isolated light should all be OFF. Publication 2030-UM003A-EN-P - May 2006 Chapter 5 Preventive Maintenance Section Page General 5-2 ElectroGuard® Power Panel 5-3 Isolation and Grounding Contactors Wiring Connections 5-8 Cooling Fans and Filters 5-11 Control Transformer and Circuit Protection 5-12 Equipment Ground 5-13 Isolated Ground Conductor 5-13 Product Information Labels 5-14 Control Module 5-16 Remote Lockout Station(s) 5-17 Expansion Module 5-22 Communication Module 5-23 Pneumatic Isolation Module 5-24 Final Preventive Maintenance Steps 5-25 ATTENTION ! ATTENTION ! 1 ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. Commissioning of the ElectroGuard® must be performed by a qualified technician familiar with the Safety Isolation System, who then seals the Remote Lockout Station(s). The Safety Isolation System Control Module, and optional Expansion and Pneumatic Isolation Modules are factory sealed. The technician responsible for the commissioning process should record the commissioning and all subsequent servicing of the system. Publication 2030-UM003A-EN-P - May 2006 5-2 Preventive Maintenance General The user has the responsibility to develop an appropriate preventive maintenance schedule per NFPA 70B. Rockwell Automation recommend at a minimum of an annual schedule. If the system is cycled more than 150 times per day a more frequent schedule is required. The following are recommended scheduled preventive maintenance inspections on various components of the SIS. Using the operational life and the estimated number of operations, the need for replacement can be estimated for the contactor assembly, the Control Module, and the RLS. The expected electrical and mechanical life for these components is listed in Table 5.1: Table 5.1 Component Anticipated Electrical Life (Operations) Anticipated Mechanical Life (Operations) Power contactor ❶ ❶ RLS switch 200,000 200,000 Safety relay (in Control Module) 500,000 2,000,000 ❶ Publication 2030-UM003A-EN-P - May 2006 Refer to life span for 100 C contactor on the 23…85 A, 100 D for 110…860 A, and 100 G for 1200 A. Preventive Maintenance ElectroGuard® Power Panel ATTENTION 5-3 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site are turned OFF and locked out. ATTENTION It is important that you inspect all product safety labels. If any of the labels are damaged, loose or illegible, they will be replaced at no charge. ! 1. Verify that product safety and information labels in Figures 2.3…2.20 are legible and not loose or damaged. If any label is damaged, loose or illegible, replacement labels can be obtained free of charge by contacting Rockwell Automation Technical Support or your local distributor. 2. Press the System OFF push button on the front of the ElectroGuard® Power Panel. 3. Follow your facility’s LOTO procedures. 4. Turn the handle of the branch circuit protection on the ElectroGuard® Power Panel, or the upstream customer-supplied branch circuit protection feeding electrical energy to the SIS OFF. Padlock the branch circuit protection operating handle in the OFF position. 5. If the SIS includes a Communication Module, de-energize and padlock the electrical energy feeding these modules. 6. If the machine has a source of pneumatic energy, shut off the air valve supplying the pneumatic energy to the machine and padlock it in the OFF position. (The pneumatic energy lockout valve must be located upstream of the Pneumatic Isolation Module.) 7. Open the ElectroGuard® Power Panel enclosure door by loosening the cover hold-down fasteners (see Figure 2.21 or 2.22). 8. Verify that product safety and information labels in Figures 5.19 and 5.20 are legible and not loose or damaged. If any label is damaged, loose or illegible, replacement labels can be obtained free of charge by contacting Rockwell Automation Technical Support or your local distributor. 9. Inspect the enclosure interior cleanliness. Clean dust and dirt from the enclosure interior with a vacuum cleaner. Publication 2030-UM003A-EN-P - May 2006 5-4 Preventive Maintenance Door Operated Devices Perform inspection of door-mounted pilot devices: Verify finger-safe covers are still on contact terminals Inspect push button operators, pilot lights, and contact blocks for physical damage and proper operation ElectroGuard® Service Log Verify the Service Log has been maintained with the following information: Serial Number of the unit Date of Commissioning Name of the Commissioning Technician Name of the Service Technician Description of the service performed Date of the service If required information has not been entered in the ElectroGuard® Service Log, report it to the department responsible for the log. Power Connections Re-torque the incoming and outgoing power cable connections. (See torque label affixed to the inside of the enclosure door for proper torque values.) Disconnect Switch (if Equipped) Depending on the type of disconnect switch, either “fold back” the terminal guard (see Figure 5.1) or loosen the shield mounting screws and lift off the safety shield (see Figures 5.2 and 5.3). Check incoming power connections for proper torque. Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance 5-5 Figure 5.1 Safety Guard and Incoming Line Connection Points on Optional Disconnect Switch Incoming power connection Figure 5.2 Boltswitch Protective Shield Attachment Screws Protective Shield Attachment Screws Figure 5.3 Typical Incoming Line Power Lugs with Safety Shield Removed for Service Access L1 L3 L2 If multi-strand wire is used, verify all strands are contained by the terminal clamp or lug. If any wire strands are not contained by the terminal clamp or Publication 2030-UM003A-EN-P - May 2006 5-6 Preventive Maintenance lug, loosen the clamp or lug set screw, remove the wire, push the strands together, insert the wire, and torque the connection to the level shown on the torque label. Thermal-Magnetic Circuit Breaker (Option) Inspect line side power connections for proper torque. If multi-stranded wire is used, verify all wire strands are contained by the terminal lug. If any wire strands are not contained, loosen the lug set screw, remove the wire, push the strands together, re-insert the wire, and torque the connection to the level shown on the torque label (see Figure 5.4). Figure 5.4 Example of Incoming Line Connection Points on Optional Thermal-Magnetic Circuit Breaker L1 L3 L2 Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance 5-7 (Non-Combination System) 1. Inspect line and load power wire connections on the power distribution block for proper torque. 2. Remove the protective shield provided, to access the power terminals. 3. If multi-stranded wire is used, verify all strands are contained in the terminal lug. If any wire strands are not contained, loosen the lug set screw, remove the wire, push the strands together, re-insert the wire, and torque the connection to the level shown on the torque label (see Figure 5.5 or 5.6). 4. Re-torque line and load power wire connections, per torque table on door. Figure 5.5 (23… 85 A) Power Distribution Block Unfasten these screws to remove shield and inspect power connections Figure 5.6 (110… 1200 A) Power Distribution Block Unfasten these screws to remove shield and inspect power connections Publication 2030-UM003A-EN-P - May 2006 5-8 Preventive Maintenance Isolation and Grounding Contactors Wiring Connections ATTENTION Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Make certain to replace the protective shield on the power distribution block after inspecting the wire connections on the power terminals. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! In order to inspect the wiring connections on the power contactors, it is first necessary to remove the tamper-indicating seal for the protective shield. Then loosen and remove the mounting screws that hold the contactor shield in place (see Figure 5.8 for the 23…85 A, and Figure 5.7 for the 110…1200 A). Figure 5.7 (110...1200 A) Removing Power Contactor Protective Shield Remove the shield mounting screws Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance 5-9 Figure 5.8 (23...85 A) Removing the Power Contactor Protective Shield Remove shield bracket mounting screws adjacent to left and right sides of contactor assembly 1. After removing the shield mounting screws, remove the contactor shield to gain access to the power contactor wiring. 2. Inspect wiring connections (see Figures 5.9 and 5.10) for proper torque as indicated on the torque label. Figure 5.9 (23...85 A) Inspect Power Connections on the Contactors Inspect power wire connections Publication 2030-UM003A-EN-P - May 2006 5-10 Preventive Maintenance Figure 5.10 (110…1200 A) Inspect Power Connections on the Contactors. Check all upper power wire connections and shorting bar attachment bolts. Also check wiring on auxiliary contacts when checking the lower power wire connections Load lug mounting bolts 3. When checking the lower power wire connections, include a re-torque of the load lug mounting bolts. See the torque specifications on the torque label location on the inside of the panel door. 4. The top covers on 1IC, 2IC, and GC contactors may be removed to allow visual inspection of the power contacts. If contacts show excessive wear or physical damage, they must be replaced. If the power contactors are near the end of their normal life expectancy, the complete contactor must be replaced (see Chapter 6 for replacement procedures). 5. Check for secure mounting of auxiliary contacts and the electrical/ mechanical interlocks on the power contactors. 6. Verify mounting screws, when used on these devices, are in place and secure. Verify the control wiring is secure and torqued to values indicated on the torque label. 7. Make certain to replace the protective shield over the power contactors after completing the inspection of the wire connections. 8. Re-install the appropriate tamper-indicating seal on the contactor shield. See Figure G.9 on page G-3 and Figure G.10 on page G-4. Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance Cooling Fans and Filters 5-11 Clean dust and dirt from the fans and filters with a vacuum cleaner. The fans should be free to rotate without binding or obstruction. Verify fan ground wire is securely attached (see Figures 5.11, 5.12, and 5.13). Figure 5.11 Typical ElectroGuard® Power Panel Fan and Fan Ground Wire Connection Fan ground connection Figure 5.12 Typical Removal of an ElectroGuard® Power Panel Filter Grille for Filter Inspection or Cleaning Figure 5.13 Removing Filter Media for Inspection or Cleaning Publication 2030-UM003A-EN-P - May 2006 5-12 Preventive Maintenance Control Transformer and Circuit Protection 1. Verify that all wire connections to the control transformer are secure as indicated on the torque label. 2. Verify the primary and secondary fuses/circuit breakers are present, and are the appropriate type, voltage, and ampacity as indicated on the fuse label affixed to the inside of the ElectroGuard® Power Panel door. Figure 5.14 Checking the Wiring and Fusing of the Control Transformer Primary Fuseholder Secondary Fuseholder IMPORTANT Publication 2030-UM003A-EN-P - May 2006 The control transformer installed in the ElectroGuard® Power Panel is dedicated to the use of the Control Module relay logic only. Additional loads or circuits must not be connected to the control transformer. Added loading could compromise the circuit integrity and prevent system operation. Preventive Maintenance Equipment Ground 5-13 Re-torque the connection to the Equipment Ground Lug and tighten as indicated on the torque Label (see Figured 5.15 and 5.16). Figure 5.15 (23…85 A) Equipment Ground Conductor (P.E.) Lug Figure 5.16 (110…1200 A) Equipment Ground Conductor (P.E.) Lug Isolated Ground Conductor Verify that the isolated ground conductor is connected to the Isolated Ground Terminal Block and re-torque as indicated on the torque label (see Figure 5.17 and Figure 5.18 on page 5-14). Figure 5.17 (110…1200 A) Isolated Ground Terminal Block Customer Connection Point Factory Connection Publication 2030-UM003A-EN-P - May 2006 5-14 Preventive Maintenance Figure 5.18 Isolated Ground Terminal Block (110…1200 A) Product Information Labels Figure 5.19 . Control Module (23…85 A) Part Number 31035-094-01 Tamper-indicating seal Factory seal #32005-386-02 OR Rockwell field seal #32005-386-03 OR customer seal #32005-386-04 Part number 32005-384-02 Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance 5-15 Figure 5.20 Control Module (110…1200 A) Part Number 31035-094-01 Tamper-indicating seal Factory seal #32005-386-02 OR Rockwell field seal #32005-386-03 OR customer seal #32005-386-04 Part number 32005-384-02 Publication 2030-UM003A-EN-P - May 2006 5-16 Preventive Maintenance Control Module ATTENTION ! ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. 1. Visually inspect for loosened parts, wires, components, and mounting hardware through the module’s shield. 2. Inspect the fuses in the Control Module to verify they are the appropriate type, voltage, and amperage as factory installed. 3. Verify all external connectors and cables are firmly attached, and have not been damaged (see Figure 5.21 or 5.22). Figure 5.21 (23...85 A) Checking the Control Module Connector Plugs Check Connector Plugs RLS1 RLS2 RLS3 RLS4 HP1 HP2 IP3 IP4 IP1 IP2 HV Figure 5.22 (110...1200 A) Checking the Control Module Connector Plugs Check Connector Plugs RLS1 RLS2 RLS3 RLS4 RLS5 RLS6 IP1 IP2 IP3 ZB HP1 HP2 FB1 FB2 HV Verify the tamper-indicating seal has not been broken or tampered with (see Figure 5.19 or 5.21). Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance Remote Lockout Station(s) IMPORTANT 5-17 The Remote Lockout Station may have a wire seal. In order to inspect the interior of the Remote Lockout Station, it will be necessary to break the wire seal (see Figure 5.23). Follow your facility’s procedures for accessing and resealing the Remote Lockout Stations. Perform the following preventive maintenance on each Remote Lockout Station. Figure 5.23 . Removing Customer Wire Seal from Remote Lockout Station Wire seal should be located here Figure 5.24 Cover Clamp Screws on the Remote Lockout Station Enclosure Cover Clamp Cover Clamp Screws Cover Clamp Publication 2030-UM003A-EN-P - May 2006 5-18 Preventive Maintenance 1. Verify the product safety label (See Appendix G, part number 32005-384-02 or 32005-383-02) is present, legible, and not damaged or loose. If this label is damaged, loose or illegible, replacement labels can be obtained at no charge to the customer by contacting Rockwell Automation Technical Support or your local distributor. 2. To open the RLS enclosure cover, rotate the operating handle in the OFF position. Squeeze the handle interlock lever and operating handle as in Figure 5.25. Lift the enclosure cover away from the base. Figure 5.25 Opening the Remote Lockout Station Pull down on operating handle interlock lever 3. Visually inspect the inside of the Remote Lockout Station for loosened parts, wires, or mounting hardware. Check to see that the enclosure external mounting bolts are tight. 4. Inspect the following and reference the torque label affixed to the inside of the ElectroGuard® Power Panel enclosure door, when applicable: Terminal block wire connections all secure. Ground wire connection to ground terminal block secure. Door/base ground bond wire securely attached. Wire connections at the load switch securely attached. Incoming cable conduit fitting secured to enclosure. The plug for unused conduit hole is in place and secure. Switch handle and locking tab not damaged. Door closing hardware in good condition. The “SYSTEM ISOLATED” light lens and LED are in place and in good condition. Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance 5-19 5. Close the RLS enclosure cover on the base. Squeeze the handle interlock lever and operating handle. Rotate the operating handle to the ON position. 6. If required, the Remote Lockout Station enclosure must be re-sealed with a new customer supplied wire seal after the inspection has been completed. Figure 5.26 Remote Lockout Station Interior Conduit Hole Plug Wire Connections to Terminal Block Ground Wire Connection “System Isolated” Pilot Light Wire Connections Wire Connections at Load Switch Door/Base Ground Wire Check each Remote Lockout Station for proper wiring and operation as follows: 1. At the power panel, remove the Remote Lockout Station connector plug from the terminal block at the Control Module or the Expansion Module (see Figure 5.27). Publication 2030-UM003A-EN-P - May 2006 5-20 Preventive Maintenance Figure 5.27 Control Module RLS Connectors Pull connector plug away from terminal block 2. Have one technician operate the Remote Lockout Station while a second technician checks continuity between connection points on the Remote Lockout Station connector plug at the Control Module or the Expansion Module as outlined in Table 5.2, “Continuity Check Table”. Table 5.2 Continuity Check Table Control Module / Expansion Module Connector Remote Lockout Station Plug Connection Point Numbers Status Continuity On 2&7 Yes On 3&8 Yes On 4&9 Yes On 1&6 No Off 2&7 No Off 3&8 No Off 4&9 No Off 1&6 Yes ❶ ❶ The “SYSTEM ISOLATED” light on the front of the Remote Lockout Station has an impedance of about 2k Ohms. If a Remote Lockout Station connector plug is not used, grip the strain relief pad holding the Remote Lockout Station connector and remove the connector by pulling it away from the control Module or Expansion Module. Verify that jumper wires have been installed at connection points (3) and (8) and (4) and (9). (See Table 5.3 and Figure 5.28 for jumper information.) Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance 5-21 Table 5.3 Jumpering Out an Unused Remote Lockout Station PortStation Connector Plug Connection Points Recommended Wire RLS1 through RLS6 3 and 8 #16 AWG MTW, blue/ 1.3mm blue 4 and 9 Figure 5.28 Jumper Wire Installation on a Connector plug for an Unused Remote Lockout Station RLS (any #) 1 2 3 4 5 IMPORTANT 6 7 8 9 10 11 When a Remote Lockout Station is installed, the two jumper wires must be removed from the plug that will be used to connect it. 3. Check that no connection point has continuity with any other connection point or ground when the Remote Lockout Station operating handle is in the ON position, except as stated in Table 5.2. 4. Check that no connection point has continuity with any other connection point or ground when the Remote Lockout Station operating handle is in the OFF position, except as stated in Table 5.2. 5. If a Remote Lockout Station fails any of the above continuity checks, check point-to-point wiring between the terminal block in the Remote Lockout Station enclosure and the Remote Lockout Station connector plug in the control module. IMPORTANT The five-step procedure outlined above must be repeated for each Remote Lockout Station. Publication 2030-UM003A-EN-P - May 2006 5-22 Preventive Maintenance Expansion Module ATTENTION ! ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. 1. If the SIS includes a Communication Module, de-energize and padlock the electrical energy feeding these modules. 2. Visually inspect for loosened parts, wires, components, and mounting hardware through the module’s shield. 3. Inspect the fuses in the Expansion Module to verify they are of the correct ampacity. 4. Verify all external connectors and cables are firmly attached, and have not been damaged (see Figure 5.26). Figure 5.29 Checking the Expansion Module Connector Plugs RLS_A…RLS_J PLC1EXB PLC2EXB EXB 5. Reference the torque label affixed to the inside of the ElectroGuard® Power Panel enclosure door when applicable. 6. Verify the tamper-indicating seal has not been broken or tampered with (see Figures 2.18 and 2.19). Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance Communication Module 5-23 1. Verify the Communication Modules are secured to the mounting rail. 2. Verify fuses are of the appropriate value. 3. Verify all control wiring to the power supplies, adapter module, and input module is secured. 4. Verify the communication cable and connectors are secured on the Communication Adapter. 5. Verify that the ferrite cores are attached to the incoming power supply wires and communication cable. 6. Refer to the torque label affixed to the inside of the ElectroGuard® Power Panel enclosure door when applicable. Publication 2030-UM003A-EN-P - May 2006 5-24 Preventive Maintenance Pneumatic Isolation Module ATTENTION ! ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. 1. Verify that the product safety labels and product information labels in Figure 2.20 are legible and not loose or damaged. If any label is damaged, loose or illegible, replacement labels can be obtained free of charge by contacting Rockwell Automation Technical Support or your local distributor. 2. Verify that the tamper-indicating seal has not been broken or tampered with. If the tamper-indicating seal has been damaged or tampered with, the module must either be replaced or recommissioned by a qualified technician familiar with the ElectroGuard® System. 3. Inspect external connector and cable to verify they are firmly attached (see Figure 5.30). Figure 5.30 Pneumatic Isolation Module Verify connector latches and cable connector are secure Tamper-indicating seal Status Indicator Light Chart 4. Verify the Indicator Light Explanation Chart is affixed to the module door and legible. 5. Check the air exhaust muffler and check valve located on the bottom of the Pneumatic Isolation Module enclosure to make sure they are securely attached and not obstructed. Publication 2030-UM003A-EN-P - May 2006 Preventive Maintenance 5-25 6. It is recommended that the customer's installed filters (as specified in the installation instructions) upstream from the Pneumatic Isolation Module, be inspected and cleaned/replaced if necessary. Follow your facility’s procedure for checking/changing system air filters upstream of the Pneumatic Isolation Module. Final Preventive Maintenance Steps 1. Close the covers of the Remote Lockout Stations. Install a wire seal on each Remote Lockout Station. 2. Close the ElectroGuard® Power Panel enclosure and secure the cover fasteners. 3. If the Safety Isolation System includes the Communication Module option, remove the padlock from the electrical energy feeding the Communication Module power supply, and turn it back “On”. 4. If pneumatic energy was isolated, remove the padlock from the shut-off valve supplying the pneumatic energy to the machine. Turn the pneumatic energy “On”. 5. Remove the padlock from the disconnecting means on the ElectroGuard® Power Panel, or the disconnecting means feeding electrical energy to the Safety Isolation System. Move the disconnecting means operating handle to the ON position. 6. Press the “SYSTEM ON” push button on the front of the ElectroGuard® Power Panel enclosure. 7. Follow the start-up procedures to re-start the machine. Publication 2030-UM003A-EN-P - May 2006 5-26 Preventive Maintenance Notes: Publication 2030-UM003A-EN-P - May 2006 Chapter 6 Replacement Procedures General 1 Section Page Remote Lockout Station 6-2 Remote Lockout Station Load Switch Assembly 6-7 Remote Lockout Station System Isolated LED 6-12 Remote Lockout Station Light Assembly 6-13 Control Module 6-16 Power Contactor and/or Mechanical Interlock (23…85 A) 6-26 Power Contactor and/or Mechanical Interlock (110…1200 A) 6-35 Control Circuit Transformer 6-39 Push Buttons/Pilot Lights 6-43 Expansion Module 6-47 Communication Module 6-51 Pneumatic Isolation Module 6-53 The information in the following sections is provided to the user as replacement procedures for the ElectroGuard® Safety Isolation System. Publication 2030-UM003A-EN-P - May 2006 6-2 Replacement Procedures Remote Lockout Station ATTENTION ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! ATTENTION ! Publication 2030-UM003A-EN-P - May 2006 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. To avoid serious injury or death, make sure that the machine or process has been stopped by the proper stopping means, and electrical and pneumatic energy isolated, before attempting to replace any of the SIS components. Replacement Procedures Remote Lockout Station 6-3 Removal 1. If it is not already OFF, turn the operating handle on the RLS to the OFF position. 2. Break the seal placed on the RLS by your facility. The seal ties the RLS cover to its base (see Figure 6.1 for the seal location). Figure 6.1 Remote Lockout Station Seal RLS seal should be located here 3. Loosen the two cover screws on the RLS (see Figure 6.2). Figure 6.2 Remote Lockout Station Cover Screws Cover Screws 4. To open the RLS enclosure cover, rotate the operating handle in the OFF position. Squeeze the handle interlock lever and operating handle and lift the enclosure cover away from the base (see Figure 6.3). Publication 2030-UM003A-EN-P - May 2006 6-4 Replacement Procedures Figure 6.3 Opening the Remote Lockout Station Slide interlock mechanism Note: If using color-coded or numbered wires, note and record their connection points on the RLS terminal block. 5. Loosen and remove the wires from the terminal block located near the top of the RLS (Nos. 1…9 and ground) (see Figure 6.4). Figure 6.4 Terminal Strip in Remote Lockout Station Ground terminal block 6. Loosen and remove the conduit hub and mounting screws from the RLS enclosure (see Figure 6.5). Note: The RLS weighs approximately 6 lbs. (2.7 kg). Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-5 Figure 6.5 Remote Lockout Station Mounting Holes Upper mounting bolt locations (two located on bottom of enclosure not shown) Installation 1. Position the replacement RLS over the four mounting holes. 2. Insert and secure the four mounting bolts for the RLS. 3. Loosen the two cover screws on the RLS. 4. If it is not already in the OFF position, rotate the operating handle of the RLS to the OFF position. 5. While holding the RLS operating handle in the OFF position, rotate the handle slide interlock mechanism clockwise and open the enclosure door. 6. Either: If wiring to the RLS is to be bottom-fed, remove and discard the red plastic conduit plug from the bottom of the RLS (see Figure 6.6). Secure the conduit fitting and conduit. or If the wiring to the RLS is to be top-fed, loosen the wing-nut and remove the top conduit plug (do not discard the conduit plug) (see Figure 6.7) Then, remove the red plastic conduit plug from the bottom of the RLS and discard. Install the conduit plug with wing-nut in the bottom conduit hole. Publication 2030-UM003A-EN-P - May 2006 6-6 Replacement Procedures Figure 6.6 Bottom-Fed Remote Lockout Station Wiring Remove and discard the red conduit plug Figure 6.7 Top-Fed Remote Lockout Station Wiring Wing nut and top conduit plug 7. Secure the conduit fitting and conduit and reinstall the control wires to the corresponding labeled terminal block. IMPORTANT Refer to the corresponding connection diagrams supplied with the RLS. 8. Secure the ground wire to the yellow/green ground terminal block. 9. While holding the RLS operating handle in the OFF position, rotate and hold the handle slide interlock mechanism as far clockwise as possible. Close the enclosure door and release the handle slide mechanism. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-7 10. Retest the RLS circuit. 11. Tighten the two cover hold-down screws securely and, if applicable, reseal the enclosure. Power Restoration 1. Remove the padlock from branch circuit protection on the SIS enclosure or the upstream customer-supplied branch circuit protection feeding electrical energy to the SIS. Turn the branch circuit protection operating handle to the ON position. 2. Turn the operating handle on the RLS to the ON position. 3. Press the System ON push button. 4. Recommission the system after the RLS is replaced.(See Chapter 3.) 5. Follow normal start-up procedures to restart the machine. Remote Lockout Station Load Switch Assembly Removal 1. If it is not already OFF, turn the operating handle on the RLS to the OFF position. 2. Break the seal placed on the RLS by your facility. The seal ties the RLS cover to its base (see Figure 6.1 for the seal location). 3. Loosen the two cover screws on the RLS (see Figure 6.2). 4. While holding the RLS operating handle in the OFF position, rotate the handle slide interlock mechanism clockwise and open the enclosure door (see Figure 6.3). 5. Remove all control wiring from load switch assembly (see Figure 6.8). IMPORTANT If using color-coded or numbered wires, note and record their connection points on the RLS terminal block. 6. Remove the two mounting screws located at the top and bottom of the load switch assembly. See Figure 6-8. Publication 2030-UM003A-EN-P - May 2006 6-8 Replacement Procedures Figure 6.8 RLS Load Switch Assembly 7. Remove the load switch from the enclosure. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-9 Installation 1. Reconnect wiring to the load switch assembly (see Figure 6.9 and Table 6.1). Figure 6.9 RLS Wiring Connections TO SIS CONTROL MODULE SYSTEM ISOLATED (-) OR EXPANSION MODULE PIN NUMBERS (+) 1 2 3 4 6 7 8 9 GRD #16 MTW BLUE EXCEPT THIS WIRE #16 MTW BLUE W/WHITE STRIPE G R D DOOR (REAR VIEW) 21 1 L1 3 L2 5 L3 13 2 T1 4 T2 6 T3 14 ON 1 OFF 0 22 #16 MTW GREEN/YELLOW GRD GRD Publication 2030-UM003A-EN-P - May 2006 6-10 Replacement Procedures Table 6.1 RLS Terminal Block (Wire No.) Connected to Terminal Load Switch 1 21 (N.C. Auxiliary Contact) 2 13 (N.O. Auxiliary Contact) 3 3 L2 4 5 L3 7 14 (N.O. Auxiliary Contact) 8 4 T2 9 6 T3 Connect the Positive Terminal of System Isolated light to 22 N.C. Auxiliary Contact. 2. Align load switch assembly mounting screws with hole pattern on mounting plate. 3. Tighten top and bottom mounting screws on load switch. 4. Close the RLS and tighten the cover fasteners. 5. Re-install the tamper-indicating seal placed on the RLS by your facility (see Figure 6.10). Figure 6.10 Remote Lockout Station Seal Tamper-indicating seal should go here Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-11 Power Restoration 1. Remove the padlock from branch circuit protection on the SIS enclosure or the upstream customer-supplied branch circuit protection feeding electrical energy to the SIS. Turn the branch circuit protection operating handle to the ON position. 2. Turn the operating handle on the RLS to the ON position. 3. Press the System ON push button. 4. Follow normal start-up procedures to restart the machine. Publication 2030-UM003A-EN-P - May 2006 6-12 Replacement Procedures Remote Lockout Station System Isolated LED ATTENTION ! The System Isolated LED lamp used in the RLS is a 24V AC/DC amber or green LED. Do not replace this LED with any other lamp type (see Appendix E for LED part no.). Removal 1. Unscrew the white or green lens cap on the System Isolated pilot light by rotating it counter-clockwise. 2. Press the LED and rotate it slightly counter-clockwise (see Figure 6.11). Figure 6.11 LED Replacement 3. Remove the LED lamp. Installation 1. Press the replacement LED and rotate clockwise to lock in place. 2. Replace the white or green lens cover on the System Isolated light and tighten it by rotating it clockwise until secure. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures Remote Lockout Station Light Assembly ATTENTION 6-13 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! To avoid serious injury or death, make sure that the machine or process has been stopped by the proper stopping means, and the electrical and pneumatic energy isolated, before attempting to replace any of the ElectroGuard® SIS components. Removal 1. Break the seal placed on the RLS by your facility. The seal ties the RLS cover to its base (see Figure 6.1 for the seal location). 2. Loosen the two cover screws on the RLS (see Figure 6.2). 3. While holding the RLS operating handle in the OFF position, rotate the handle slide interlock mechanism clockwise and open the enclosure door (see Figure 6.12). Publication 2030-UM003A-EN-P - May 2006 6-14 Replacement Procedures Figure 6.12 Opening the Remote Lockout Station Slide interlock mechanism 4. Remove the wiring from the back of the “System Isolated” pilot light, noting which terminal the blue wire is connected to, and to which terminal the blue wire with white stripe is connected (see Figure 6.13). Figure 6.13 Removing Control Wires from the “System Isolated” Light Assembly Remove these two wires 5. Using a wrench, loosen and remove the retaining ring on the front of the “System Isolated” pilot light by rotating the ring counter-clockwise (see Figure 6.14). Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-15 Figure 6.14 Removing the “System Isolated” Light Assembly Retaining Ring 6. Remove the “System Isolated” pilot light assembly from the rear (inside of the RLS). Installation 1. Install the new “System Isolated” pilot light assembly by following its installation instructions and re-connect the wiring to the back of the “System Isolated” pilot light assembly. 2. Close the RLS and tighten the cover fasteners and reseal. Power Restoration 1. Remove the padlock from the branch circuit protection on the ElectroGuard® Power Panel or the branch circuit protection feeding electrical energy to the SIS. 2. Turn the branch circuit protection operating handle to the ON position. 3. Turn the operating handle on the RLS to the ON position. 4. Press the System ON push button. 5. Recommission the system for the RLS that had the “System Isolated” light replaced. Publication 2030-UM003A-EN-P - May 2006 6-16 Replacement Procedures Control Module ATTENTION ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! Publication 2030-UM003A-EN-P - May 2006 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: To avoid serious injury or death, make sure that the machine or process has been stopped by the proper stopping means, and the electrical and pneumatic energy isolated, before attempting to replace any of the ElectroGuard®. Replacement Procedures 6-17 Removal 1. Open the ElectroGuard® Power Panel enclosure door by loosening the cover hold-down fasteners (see Figures 2.21 and 2.22). 2. Disconnect the following connector plugs from the terminal blocks located at the bottom of the Control Module by firmly gripping the strain relief pad (see Figures 6.15 or 6.16): RLS1…RLS6 IP1 IP2 IP3 IP4 (23…85 A only) ZB (110…1200 A only) HP1 and HP2 FB1 and FB2 (110…1200 A only) Figure 6.15 (110...1200 A) Control Module Connector Plugs RLS1 RLS2 RLS3 RLS4 RLS5 RLS6 IP1 IP2 IP3 ZB HP1 HP2 FB1 FB2 HV Figure 6.16 (23...85 A) Control Module Connector Plugs RLS1 RLS2 RLS3 RLS4 IP1 IP2 IP3 IP4 HP1 HP2 HV Publication 2030-UM003A-EN-P - May 2006 6-18 Replacement Procedures 3. Loosen the two screws holding the HV connector, and remove the connector by pulling it away from the Control Module (see Figure 6.17). Figure 6.17 HV Connector Plug Removal Loosen these screws HV Connector Plug ATTENTION ! ATTENTION ! In order to help avoid serious injury or death, proper lifting techniques and equipment must be used when moving and installing the ElectroGuard®. The lifting means must be capable of lifting the weight of the panel. The Control Module for the 25...85 A weighs 72 lbs (32.6 kg), and the 110...1200 A Control Module weighs 85 lbs (39.7 kg). The lifting means (hoist or fork truck) must be certified to lift the weight of the panel. The module must be secured so that unexpected movement will not occur. 4. Remove and set aside the lower two bolts that secure the lower portion of the Control Module to the mounting plate (see Figure 6.18). Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-19 Figure 6.18 Removing the Bottom Two Mounting Bolts that Secure the Control Module Bottom Mounting Bolts (on sides of Control Module) 5. If a hoist will be used to remove the Control Module, fasten the lifting chain to the two side lifting ears (see Figure 6.19). Figure 6.19 Side Lifting Ears on Control Module 6. Remove the top two bolts that secure the Control Module to the mounting plate (see Figure 6.20). Publication 2030-UM003A-EN-P - May 2006 6-20 Replacement Procedures Figure 6.20 Removing the Top Two Mounting Bolts that Secure the Control Module Mounting bolts 7. Carefully lift and remove the Control Module. Installation ATTENTION ! ATTENTION ! In order to help avoid serious injury or death, proper lifting techniques and equipment must be used when moving and installing the ElectroGuard®. The lifting means must be capable of lifting the weight of the panel. The Control Module for the 25...83 A weighs 72 lbs (32.6 kg), and the 110...1200 A Control Module weighs 85 lbs (39.7 kg). The lifting means (hoist or fork truck) must be certified to lift the weight of the panel. The module must be secured so that unexpected movement will not occur. 1. With the lifting means attached to the replacement Control Module, position the module on the two support brackets located near the bottom of the enclosure (see Figure 6.21). Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-21 Figure 6.21 Control Module Bottom Mounting Bolts Bottom Mounting Bolts 2. Insert the two right-hand Control Module mounting bolts and rotate several turns, but do not tighten. 3. Slide the Control Module to the right against the two mounting bolts. 4. Install the two left-hand Control Module mounting bolts. 5. Tighten all four Control Module mounting bolts to 50…60 lb-in. (5.6…6.8 N•m). IMPORTANT Refer to the corresponding connection diagram supplied with the Control Module. Note: The RLS connectors as well as HP1, HP2, IP1, IP2, IP3, and IP4 (23…85 A only) or HP1, HP2, IP1, IP2, IP3, ZB, FB1, and FB2 (110…1200 A only) are keyed. If a connector does not re-connect easily, make sure it is installed in the proper position. These connectors are keyed. 6. Re-install connector HV. Press the connector firmly into place and secure by tightening the two screws located at the ends of the connector (see Figure 6.27). IMPORTANT On ElectroGuard® in the 110…1200 A size, where the Control Module is being replaced, if the Control Modules (2030-CH1200X) are different series, some wiring changes must be made to the Power panel for compatibility. If these changes are not made, the ElectroGuard® will not function. When installing a replacement 110…1200 A Control Module (2030-CH1200X), check the series letter of the Control Module (Catalog Publication 2030-UM003A-EN-P - May 2006 6-22 Replacement Procedures number and Series information can be found on the main label of the Control Module (inside the Control Module enclosure, top, right side) or on the inside of the door of the Power Panel). If they do not match, complete the correct rewiring described below. Once complete, make a note of the wiring change in the ElectroGuard® Service Log. Series A Control Module Replacing a Series B Control Module 1. Re-label wire #107A from 1IC (21) to ZB(3) as wire #103. (See Figure 6.22) Figure 6.22 Series A ZB Plug ZB (3) ZB (7) 2. Disconnect wire #119A from ZB(7) to GC(21). (See Figure 6.23) Figure 6.23 Series B ZB Plug ZB (3) ZB (7) Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-23 3. Disconnect wire #113A from IP3(7) to 2IC(22). (See Figure 6.24) Figure 6.24 Series B 2IC Connections 2IC (22) 4. Disconnect wire #113 from IP3(8) and connect to ZB(7). (See Figure 6.22) 5. Install wire #103 from 1IC (21) to GC (21). (See Figures 6.25 and 6.26) Figure 6.25 SIS Series A Contactor Connections 1IC (21) GC (21) 6. Install wire #103 from GC (21) to 2IC (22). (See Figures 6.25 and 6.26) Figure 6.26 Series A 2IC Connections 2IC (22) Publication 2030-UM003A-EN-P - May 2006 6-24 Replacement Procedures Series B Control Module Replacing a Series A Control Module 1. Re-label wire #103 from 1IC (21) to ZB(3) as wire #107A. (See Figure 6.23) 2. Disconnect wire #103 from 1IC (21) to GC (21). (See Figure 6.25) 3. Disconnect wire #103 from GC (21) to 2IC (22). (See Figures 6.25 and 6.26) 4. Disconnect wire #113 from ZB(7) and connect to IP3(8). (See Figure 6.22) 5. Install wire #113A from IP3(7) to 2IC(22). (See Figure 6.24) 6. Install wire #119A from ZB(7) to GC(21). (See Figure 6.23) Figure 6.27 Re-Installing the HV Connector Plug HV connector mounting screws 7. Re-install the connector plugs in the following order: RLS2, RLS1, RLS4, RLS3, IP2, IP1, IP4/ZB, IP3, HP2, HP, FB2, and FB1. Press the plugs firmly into place (see Figure 6.28 and 6.29). Figure 6.28 (110...1200 A) Connector Plugs in the Control Module RLS1 RLS2 RLS3 RLS4 RLS5 RLS6 Publication 2030-UM003A-EN-P - May 2006 IP1 IP2 IP3 ZB HP1 HP2 FB1 FB2 HV Replacement Procedures 6-25 Figure 6.29 (23...85 A) Connector Plugs in the Control Module RLS1 RLS2 RLS3 RLS4 IP1 IP2 IP3 IP4 HP1 HP2 HV 8. Close the ElectroGuard® Power Panel door and secure the cover fasteners. Power Restoration 1. If pneumatic energy was isolated, remove the padlock from the pneumatic energy isolating device. Turn the pneumatic energy ON. 2. Remove the padlock from the branch circuit protection on the ElectroGuard® Power Panel or the upstream customer-supplied branch circuit protection feeding electrical energy to the SIS. Move the branch circuit protection operating handle to the ON position. 3. If the SIS includes the Communication Module, remove the padlock from the source feeding electrical energy to the module and restore the supply voltage. 4. Press the “System On” push button. 5. Perform recommissioning of the system. 6. Follow the proper start-up procedures to restart the machine. Publication 2030-UM003A-EN-P - May 2006 6-26 Replacement Procedures Power Contactor and/or Mechanical Interlock (23…85 A) ATTENTION ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! ATTENTION ! Publication 2030-UM003A-EN-P - May 2006 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. The ElectroGuard® is not designed to provide the start and stop functions for the machine or process. The proper starting and stopping means of the machine or process must be used. Replacement Procedures 6-27 Removal 1. Open the ElectroGuard® Power Panel door by loosening the cover hold-down fasteners. IMPORTANT The power contactors are mechanically interlocked. The three contactors must be removed as an assembly. Once removed from the enclosure, the entire contactor assembly can be replaced or individual contactors can be removed from the assembly and replaced. 2. Loosen and remove the mounting screws that hold the power contactor shield to the equipment mounting plate and remove the shield (see Figure 6.30). Figure 6.30 Removing the Power Contactor Protective Shield Factory Seal Remove shield bracket mounting screws adjacent to left and right sides of contactor assembly 3. Loosen and remove the three power conductors connected to the line side of Contactor 1IC, the three power conductors connected to the load side of Contactor 2IC feeding the machine, and the conductor connected to the GC side of the isolated ground conductor (see Figure 6.31). Publication 2030-UM003A-EN-P - May 2006 6-28 Replacement Procedures Figure 6.31 Power Wire Removal from Power Contactor Assembly Remove these power conductors Remove Isolated Ground Conductor 4. Remove control wiring from the power contactor assembly. 5. Remove the power contactor assembly from the DIN Rail. Note: The power contactor assembly weighs approximately 12 lbs. (5.4 kg) 6. Once the contactor assembly has been removed from the DIN Rail, disassemble the contactor assembly to replace the faulty contactor(s) by removing the following components: Control and power wiring from contactor assembly Shorting bar when replacing GC or 2IC (see Figure 6.32). Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-29 Figure 6.32 1IC GC 2IC Shorting Bar between GC and 2IC Figure 6.33 Dovetail Connectors Figure 6.34 Mechanical Interlock Publication 2030-UM003A-EN-P - May 2006 6-30 Replacement Procedures Installation Installing 1IC Isolation Contactor Re-install the 1IC power contactor by assembling the following components: 1. Install auxiliary contactor block to 1IC (see Figure 6.35). Figure 6.35 Auxiliary Contactor Block 2. Install mechanical interlock between 1IC and GC and mount 1IC to GC (see Figure 6.36) Figure 6.36 Mechanical Interlock 1IC Contactor GC Contactor 3. Install dovetail (see Figure 6.37). Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-31 Figure 6.37 1IC GC 4. Align the contactor assembly on the DIN Rail and snap into place. 5. Reconnect the power and control conductors per the corresponding connection diagram. 6. Re-install the power contactor shield to the equipment mounting plate. 7. Place a tamper-indicating seal on contactor shield. Publication 2030-UM003A-EN-P - May 2006 6-32 Replacement Procedures Installing 2IC Isolation Contactor Re-install the 2IC power contactor by assembling the following components: 1. Install auxiliary contact block to 2IC (see Figure 6.38). Figure 6.38 Auxiliary Contact Block 2. Install mechanical interlock between 2IC and GC and mount 2IC to GC (see Figure 6.39). Figure 6.39 Mechanical Interlock 2IC Contactor GC Contactor 3. Install dovetail. Figure 6.40 GC Publication 2030-UM003A-EN-P - May 2006 2IC Replacement Procedures 6-33 4. Install shorting bar. Figure 6.41 5. Align the contactor on the DIN Rail and snap into place. 6. Reconnect the power and control conductors per the corresponding connection diagram. 7. Reinstall the power contactor shield to the equipment mounting plate. 8. Place a tamper-indicating seal on shield. Installing GC Grounding Contactor Re-install the GC grounding contactor by assembling the following components: 1. Install 1IC isolation contactor to GC. See Installation of the 1IC Isolation Contactor. 2. Install 2IC Isolation Contactor to GC. See Installation of the 2IC Isolation Contactor. Publication 2030-UM003A-EN-P - May 2006 6-34 Replacement Procedures 3. Install shorting bar (see Figure 6.42). Figure 6.42 4. Align the contactor assembly on the DIN Rail and snap into place. 5. Reconnect the power and control conductors per the corresponding connection diagram. 6. Reinstall the power contactor shield to the equipment mounting plate. 7. Place a tamper-indicating seal on shield. Power Restoration 1. Remove the padlock from the disconnecting means on the ElectroGuard® Power Panel or the upstream customer supplied disconnecting means feeding electrical energy to the Safety Isolation System. 2. If the Safety Isolation System includes the Communication Module, remove the padlock from the source feeding electrical energy to these modules, and restore the supply voltage. 3. Turn the disconnecting means operating handle to the ON position. 4. Turn the operating handle on the Remote Lockout Station to the ON position. 5. Press the “SYSTEM ON” push button. 6. Perform recommissioning of the system. 7. Follow the normal start-up procedures to restart the machine. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures Power Contactor and/or Mechanical Interlock (110…1200 A) ATTENTION 6-35 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! ATTENTION ! Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. The ElectroGuard® is not designed to provide the start and stop functions for the machine or process. The proper starting and stopping means of the machine or process must be used. Publication 2030-UM003A-EN-P - May 2006 6-36 Replacement Procedures Removal IMPORTANT In 110…1200 A ElectroGuard® Power Panels, the power contactors must be removed individually for replacement. To replace the mechanical interlock between contactors 1IC and GC, contactor 1IC must be removed first. To replace the mechanical interlock between contactors 2IC and GC, contactor 2IC must be removed. To replace contactor GC, first remove any attachment hardware for both mechanical interlocks mounted on the contactors and then remove power isolation contactor 1IC. 1. Determine which power contactor or mechanical interlock is being replaced, and disconnect all required power wires attached to the contactor to allow its removal. If contactor GC is being replaced, remove the shorting bar and install it on the replacement contactor. 2. Remove all of the control wiring from the contactor and/or mechanical interlock being removed. ATTENTION ! Contactor weight depends on the ElectroGuard® amperage rating. Approximate weight of a single contactor can be as low as 8.5 lbs (3.8 kg) up to as high as 118 lbs (53.1 kg). In order to prevent physical injury to personnel and/or equipment damage, customer must make provisions as needed to support the heavier contactors prior to and during the replacement process. 3. Remove the two lower contactor mounting screws or bolts first (see Figure 6.43). Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-37 Figure 6.43 Lower mounting screws or bolts 4. Support the contactor and then remove the two upper contactor mounting screws or bolts (see Figure 6.44) and remove the contactor from the enclosure. Figure 6.44 Upper mounting screws or bolts 5. Remove the mechanical interlock if replacement is required (see Figure 6.45). Figure 6.45 Publication 2030-UM003A-EN-P - May 2006 6-38 Replacement Procedures 6. Install replacement mechanical interlock(s) according to the instruction sheet supplied with the replacement part. 7. Align the replacement contactor with the mounting holes in the equipment mounting plate and insert the mounting bolts. Tighten bolts to the torque listed on the replacement contactor instruction sheet. IMPORTANT Reference the corresponding connection diagram supplied with the ElectroGuard® Power Panel. 8. Reconnect all control wires to the power contactor or mechanical interlock that was removed during maintenance. 9. Reconnect all power conductors to the power contactor that was removed during maintenance. 10. If contactor GC was replaced, reconnect the Isolated Ground Conductor to the shorting bar mounted on contactor GC. 11. Re-install the power contactor shield and install a new tamper-indicating seal to reseal the shield. Power Restoration 1. Remove the padlock from the disconnecting means on the ElectroGuard® Power Panel or the upstream customer supplied disconnecting means feeding electrical energy to the Safety Isolation System. 2. If the Safety Isolation System includes the Communication Module, remove the padlock from the source feeding electrical energy to these modules, and restore the supply voltage. 3. Turn the disconnecting means operating handle to the ON position. 4. Turn the operating handle on the Remote Lockout Station to the ON position. 5. Press the “SYSTEM ON” push button. 6. Perform recommissioning of the system. 7. Follow the proper start-up procedures to restart the machine. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures Control Circuit Transformer ATTENTION 6-39 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! ATTENTION ! Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. The ElectroGuard® is not designed to provide the start and stop functions for the machine or process. The proper starting and stopping means of the machine or process must be used. Publication 2030-UM003A-EN-P - May 2006 6-40 Replacement Procedures Removal 1. Open the ElectroGuard® Power Panel door by loosening the cover hold-down fasteners (see Figure 2.21 and 2.22). 2. If the Safety Isolation System includes the Communication Module, de-energize and padlock the electrical energy feeding these modules. 3. Open the two primary fuse holders adjacent to the Control Circuit Transformer by pulling the fuse covers downward (see Figures 6.46 and 6.47). Figure 6.46 (23…85 A) Control Circuit Transformer and Primary Fusing Primary Fuseholders Figure 6.47 (110…1200 A) Control Transformer Primary Fuseholders Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-41 4. Remove the wires from the primary and secondary sides of the Control Circuit Transformer. Loosen and remove the four control transformer mounting screws (see Figure 6.48 and 6.49). Figure 6.48 (110…1200 A) Control Circuit Transformer Mounting Transformer Mounting Bolts Figure 6.49 (23…85 A) Control Circuit Transformer Mounting Transformer Mounting Bolts 5. Remove the Control Circuit Transformer. Installation 1. Line-up the four mounting holes on the replacement Control Circuit Transformer with the holes in the equipment mounting plate. Install the four mounting screws and torque to 50…60 lb-in. (5.6…6.8 N•m). IMPORTANT Refer to the corresponding connection diagrams supplied with the ElectroGuard® Power Panel. 2. Reconnect the primary and secondary wiring to the Control Circuit Transformer. Torque wire connections as specified inside of SIS door. Publication 2030-UM003A-EN-P - May 2006 6-42 Replacement Procedures Figure 6.50 Control Circuit Transformer Wiring INSTALL JUMPER 1 1497-H- BASX-0-N 1497-H-M2-0-N H1 H3 GRD H2 X2 X1 21 F U 22 F U GRD 7 F U H3 H4 X4 X2 X3 X1 22 F U 7 F U INSTALL JUMPER 2 Transformer shown connected for 415V primary / 115V secondary. For other primary voltages see chart: Primary Secondary H1-H4 H1-H3 H1-H2 X1-X4 415 (50 Hz) 400 (50 Hz) 380 (50 Hz) 115 Jumper X1-X3 X2-X4 PRIMARY 208V (60Hz) 1497-H-HXDX-0-N H2 H1 H2 H1 GRD GRD 21 F U WIRE #1 PRIMARY 600V (60Hz) 550V (50Hz) WIRE #2 ENCLOSURE FAN WIRE #1 WIRE #2 ENCLOSURE FAN Transformer shown connected for 480V primary / 120V secondary. For other primary voltages see chart: Primary Secondary H1-H4 H1-H4 X1-X2 220 (50 Hz) 440 (50 Hz) 110 (50 Hz) 240 (60 Hz) 480 (60 Hz) 120 (60 Hz) Jumper Jumper H1-H3 H2-H3 H2-H4 1497-H- CXSX-0-N H2 H1 H4 X2 X1 SECONDARY 120V (60Hz) X1 21 F U 22 F U 7 F U WIRE #1 WIRE #2 7 F U ENCLOSURE FAN 22 F U WIRE #1 WIRE #2 ENCLOSURE FAN SECONDARY 120V (60Hz) 110V (50Hz) 21 F U X2 3. Replace the voltage selection jumper on the primary of the transformer. See nameplate and transformer documentation for selection and setting up primary of the transformer for system voltage. 4. Close the primary fuse holder covers. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures Push Buttons/Pilot Lights ATTENTION 6-43 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! ATTENTION ! Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. The ElectroGuard® is not designed to provide the start and stop functions for the machine or process. The proper starting and stopping means of the machine or process must be used. Removal 1. Open the ElectroGuard® Power Panel enclosure door by loosening the cover hold-down fasteners. 2. Remove the finger-safe cover(s) from the wiring terminals of the push button or pilot light (see Figures 6.51 and 6.52). Publication 2030-UM003A-EN-P - May 2006 6-44 Replacement Procedures Figure 6.51 Removing the Finger-Safe Cover. Step a: Pry up the Cover Figure 6.52 Removing the Finger-Safe Cover. Step b: Remove the Cover 3. Remove the wiring from the back of the push button operator/pilot light to be replaced (see Figure 6.53). Figure 6.53 Push Button/Pilot Light Replacement on Power Panel Inside View of Enclosure Door 4. Using a wrench, loosen and remove the retaining ring on the front of the push button/pilot light by rotating the ring counter-clockwise (see Figure 6.54). Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-45 Figure 6.54 Push Button/Pilot Light 5. Remove the push button/pilot light from the rear (inside of enclosure door). Installation 1. Insert the new push button/pilot light from the inside of the enclosure door. Place the nameplate and the retaining ring on the push button/ pilot light from the outside of the enclosure door, and tighten the retaining ring by turning the ring clockwise with a wrench until secure. IMPORTANT Reference the corresponding connection diagram supplied with the ElectroGuard® Power Panel. Reconnect the control wiring to the back of the push button/pilot light (see Figure 6.55). Publication 2030-UM003A-EN-P - May 2006 6-46 Replacement Procedures Figure 6.55 Wiring to the ElectroGuard® Power Panel (110…1200 A — system wires shown in parentheses) DOOR PILOT DEVICES SYSTEM GROUND CONNECTED WIRE #25 WIRE #2 G (WIRE #31) () () PART # 800T-PT16G WIRE #1 () () SYSTEM ON SYSTEM OFF WIRE #15 WIRE #1 (WIRE #12) () WIRE #15 () WIRE #18 () PART # 800T-B6D2 () (Wire #25) PART # 800T-A1D1 SYSTEM CONTROL ON WIRE #6 WIRE #5 R (Wire #2) (Wire #13) () () WIRE #1 () COAST-TO-STOP PUSH FOR STOP PULL TO RESET WIRE #20 (Wire #25) PART # 800T-PT16R WIRE #21 () () WIRE #22 (Wire #28) () (Wire #27) WIRE #23 () () (Wire #29) PART # 800T- FXT9A5 2. Re-install the finger-safe covers that were removed during maintenance. 3. Close the enclosure door and tighten the enclosure door fasteners. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures Expansion Module ATTENTION 6-47 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! ATTENTION ! ATTENTION ! Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. The ElectroGuard® is not designed to provide the start and stop functions for the machine or process. The proper starting and stopping means of the machine or process must be used. In order to help avoid serious injury or death, proper lifting techniques and equipment must be used when moving and installing the ElectroGuard®. The lifting means must be capable of lifting the weight of the panel. Publication 2030-UM003A-EN-P - May 2006 6-48 Replacement Procedures Removal 1. Open the customer- or factory-supplied enclosure housing the Expansion Module. 2. Disconnect the following connector plugs from the terminal blocks located at the bottom of the Expansion Module by firmly gripping the strain relief pad (see Figures 6.56 and 6.57): RLS_A…RLS_D for the 4-port Expansion Module RLS_A…RLS_J for the 10-port Expansion Module PLC1EXB and PLC2EXB The EXB connector Figure 6.56 Removing Connectors from the Expansion Module Figure 6.57 Expansion Module Connectors RLS_A… RLS_J Publication 2030-UM003A-EN-P - May 2006 PLC1EXB PLC2EXB EXB Replacement Procedures ATTENTION ! 6-49 The Expansion Module weighs approximately 25 lbs (11.3 kg). The lifting means (hoist or fork truck) must be certified to lift the weight of the panel. The module must be secured so that unexpected movement will not occur. 3. Remove the four bolts securing the Expansion Module to the customeror factory-supplied enclosure (see Figure 6.58). Figure 6.58 Expansion Module Mounting Bolts Bottom mounting bolts (also, two top mounting bolts [not shown]) Installation 1. With the lifting means secured to the replacement Expansion Module, position the module on the four mounting bolt holes in the enclosure. 2. Install the four mounting bolts and tighten to 50…60 lb-in. (5.6…6.8 N•m). 3. Re-install the connector plugs. 4. Close the enclosure door and secure the cover fasteners. Publication 2030-UM003A-EN-P - May 2006 6-50 Replacement Procedures Power Restoration 1. If pneumatic energy was isolated, remove the padlock from the pneumatic energy isolating device. Turn the pneumatic energy ON. 2. Remove the padlock from the branch circuit protection on the ElectroGuard® Power Panel or the upstream customer-supplied branch circuit protection feeding electrical energy to the SIS. Move the branch circuit protection operating handle to the ON position. 3. If the SIS includes the Communication Module, remove the padlock from the source feeding electrical energy to the module and restore the supply voltage. 4. Press the “System On” push button. 5. Perform recommissioning of the system. 6. Follow the proper start-up procedures to restart the machine. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-51 Communication Module ATTENTION Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. Energy Lockout/Tagout 1. Press the System OFF push button on the front of the ElectroGuard® Power Panel. 2. Turn the branch circuit protection on the ElectroGuard® Power Panel, or the upstream customer-supplied branch circuit protection feeding electrical energy to the SIS OFF. Padlock the branch circuit protection handle in the OFF position. 3. If the machine has a source of pneumatic energy, shut off the air valve supplying the pneumatic energy to the machine and padlock it in the OFF position. (The pneumatic energy lockout valve must be located upstream of the Pneumatic Isolation Module.) 4. If the SIS includes the Communication Module, open the ElectroGuard® Power Panel enclosure and de-energize and padlock the electrical energy feeding the module. 5. If it is not already OFF, turn the operating handle on the RLS to the OFF position. Publication 2030-UM003A-EN-P - May 2006 6-52 Replacement Procedures Removal and Installation 1. Open the ElectroGuard® Power Panel enclosure door by loosening the cover hold-down fasteners. See Figure 2.21 (23…85 A) and Figure 2.22 (110…1200 A). 2. Remove the control wiring from the module to be replaced. 3. Refer to the applicable Communication Module installation instructions in the documentation folder. IMPORTANT Refer to the corresponding connection diagrams supplied with the ElectroGuard® Power Panel. 4. Reconnect the control wiring to the Communication Module. 5. Close the enclosure door and tighten the enclosure door fasteners. Power Restoration 1. Remove the padlock from the branch circuit protection on the ElectroGuard® Power Panel or the upstream customer-supplied branch circuit protection feeding electrical energy to the SIS. 2. Turn the branch circuit protection operating handle to the ON position. 3. Remove the padlock from the source feeding electrical energy to the Communication Module and restore the supply voltage. 4. Press the System ON push button. 5. Follow proper start-up procedures to restart the machine or process. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures Pneumatic Isolation Module ATTENTION 6-53 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! ATTENTION ! Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. In order to help avoid serious injury or death, proper lifting techniques and equipment must be used when moving and installing the ElectroGuard®. The lifting means must be capable of lifting the weight of the panel. Publication 2030-UM003A-EN-P - May 2006 6-54 Replacement Procedures Figure 6.59 Pneumatic Isolation Module Muffler Muffler (bottom view of enclosure) Removal 1. Unlatch the electrical connector from the right side of the Pneumatic Isolation Module (see Figure 6.60). Figure 6.60 Unlatching the Electrical Connector from the Pneumatic Isolation Module Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-55 2. Using appropriately-sized wrenches, disconnect the air inlet piping from the right side of the Pneumatic Isolation Module (see Figure 6.61). Hold the Pneumatic Isolation Module air inlet fitting when disconnecting the inlet piping so internal fittings do not loosen up. Figure 6.61 Pneumatic Isolation Module Air Inlet 3. Using appropriately-sized wrenches, disconnect the air outlet piping from the bottom of the Pneumatic Isolation Module (see Figure 6.62). hold the Pneumatic Isolation Module air outlet fitting when disconnecting the outlet piping so internal fittings do not loosen up. Figure 6.62 Pneumatic Isolation Module Air Outlet Piping (Bottom View of Module) Exhaust Check Valve ATTENTION ! Air Outlet The Pneumatic Isolation Module weighs approximately 135 lbs (61.2 kg). The lifting means (hoist or fork truck) must be certified to lift the weight of the panel. Publication 2030-UM003A-EN-P - May 2006 6-56 Replacement Procedures 4. If a hoist is used to remove the Pneumatic Isolation Module, fasten the lifting chain to the two eyebolts located on the top surface of the module (see Figure 6.63). Figure 6.63 Pneumatic Isolation Module Lifting Eyebolts and Top Mounting Means Top mounting means for module Lifting Eyebolts 5. Loosen, but do not remove the two bolts securing the bottom of the enclosure to the mounting surface (see Figure 6.64). Figure 6.64 Pneumatic Isolation Module Bottom Mounting Means Bottom Mounting Means 6. Loosen and remove the two bolts securing the top of the enclosure to the mounting surface (see Figure 6.63). 7. Carefully lift and remove the Pneumatic Isolation Module from the two bottom mounting bolts. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-57 Installation 1. With the lifting means attached to the replacement Pneumatic Isolation Module, position the module on the two bottom enclosure mounting bolts. 2. Re-install the two top enclosure mounting bolts. 3. Tighten all four enclosure mounting bolts securely. 4. Remove the lifting means. 5. Affix Teflon tape to the threaded ends of the air inlet and air outlet piping. 6. Connect the air outlet piping to the bottom of the enclosure. Fasten securely. 7. Connect the air inlet piping to the right side of the enclosure. Fasten securely. 8. Reconnect the electrical connector to the right side of the Pneumatic Isolation Module. Press down on the connector locking tabs to secure. Publication 2030-UM003A-EN-P - May 2006 6-58 Replacement Procedures Power Restoration 1. Remove the padlock from the pneumatic energy shut-off valve. 2. Turn the pneumatic energy source ON. 3. Remove the padlock from the branch circuit protection on the ElectroGuard® Power Panel or the upstream customer-supplied branch circuit protection feeding electrical energy to the SIS. 4. If the SIS includes the Communication Module, remove the padlock from the source feeding electrical energy to the module and restore the supply voltage. Close the ElectroGuard® Power Panel door and secure the cover fasteners. 5. Turn the branch circuit protection operating handle to the ON position. 6. Remove the padlock from the RLS. 7. Press the System ON push button. 8. Perform recommissioning of the system. 9. Follow proper start-up procedures to restart the machine or process. Publication 2030-UM003A-EN-P - May 2006 Replacement Procedures 6-59 Notes: Publication 2030-UM003A-EN-P - May 2006 6-60 Replacement Procedures Publication 2030-UM003A-EN-P - May 2006 Appendix A Cat. No. Explanation Section Page Bulletin 2031 Non-Combination Systems (23…85 A) A-2 Bulletin 2031 Non-Combination Systems (110…1200 A) A-3 Bulletin 2032 Combination Systems with Fusible Disconnect (23…85 A) A-4 Bulletin 2032 Combination Systems with Fusible Disconnect (110…1200 A) A-5 Bulletin 2033 Combination Systems with Thermal-Magnetic Circuit Breaker (23…85 A) A-6 Bulletin 2033 Combination Systems with Thermal-Magnetic Circuit Breaker (110…1200 A) A-7 Bulletin 2030 Remote Lockout Station A-8 Bulletin 2030 Expansion Module A-8 Bulletin 2030 Pneumatic Isolation Module A-9 Bulletin 2030 Control Module A-9 IMPORTANT 1 This information is presented only as an aid to understanding cat. nos. It is not to be used to build cat. nos. for the ElectroGuard® system or its components. Publication 2030-UM003A-EN-P - May 2006 A-2 Cat. No. Explanation Bulletin 2031 Non-Combination Systems (23…85 A) 2031 – A 0085 A B – 1PN Bulletin No. Code 2031 Factory-Installed Options Description Non-combination system Code Construction Code Code A Standard, North America M MCC*, 600 A Line Side Bus and Load Side Power Cables, North America S MCC*, 1200 A Line Side Bus and Load Side Power Cables, North America F MCC*, Line Side Power Cables and 600 A Load Side Bus, North America B MCC*, Line Side Power Cables and 1200 A Load Side Bus, North America C Standard, outside North America E Description Control Module with factory set 30-second Time Delay Safety Isolation System to be supplied 1PN “Pneumatic-ready” Communication Module Options (Select Only One) 1 Flex I/O Module 1COM (16 points of Remote I/O) 2 Flex I/O Module 2COM (32 points of Remote I/O) 3 Flex I/O Module 3COM (48 points of Remote I/O) 1DNET 1 DeviceNet Modules (16 points of I/O) 2DNET 2 DeviceNet Modules (32 points of I/O) 3DNET 3 DeviceNet Modules (48 points of I/O) Cover-mounted Meter Options 1AM Single-phase ammeter 3AM Three-phase ammeter 1TD Description 1VM 3VM Single-phase voltmeter Three-phase voltmeter MCC*, 600 A Line Side Bus and Load Side Power Cables, outside North America D MCC*, 1200 A Line Side Bus and Load Side Power Cables, outside North America H MCC*, Line Side Power Cables and 600 A Load Side Bus, outside North America R Input Line Voltage MCC*, Line Side Power Cables and 1200 A Load Side Bus, outside North America * Bus Type: Copper with tin plating Code A B C G H M N Ratings Ampere Rating (AC-3) 3-Phase Max. Hp Rating (60 Hz) 3-Phase Max. kW Rating (50 Hz) 200V 230V 460V 460V 230V 400V 500V 600V 0023 5 7.5 15 15 7.5 11 11 11 0043 10 15 30 30 13 22 22 22 0085 25 30 60 60 25 45 45 45 Publication 2030-UM003A-EN-P - May 2006 Description 240V 60Hz / 220V 50Hz, 3-phase 480V 60Hz / 440V 50Hz, 3-phase 60V 60Hz / 550V 50Hz, 3-phase 400…415V 50Hz, 3-phase 208V / 60Hz, 3-phase 500V 50Hz, 3-phase 380…400V 50Hz, 3-phase Enclosure Type Code A C F H J P W Description Type 1 General Purpose Type 4X Water-Tight Stainless Steel Type 4 Water Tight Painted Steel IP54 Type 12 Dust Tight IP30 IP65 Cat. No. Explanation A-3 Bulletin 2031 Non-Combination Systems (110…1200 A) 2031 – T 2031 Description Represents a non-combination system (i.e. one without a disconnecting means or branch circuit protection). 0420 Code B T Description No need to specify on 110…420 A Systems Bottom Feed for 630…1200 A Systems Top Feed for 630…1200 A Systems Construction Code Code A B C D E F H M Description Free-Standing Enclosure design for North America Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Free-standing Enclosure design for outside of North America Motor Control Center enclosure for outside of North America with 1200 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for outside of North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* B – 1PN Enclosure Type Code C F H J W Description Type 4X Water Tight Stainless Steel Type 4 Water Tight Painted Steel IP54 Type 12 Dust Tight IP65 Ratings Ampere Rating (AC-3) 0110 0180 0210 0300 0420 0630 0860 1200 3-Phase Max. Hp rating 3-Phase Max. kW rating (60Hz) (50 Hz) 200V 230V 460V 575V 230V 400V 500V 600V 40 40 74 100 32 55 63 100 50 60 150 150 55 90 110 160 60 75 200 63 110 150 200 100 125 250 300 90 160 200 300 150 175 350 400 132 220 300 425 200 250 500 600 200 355 450 500 250 300 600 700 250 500 560 600 450 450 900 900 391 710 888 1043 Input Line Voltage Code A B C G H M N Description 240V 60Hz / 220V 50Hz 480V 60Hz / 440V 50Hz 60V 60Hz / 550V 50Hz 400…415V 50Hz 208V / 60Hz 500V 50Hz 380…400V 50Hz Motor Control Center enclosure for North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Motor Control Center enclosure for North America S with 1200 A Line Side Incoming Bus* and Outgoing Power Cables * Bus Type: Copper with tin plating. R A Input Power Feed Bulletin No. Code H Factory-Installed Options Code 1AM 3AM 1COM 2COM 1CNET 2CNET 1DNET 2DNET 1ENET 2ENET 1 PNET 2 PNET 1EUF* 2EUF** Description Single-phase ammeter 3-phase ammeter One Flex I/O Module (16 points of I/O) Two Flex I/O Modules (32 points of I/O) One ControlNet Module Two ControlNet Modules One DeviceNet Module (16 points of I/O) Two DeviceNet Modules (32 points of I/O) One EtherNet Module Two EtherNet Modules One Profibus Module Two Profibus Modules One 4-port Expansion Module installed in the ElectroGuard® Power Panel Two 4-port Expansion Modules installed in the ElectroGuard® Power Panel One 4-port Expansion Module with adjustable 1…30 second time delay, installed in the 1EUFTDA* ElectroGuard® Power Panel 2EUFTDA** Two 4-port Expansion Modules with 1…30 second time delay, installed in the ElectroGuard® Power Panel 1EUT* One 10-port Expansion Module installed in the ElectroGuard® Power Panel 2EUT** Two 10-port Expansion Modules installed in the ElectroGuard® Power Panel 1EUTTDA* One 10-port Expansion Module with 1…30 second time delay, installed in the ElectroGuard® Power Panel 2EUTTDA** Two 10-port Expansion Modules with 1…30 second time delay, installed in the ElectroGuard® Power Panel 1PN Safety Isolation System to be supplied “Pneumatic ready” 1TD Control Module with factory-set 30 second time delay 1VM Single-phase voltmeter 3VM 3-phase voltmeter * 110…420 A ElectroGuard® maximum of one Expansion Module ** 630…1200 A ElectroGuard® maximum of two Expansion Modules Publication 2030-UM003A-EN-P - May 2006 A-4 Cat. No. Explanation Bulletin 2032 Combination Systems with Fusible Disconnect (23…85 A) 2032 – A 0085 A B – 26J – 1PN Bulletin No. Code 2032 Description Combination system with a fusible disconnect switch as the disconnect/branch circuit protection Factory-Installed Options Code Ratings Ampere Rating (AC-3) 0023 0043 0085 3-Phase Max. Hp Rating 3-Phase Max. kW Rating (60 Hz) (50 Hz) 200V 230V 460V 575V 230V 400V 500V 600V 5 7.5 15 15 5.5 11 11 11 10 15 30 30 11 22 22 22 25 30 60 60 22 45 45 45 Construction Code Code A B C D E F H M R S Description Free-Standing Enclosure design for North America Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Free-standing Enclosure design for outside of North America Motor Control Center enclosure for outside of North America with 1200 A Line Side Incoming Bus* and Outgoing Power Cables Enclosure Type Code C F H J W Description Type 4X Water Tight Stainless Steel Type 4 Water Tight Painted Steel IP54 Type 12 Dust Tight IP65 Motor Control Center enclosure for outside of North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* Motor Control Center enclosure for North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Motor Control Center enclosure for North America with 1200 A Line Side Incoming Bus* and Outgoing Power Cables Input Line Voltage Code A B C G H M N Description 240V 60 Hz/220V 50 Hz, 3phase 480V 60 Hz/440V 50 Hz, 3phase 600V 60 Hz/550V 50 Hz, 3phase 400…415V 50 Hz, 3phase 208V 60 Hz, 3phase 500V 50 Hz, 3phase 380…400V 50 Hz, 3phase * Bus Type: Copper with tin plating. Fuse Clip Rating/Type Code Description 24J 30 A, Class J-type fuses 25J 60 A, Class J-type fuses 26J 100 A, Class J-type fuses 27J 200 A, Class J-type fuses Note: Power fuses are not included with the disconnect switch. Publication 2030-UM003A-EN-P - May 2006 1TD Description Control Module with factory set 30-second time delay Safety Isolation System to be supplied “Pneumatic-ready” Communication Module Options 1COM 1 Flex I/O Module (16-points of I/O) 2COM 2 Flex I/O Modules (32-points of I/O) 1CNET 1 ControlNet Module 2CNET 2 ControlNet Modules 1DNET 1 DeviceNet Module (16-points of I/O) 2DNET 2 DeviceNet Modules (32-points of I/O) 1ENET 1 EtherNet Module 2ENET 2 EtherNet Modules 1PNET 1 Profibus Module 2PNET 2 Profibus Modules Cover-mounted Meter Options 1AM Single-phase ammeter 3AM Three-phase ammeter Expansion Module Options One 4-Port Expansion Module installed in 1EUF* the ElectroGuard® power Panel Two 4-Port Expansion Modules installed in 2EUF** the ElectroGuard® Power Panel One-4-Port Expansion Module with 1EUFTDA* adjustable 1-30 second time delay, installed in the ElectroGuard® Power Panel Two 4-Port Expansion Modules with 1-30 2EUFTDA** second time delay, installed in the ElectroGuard® Power Panel One 10-Port Expansion Module installed in 1EUT* the ElectroGuard® Power Panel Two 10-Port Expansion Modules installed in 2EUT** the ElectroGuard® Power Panel One 10-Port Expansion Module with 1-30 1EUTTDA* second time delay, installed in the ElectroGuard® Power Panel Two 10-Port Expansion Modules with 1-30 2EUTTDA** second time delay, installed in the ElectroGuard® Power Panel * 110…420 A ElectroGuard® maximum of one Expansion Module ** 630…1200 A ElectroGuard® maximum of two Expansion Modules 1PN Cat. No. Explanation A-5 Bulletin 2032 Combination Systems with Fusible Disconnect (110…1200 A) 2032 – T 2032 0420 A B – 29J – 1PN Input Power Feed Bulletin No. Code H Description Represents a combination system with a fusible disconnect switch as the disconnecting / branch circuit protection means. Code B T Description No need to specify on 110…420 A Systems Bottom Feed for 630…1200 A Systems Top Feed for 630…1200 A Systems Enclosure Type Code C F H J W Description Type 4X Water Tight Stainless Steel Type 4 Water Tight Painted Steel IP54 Type 12 Dust Tight IP65 Construction Code Code A B C D E F H M R S Description Free-standing enclosure design for North America without power bussing Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Free-standing enclosure design for outside of North America Motor Control Center enclosure for outside of North America with 1200 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for outside of North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* Motor Control Center enclosure for North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Motor Control Center enclosure for North America with 1200 A Line Side Incoming Bus* and Outgoing Power Cables * Bus Type: Copper with tin plating. Fuse Clip Rating / Type Code 27B 27D 27J 28D 29B 29D 29J 30B 30D 30L 31B 31D 32B 34L Description 200 A BS88 160 A DIN 200 A Class J 250 A DIN 400 A BS88 400 A DIN 400 A Class J 600 A BS88 630 A DIN 800 A Class L 800 A BS88 1600 A DIN 1250 A BS88 2000 A Class L Ratings Ampere Rating (AC-3) 0110 0180 0210 0300 0420 0630 0860 1200 3-Phase Max. Hp rating 3-Phase Max. kW rating (60Hz) (50 Hz) 200V 230V 460V 575V 230V 400V 500V 600V 40 40 74 100 32 55 63 100 50 60 150 150 55 90 110 160 60 75 200 63 110 150 200 100 125 250 300 90 160 200 300 150 175 350 400 132 220 300 425 200 250 500 600 200 355 450 500 250 300 600 700 250 500 560 600 450 450 900 900 391 710 888 1043 Input Line Voltage Code A B C G H M N Description 240V 60Hz / 220V 50Hz 480V 60Hz / 440V 50Hz 60V 60Hz / 550V 50Hz 400…415V 50Hz 208V / 60Hz 500V 50Hz 380…400V 50Hz Factory-Installed Options Code 1AM 3AM 1COM 2COM 1CNET 2CNET 1DNET 2DNET 1ENET 2ENET 1PNET 2PNET 1EUF* 2EUF** Description Single-phase ammeter 3-phase ammeter One Remote I/O Module (16 points of I/O) Two Remote I/O Modules (32 points of I/O) One ControlNet Module Two ControlNet Modules One DeviceNet Module (16 points of I/O) Two DeviceNet Modules (32 points of I/O) One EtherNet Module Two Ethernet Modules One Profibus Module Two Profibus Modules One 4-port Expansion Module installed in the ElectroGuard® Power Panel Two 4-port Expansion Modules installed in the ElectroGuard® Power Panel One 4-port Expansion Module with adjustable 1…30 second time delay, installed in the ElectroGuard® Power Panel Two 4-port Expansion Modules with adjustable 1…30 second time delay, installed in the 2EUFTDA** ElectroGuard® Power Panel 1EUT* One 10-port Expansion Module installed in the ElectroGuard® Power Panel 2EUT** Two 10-port Expansion Modules installed in the ElectroGuard® Power Panel One 10-port Expansion Module with adjustable 1-30 second time delay, installed in the 1EUTTDA* ElectroGuard® Power Panel 1EUFTDA* Two 10-port Expansion Modules with adjustable 1…30 second time delay, installed in the ElectroGuard® Power Panel 1PN Safety Isolation System to be supplied “pneumatic ready” 1TD Control Module with factory-set 30-second time delay 1VM Single-phase voltmeter 3VM 3-phase voltmeter * 110…420 A ElectroGuard® maximum of one internal Expansion Module ** 630…1200 A ElectroGuard® maximum of two internal Expansion Modules 2EUTTDA** Publication 2030-UM003A-EN-P - May 2006 A-6 Cat. No. Explanation Bulletin 2033 Combination Systems with Thermal-Magnetic Circuit Breaker (23…85 A) 2033 – A 0085 A B – 46 – 1PN Factory-Installed Options Bulletin No. Code 2033 Description Combination system with a thermal-magnetic circuit breaker as the disconnect/ branch circuit protection Code Ratings Ampere Rating (AC-3) 0023 0043 0085 3-Phase Max. Hp Rating 3-Phase Max. kW Rating (60 Hz) (50 Hz) 200V 230V 460V 575V 230V 400V 500V 600V 5 7.5 15 15 7.5 11 11 11 10 15 30 30 13 22 22 22 25 30 60 60 25 45 45 45 Construction Code Code A B C D E F H M 1TD Description Free-Standing Enclosure design for North America Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Free-standing Enclosure design for outside of North America Motor Control Center enclosure for outside of North America with 1200 A Line Side Incoming Bus* and Outgoing Power Cables Enclosure Type Code C F H J W Description Type 4X Water Tight Stainless Steel Type 4 Water Tight Painted Steel IP54 Type 12 Dust Tight IP65 Motor Control Center enclosure for outside of North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* Motor Control Center enclosure for North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Motor Control Center enclosure for North America S with 1200 A Line Side Incoming Bus* and Outgoing Power Cables * Bus Type: Copper with tin plating. R Publication 2030-UM003A-EN-P - May 2006 Input Line Voltage Code A B C G H M N Description 240V 60 Hz/220V 50 Hz, 3-phase 480V 60 Hz/440V 50 Hz, 3-phase 600V 60 Hz/550V 50 Hz, 3-phase 400…415V 50 Hz, 3-phase 208V 60 Hz, 3-phase 500V 50 Hz, 3-phase 380…400V 50 Hz, 3-phase Circuit Breaker Hp/kW Rating Code 39 40 41 42 43 44 45 46 47 48 — Description 5 Hp 7.5 Hp 10 Hp 15 Hp 20 Hp 25 Hp 30 Hp 40 Hp 50 Hp 60 Hp — Code 39K 40K 41K 42K 43K 44K 46K 47K 48K 49K 50K Description 4 kW 5.5 kW 7.5 kW 11 kW 13 kW 15 kW 22 kW 25 kW 32 kW 37 kW 45 kW Description Control Module with factory set 30-second time delay Safety Isolation System to be supplied “Pneumatic-ready” Communication Module Options 1COM 1 Flex I/O Module (16-points of I/O) 2COM 2 Flex I/O Modules (32-points of I/O) 1CNET 1 ControlNet Module 2CNET 2 ControlNet Modules 1DNET 1 DeviceNet Module (16-points of I/O) 2DNET 2 DeviceNet Modules (32-points of I/O) 1ENET 1 EtherNet Module 2ENET 2 EtherNet Modules 1PNET 1 Profibus Module 2PNET 2 Profibus Modules Cover-mounted Meter Options 1AM Single-phase ammeter 3AM Three-phase ammeter Expansion Module Options One 4-Port Expansion Module installed in 1EUF* the ElectroGuard® Power Panel Two 4-Port Expansion Modules installed in 2EUF** the ElectroGuard® Power Panel One-4-Port Expansion Module with adjustable 1…30 second time delay, 1EUFTDA* installed in the ElectroGuard® Power Panel 1PN Two 4-Port Expansion Modules with 2EUFTDA** 1…30 second time delay, installed in the ElectroGuard® Power Panel One 10-Port Expansion Module installed 1EUT* in the ElectroGuard® Power Panel Two 10-Port Expansion Modules installed 2EUT** in the ElectroGuard® Power Panel One 10-Port Expansion Module with 1-30 1EUTTDA* second time delay, installed in the ElectroGuard® Power Panel Two 10-Port Expansion Modules with 1-30 2EUTTDA** second time delay, installed in the ElectroGuard® Power Panel * 110…420 A ElectroGuard® maximum of one Expansion Module ** 630…1200 A ElectroGuard® maximum of two Expansion Modules Cat. No. Explanation A-7 Bulletin 2033 Combination Systems with Thermal-Magnetic Circuit Breaker (110…1200 A) 2033 – T 2033 0300 A Input Power Feed Bulletin No. Code H Code Description Represents a combination system with a thermal-magnetic circuit breaker as the disconnecting / branch circuit protection means. B T B – 56 – 1PN Enclosure Type Description No need to specify on 110…420 A Systems Bottom Feed for 630…1200 A Systems Top Feed for 630…1200 A Systems Code C F H J W Description Type 4X Water Tight Stainless Steel Type 4 Water Tight Painted Steel IP54 Type 12 Dust Tight IP65 Construction Code Code Description A Wall mount enclosure design for North America Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Wall mount enclosure design for outside of North America Motor Control Center enclosure for outside of North America with 1200 A Line Side Incoming Bus* and Outgoing Power Cables B C D E F H M Motor Control Center enclosure for outside of North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* Motor Control Center enclosure for outside of North America with Line Side Incoming Power Cables and 600 A Load Side Outgoing Bus* 0110 0180 0210 0300 0420 0630 0860 1200 Circuit Breaker Hp/kW Rating Description 30 Hp 40 Hp 50 Hp 60 Hp 32 kW 75 Hp 37 kW 45 kW 125 Hp 55 kW 150 Hp 63 kW 175 Hp 75 kW 200 Hp 90 kW Code 55K 56 56K 57 57K 58 58K 59 59K 60 60K 61 61K 62 62K 63 Description 100 kW 250 Hp 110 kW 300 Hp 132 kW 350 Hp 150 kW 400 Hp 160 kW 450 Hp 185 kW 500 Hp 200 kW 600 Hp 220 kW 700 Hp Code 63K 64K 65K 66 66K 67K 68K 69K 70K 71K 72K 73K 74K 75K 76K 3-Phase Max. Hp rating (60Hz) 3-Phase Max. kW rating (50 Hz) 200V 230V 460V 575V 230V 400V 500V 600V 40 40 74 100 32 55 63 100 50 60 150 150 55 90 110 160 60 75 200 63 110 150 200 100 125 250 300 90 160 200 300 150 175 350 400 132 220 300 425 200 250 500 600 200 355 450 500 250 300 600 700 250 500 560 600 450 450 900 900 391 710 888 1043 Code A B C G H M N Description 240V 60Hz / 220V 50Hz 480V 60Hz / 440V 50Hz 60V 60Hz / 550V 50Hz 400…415V 50Hz 208V / 60Hz 500V 50Hz 380…400V 50Hz Factory-Installed Options Motor Control Center enclosure for North America with 600 A Line Side Incoming Bus* and Outgoing Power Cables Motor Control Center enclosure for outside of North R America with Line Side Incoming Power Cables and 1200 A Load Side Outgoing Bus* Motor Control Center enclosure for North America S with 1200 A Line Side Incoming Bus* and Outgoing Power Cables * Bus Type: Copper with tin plating Code 45 46 47 48 48K 49 49K 50K 51 51K 52 52K 53 53K 54 54K Input Line Voltage Ratings Ampere Rating (AC-3) Description 250 kW 300 kW 355 kW 900 Hp 390 kW 425 kW 450 kW 500 kW 560 kW 600 kW 710 kW 750 kW 850 kW 888 kW 1043 kW Code 1AM 3AM 1COM 2COM 1CNET 2CNET 1DNET 2DNET 1ENET 2ENET 1PNET 2PNET 1EUF* 2EUF** 1EUFTDA* 2EUFTDA** 1EUT* 2EUT** 1EUTTDA* 2EUTTDA** 1PN 1TD 1VM Description Single-phase ammeter 3-phase ammeter One Remote I/O Module (16 points of I/O) (85 A frame) Two Remote I/O Modules (32 points of I/O) (1200 A frame) One ControlNet Module Two ControlNet Modules One DeviceNet Module (16 points of I/O) Two DeviceNet Modules (32 points of I/O) One EtherNet Module Two EtherNet Modules One Profibus Module Two Profibus Modules One 4-port Expansion Module installed in the ElectroGuard® Power Panel Two 4-port Expansion Modules installed in the ElectroGuard® Power Panel One 4-port Expansion Module with adjustable 1…30 second time delay, installed in the ElectroGuard® Power Panel Two 4-port Expansion Modules with adjustable 1…30 second time delay, installed in the ElectroGuard® Power Panel One 10-port Expansion Module installed in the ElectroGuard® Power Panel Two 10-port Expansion Modules installed in the ElectroGuard® Power Panel One 10-port Expansion Module with adjustable 1…30 second time delay, installed in the ElectroGuard® Power Panel Two 10-port Expansion Modules with adjustable 1…30 second time delay, installed in the ElectroGuard® Power Panel Safety Isolation System to be supplied “pneumatic ready” Control Module with factory-set 30-second time delay Single-phase voltmeter 3VM 3-phase voltmeter * 110…420 A ElectroGuard® maximum of one internal Expansion Module ** 630…1200 A ElectroGuard® maximum of two internal Expansion Modules Publication 2030-UM003A-EN-P - May 2006 A-8 Cat. No. Explanation Bulletin 2030 Remote Lockout Station 2030 – RLS Bulletin No. Description Remote lockout station Code Description Type 4X Water Tight Stainless Steel Type 4 Water Tight Painted Steel IP54 Type 12 Dust Tight IP65 C F H J W W D System Isolated Light Color Enclosure Type Product Descriptor Code RLS J Code G W Dual RLS Color Green White Bulletin 2030 Expansion Module 2030 – EU Bulletin No. Product Descriptor Code EU Description Expansion Module N F – 1TD Enclosure Type Code C F H J N W Description Type 4X Water Tight Stainless Steel Type 4 Water Tight Painted Steel IP54 Type 12 Dust Tight Open Type IP65 “System Isolated” Light Color Factory-Installed Options Code F T 1COM Description Four-port Ten-port Code 1CNET 1DNET 1ENET 1PNET 1TD Publication 2030-UM003A-EN-P - May 2006 Description One Flex I/O Module (16 points of I/O) One ControlNet Module One DeviceNet Module (16 points of I/O) One EtherNet Module One Profibus Module Expansion Module with factory set 30 second time delay Cat. No. Explanation A-9 Bulletin 2030 Pneumatic Isolation Module 2030 – P Bulletin No. Product Descriptor Code P J 120 1 Pressure Range Enclosure Type Description Pneumatic isolation Module Code C F H J W Description Type 4X Water Tight Stainless Steel Type 4 Water Tight Painted Steel Code 120 007 Port Size Description 30…120 psi 2…7 bar IP54 Type 12 Dust Tight IP65 Code Description CFM at 90 PSI 1 2 3 4 6 1 in. 1/2 in. 3/4 in. 1 in. 1-1/2 in. 380 160 380 650 1750 Bulletin 2030 Control Module 2030 – CH1200 Bulletin No. Product Descriptor Code CH1200 CH0085 Input Line Voltage Description 110…1200 A Control Module 23…85 A Control Module 220…240V 50…60 Hz 440…480V 50…60 Hz 550…600V 50…60 Hz 400…415V 50 Hz 208V 60 Hz 500V 50 Hz 380…400V 50 Hz 1TD Input Line Voltage Code A Factory-Installed Options Code 1TD 1PN Description Time Delay Pneumatic Ready B C G H M N Bulletin 2030 Verification Module 2030 – VM Bulletin No. C Enclosure Type Product Description Code VM Description Verification Module Code C J Description Type 4X Stainless Steel Type 12 Dust Tight Publication 2030-UM003A-EN-P - May 2006 A-10 Cat. No. Explanation Notes: Publication 2030-UM003A-EN-P - May 2006 Appendix B Specifications Table B.1 Specifications Power Panel Line/Load Specifications Terminals L1, L2, L3, T1, T2, T3, PE, & ISOLATED GND Rated Insulation Voltage 208…600V AC, see catalog number explanation Rated Operating Voltage 208…600V AC, see catalog number explanation Rated Operating Voltage Range -15%, +10% of rated voltage Rated Operating Current 0…1200 A, see catalog explanation Rated Operating Frequency 50/60 Hz, see catalog explanation Rated Operating Frequency Range 47…62 Hz, see catalog explanation Numbers of poles 3 Application 3 phase Dielectric Withstand 2,200V AC Utilization Category AC 3 Power Contactor operational life (isolating and ground) 2,000,000 operations (approximate) Control Module Specifications RLS Terminals 23...85 A models include RLS1, RLS2, RLS3, RLS4, 110...1200 A models also include RLS5 and RLS6. 23...85 A support 4 directly connected Remote Lockout Stations; 110...1200 A models support 6 directly connected Remote Lockout Stations Supports up to 40 (23...85 A) and 60 (110...1200 A) Remote Lockout Stations with the use of Expansion Modules I/O Terminals IP2 system status HP1, HP2 optional Pneumatic Module IP1 signal from optional power panel time delay IP4 & ZB signal from optional Expansion Module time delay HV voltage monitor IP3 interconnections FB1, FB2 (110…1200 A only) Contact Closure, 1 A @ 120V Construction 1 Factory sealed. Viewing window for visual verification of status indicating lights. NEMA Type 0 Publication 2030-UM003A-EN-P - May 2006 B-2 Specifications Table B.1 Specifications (Continued) Remote Lockout Station Specifications Terminals 1, 2, 3, 4, 6, 7, 8, 9, GND Control Voltage 24V DC Construction Top and bottom 25.4 mm (1 in.) conduit entry holes, with hole seal in top entry hole and removable plug in bottom entry hole. Provision for tamper-indicating seal. Operating handles accept up to three padlocks Operating Handle Operation Life 200,000 operations Expansion Module Specifications Terminals (11-pin pluggable connectors) RLS_A…D for 4 port modules RLS_A…J for 10 port modules PLC1EXB, PLC2EXB, EXB Control Voltage 24V DC Construction Factory sealed. Viewing window for visual verification of status indicating lights. Pneumatic Isolation Module Specifications Terminals Air inlet, air outlet, and HC (24 pin) Control Voltage 120V AC Rated Pneumatic Range 30…120 psi (2…7 bar) Environmental Operating Temperature Range 0…40C (32…104F) Storage and transportation temperature range –20…+75C (–4…+167°F) Altitude 2,000 m (6,560 ft) Environmental Rating NEMA Type 1, 12, 4, 4X, or IP30, IP54, and IP65 (See catalog explanation) Enclosure Styles Wall mounted, floor standing, motor control center, or other available as a custom (See catalog explanation) Humidity 5…95% (non-condensing) Cooling NEMA Type 1 and 12 fan cooled, NEMA Type 4 and 4X vortex tube, or air conditioner cooled Approximate Dimensions Refer to Chapter 2, Table 2.1 and Table 2.2, pages 2-5 and 2-6, respectively. Also refer to Figure 2.3 on page 2-5 through Figure 2.20 on page 2-24. Publication 2030-UM003A-EN-P - May 2006 Specifications Standards and Certifications - Conformity to Industry Standards B-3 UL508A with cUL listing, Industrial Control Panel TUV Rheinland certified to EN954-1 Category 4 TUV Rheinland certified to EN60204-1 Designed to conform to OSHA for control of hazardous energy CE (2030-VM* and 2030-RLS**D excluded) Publication 2030-UM003A-EN-P - May 2006 B-4 Specifications Notes: Publication 2030-UM003A-EN-P - May 2006 Appendix C Sample Calculations of Remote Lockout Station Total Cable Length IMPORTANT Scenario 1 It is important not to exceed the maximum cable length values shown in Table 2.13 on page 2-63. If the maximum values are exceeded, this may result in an unreliable signal. Consider using an optional Expansion Module if cable lengths greater than those shown for the cable length to the Control Module are needed (see Installation and Wiring of the ElectroGuard® Remote Lockout Station(s) on page 2-56). An application will require two RLSs. The cable length from RLS 1 to the Control Module (in the ElectroGuard® Power Panel) will be 5,000 ft. The cable length from RLS 2 to the Control Module will be 10,000 ft. #14 AWG cable will be used to connect the RLSs to the Control Module (see Figure C.1). Figure C.1 Power Panel RLS #1 ALLEN-BRADLEY SYSTEM ISOLATED Control Module 5,000 ft. 10,000 ft. RLS #2 ALLEN-BRADLEY SYSTEM ISOLATED PILOT LIGHT PILOT LIGHT PHENOLIC NAMEPLATE PHENOLIC NAMEPLATE Analysis The total cable length for the two RLSs is: 10,000 ft.+ 5,000 ft. = 15,000 ft. 1 Publication 2030-UM003A-EN-P - May 2006 C-2 Sample Calculations of Remote Lockout Station Total Cable Length The maximum allowable cable length for #14 AWG cable is 19,500 ft. for the RLSs to be connected to the Control Module. This installation will be within the maximum cable length permitted. (Install jumpers between connection points 3 and 8, and between connection points 4 and 9 of all unused RLS connectors on the Control Module.) Scenario 2 An application will require eight RLSs: From RLS 1 to the Control Module (in the ElectroGuard® Power Panel): cable length = 500 ft. RLS 2 to the Control Module: cable length = 1,000 ft. RLS 3 to the Control Module: cable length = 2,000 ft. RLS 4 to the Control Module: cable length = 3,000 ft. RLS 5 to the Control Module: cable length = 5,000 ft. RLS 6 to the Expansion Module: cable length = 750 ft. RLS 7 to the Expansion Module: cable length = 850 ft. RLS 8 to the Expansion Module: cable length = 1,000 ft. #14 AWG cable will be used to connect the RLSs to the Control Module and the Expansion Module (see Figure C.2). Figure C.2 RLS #6 RLS #7 RLS #8 ALLEN-BRADLEY SYSTEM ISOLATED 1,000 ft. 850 ft. PILOT LIGHT 750 ft. PILOT LIGHT ALLEN-BRADLEY SYSTEM ISOLATED ALLEN-BRADLEY SYSTEM ISOLATED PHENOLIC NAMEPLATE PHENOLIC NAMEPLATE PILOT LIGHT RLS #5 PHENOLIC NAMEPLATE ALLEN-BRADLEY SYSTEM ISOLATED RLS #3 RLS #2 ALLEN-BRADLEY Expansion Module RLS #1 PILOT LIGHT PHENOLIC NAMEPLATE RLS #4 ALLEN-BRADLEY SYSTEM ISOLATED PILOT LIGHT SYSTEM ISOLATED ALLEN-BRADLEY PILOT LIGHT PHENOLIC NAMEPLATE ALLEN-BRADLEY SYSTEM ISOLATED SYSTEM ISOLATED Control Module PHENOLIC NAMEPLATE PILOT LIGHT PHENOLIC NAMEPLATE PILOT LIGHT PHENOLIC NAMEPLATE 5,000 ft. 2,000 ft. Publication 2030-UM003A-EN-P - May 2006 1,000 ft. 500 ft. SIS 3,000 ft. Sample Calculations of Remote Lockout Station Total Cable Length C-3 Analysis Calculations for this scenario may be different, depending on your model. 110...1200 A The Control Module furnished with the SIS 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. Therefore, wire five of the RLS directly to the Control Module, and three of the RLS to the Expansion Module. The total wire length for the five (5) RLS to be wired to the Control Module will be 500 ft. + 1,000 ft. + 2,000 ft. + 3,000 ft. + 5,000 ft. = 11,500 ft. The maximum allowable wire length for #14 AWG wire is 19,500 ft. for the RLS to be wired to the Control Module. This portion of the installation will be within the maximum wire length permitted. Next, check the wire length calculation for the RLSs to be wired to the Expansion Module. For RLS # 6: wire length = 750 ft. For RLS # 7: wire length = 850 ft. For RLS # 8: wire length = 1,000 ft. The total wire length for the three RLSs to be wired to the Expansion Module will be 750 ft. + 850 ft. + 1,000 ft. = 2,600 ft. The maximum allowable wire length for #14 AWG wire is 19,500 ft. for the RLSs to be wired to the Expansion Module. This portion of the installation will also be within the maximum wire length permitted. (Install jumpers between pins 3 and 8, and between pins 4 and 9 of all unused RLS connectors on the Expansion Module. See Chapter 2 in the User Manual for details.) 23...85 A The Control Module furnished with the ElectroGuard® is capable of supporting a maximum of four RLSs. Since this installation will require eight RLSs, an optional 10-port Expansion Module will also be used. The Expansion Module will be connected to the Control Module and will take the place of one of the original four RLSs. The cable length from the Control Module to the Expansion Module must also be considered when estimating maximum cable length for the Control Module. Therefore, connect three of the RLSs directly to the Control Module, and five of the RLSs to the Publication 2030-UM003A-EN-P - May 2006 C-4 Sample Calculations of Remote Lockout Station Total Cable Length Expansion Module. The Expansion Module is mounted 500 ft. away from the Control Module. The total cable length for the three RLSs and the Expansion Module to be connected to the Control Module will be: 500 ft. + 1,000 ft. + 2,000 ft. + 500 ft. = 4,000 ft. The maximum allowable cable length for #14 AWG cable is 19,500 ft. for the RLSs and the Expansion Module to be connected to the Control Module. This portion of the installation will be within the maximum cable length permitted. Next, check the cable length for the RLSs to be connected to the Expansion Module. The total cable length for the five RLSs to be connected to the Expansion Module will be: 3,000 ft. + 5,000 ft. + 750 ft. + 850 ft. + 1,000 ft. = 10,600 ft. The maximum allowable cable length for #14 AWG cable is 19,500 ft. for the RLSs to be connected to the Expansion Module. This portion of the installation will also be within the maximum cable length permitted. Publication 2030-UM003A-EN-P - May 2006 Appendix D Expansion Module Target Table The Control Module in the ElectroGuard® Power Panel can accept four to six RLSs. When more RLSs are required for the application than the central module can hold, an expansion module can be used to accommodate the additional RLSs. Table D.1 Maximum # of RLS Units 1 Expansion Units 23…85 A 110…1200 A None 4 6 1…4 Port 7 9 1…10 Port 13 15 1…10 Port 1…4 Port 16 18 2…10 Port 22 24 2…10 Port 1…4 Port 25 27 3…10 Port 31 33 3…10 Port 1…4 Port 34 36 4…10 Port 40 42 4…10 Port 1…4 Port — 45 5…10 Port — 51 5…10 Port 1…4 Port — 54 6…10 Port — 60 Publication 2030-UM003A-EN-P - May 2006 D-2 Expansion Module Target Table Notes: Publication 2030-UM003A-EN-P - May 2006 Appendix E Replacement Parts Section General Replacement Parts for the ElectroGuard® Power Panel Replacement Control Modules Replacement Remote Lockout Station System Isolated Light LED Lamps Replacement Remote Lockout Station Load Switch Assemblies General ATTENTION Page E-1 E-2 E-9 E-10 E-10 Hazardous voltage or other forms of energy could be present. To avoid serious injury or death: ! Prior to beginning the installation and wiring process, make sure that all forms of energy to the installation site have been properly turned OFF and locked out. ATTENTION ElectroGuard® system modules are factory sealed with a tamper-indicating seal. Altering, defeating, or bypassing any module or component of the Safety Isolation System may result in personal injury, death, property damage, or economic loss. Only qualified service technicians must perform service or maintenance. Resealing of the modules is the responsibility of the person or organization performing the service or maintenance. ! ATTENTION ! Only qualified service technicians familiar with the ElectroGuard® and associated machinery should plan or implement the installation, commissioning, and subsequent maintenance of the system. Failure to do this may result in personal injury and/or equipment damage. With the exception of some basic components in the ElectroGuard® Power Panel, replacement parts for the SIS are limited to complete modules. See Chapter 4, Troubleshooting, in order to identify the specific module or component that should be replaced, and Chapter 6, Replacement Procedures, for information on how to replace the component or module. The ElectroGuard® Power Panel is the only portion of the SIS that has component replacement parts available, as shown in Tables E.1 … E.10. 1 Publication 2030-UM003A-EN-P - May 2006 E-2 Replacement Parts Replacement Parts for the ElectroGuard® Power Panel Table E.1 Replacement Power Contactors (Isolation or Grounding) System Rating Part Number 23 A 100S-C23D23C contactor 100-SA20 auxiliary contact blocks 100-MCA02 mechanical interlock 43 A 100S-C43D22C contactor 100-SA20 auxiliary contact blocks 100-MCA02 mechanical interlock 85 A 100S-C85D22C contactor 100-SA20 auxiliary contact blocks 100-MCA02 mechanical interlock 110 A 100S-D110ED22C Contactor Auxiliary Contact – Not Required 100-DMD02 Electrical/Mechanical Interlock 180 A 100S-D180ED22C Auxiliary Contact – Not Required 100-DMD02 Electrical/Mechanical Interlock 210 A 100S-D210ED22C Contactor Auxiliary Contact – Not Required 100-DMD02 Electrical/Mechanical Interlock 300 A 100S-D300ED22C Contactor Auxiliary Contact – Not Required 100-DMD02 Electrical/Mechanical Interlock 420 A 100S-D420ED22C Contactor Auxiliary Contact – Not Required 100-DMD02 Electrical/Mechanical Interlock 630 A 100S-D630ED22C Contactor Auxiliary Contact – Not Required 100-DMD02 Electrical/Mechanical Interlock 860 A 100S-D860ED22C Contactor Auxiliary Contact – Not Required 100-DMD02 Electrical/Mechanical Interlock 1200 A 100-G1200KD12 Contactor 100-EB11 Auxiliary Contact 100-MC007H Mechanical Interlock horizontal 100-MC007V Mechanical Interlock vertical Publication 2030-UM003A-EN-P - May 2006 Replacement Parts E-3 Table E.2 Replacement Fusible Disconnect Switch System Rating Catalog Suffix Disconnect Switch Part Number 23 A -24J 1494V-DS30 -25J 43 A -25J 1494V-DS60 -26J 85 A -26J 1494V-DS100 -27J 110 A -27J 40126-931-11 (200 A Class J Fusing) -28J 40126-931-14 (400 A Class J Fusing) -27J 40126-934-06 (200 A Class J Fusing) -28J 40126-934-11 (400 A Class J Fusing) 210 A -28J 40126-934-11 (400 A Class J Fusing) 300 A -28J 40126-934-11 (400 A Class J Fusing) -29J 40126-934-15 (600 A Class J Fusing) -29J 40116-491-01 (600 A Class J Fusing) -30L 40116-491-02 (800 A Class L Fusing) -30L 40116-491-03 (800 A Class L Fusing) -34L 40116-491-03 (2000 A Class L Fusing) 860 A -34L 40116-491-03 (2000 A Class L Fusing) 1200 A -34L 40116-512-01 for “Top Feed” Incoming Lines 40116-512-21 for “Bottom Feed” Incoming Lines 180 A 420 A 630 A In Standard MCC Style Enclosures Publication 2030-UM003A-EN-P - May 2006 E-4 Replacement Parts Table E.3 (23...1200 A) Replacement Thermal-Magnetic Circuit Breaker Current Rating (A) Line Voltage Circuit Breaker Rating Breaker Rating Plug 208V AC, 3-Phase, 60 Hz 39 25105-265-06 N/A (40 A) 39 25105-265-04 N/A (30 A) 40 25105-265-07 N/A (50 A) 39 25105-265-02 N/A (20 A) 25105-265-04 N/A (30 A) 42 25105-265-07 N/A (50 A) 39 25105-265-01 N/A (15 A) 40 25105-265-02 N/A (20 A) 41 25105-265-04 N/A (30 A) 42 25105-265-06 N/A (40 A) 40 25105-265-07 N/A (50 A) 41 25105-265-08 N/A (60 A) 41 25105-265-07 N/A (50 A) 42 25105-265-09 N/A (70 A) 43 25105-265-07 N/A (50 A) 44 25105-265-08 N/A (60 A) 45 25105-265-09 N/A (70 A) 25105-265-07 N/A (50 A) 45 25105-265-08 N/A (60 A) 42 25105-265-11 N/A (100 A) 43 25105-265-12 N/A (125 A) 44 25105-265-13 N/A (150 A) 43 25105-265-12 N/A (125 A) 25105-265-13 N/A (150 A) 46 25105-265-11 N/A (100 A) 47 25105-265-12 N/A (125 A) 48 25105-265-04 N/A (125 A) 46 25105-265-09 N/A (70 A) 47 25104-265-11 N/A (100 A) 48 25105-348-04 N/A (125 A) 240V AC, 3-Phase, 60 Hz 0023 480V AC, 3-Phase, 60 Hz 600V AC, 3-Phase, 60 Hz 208V AC, 3-Phase, 60 Hz 240V AC, 3-Phase, 60 Hz 0043 480V AC, 3-Phase, 60 Hz 600V AC, 3-Phase, 60 Hz 208V AC, 3-Phase, 60 Hz 240V AC, 3-Phase, 60 Hz 0085 480V Ac, 3-Phase, 60 Hz 600V AC, 3-Phase, 60 Hz Publication 2030-UM003A-EN-P - May 2006 40 41 43 44 44 45 Replacement Parts E-5 Table E.3 (23...1200 A) Replacement Thermal-Magnetic Circuit Breaker (Continued) 45 25104-348-05 N/A (150 A) 46 25104-348-06 N/A (175 A) 25104-348-05 N/A (150 A) 49 25104-348-04 N/A (125 A) 50 25104-348-05 N/A (150 A) 47 25104-348-09 N/A (250 A) 47 25104-348-06 N/A (175 A) 48 25104-348-09 N/A (250 A) 50 25104-348-06 N/A (175 A) 25104-348-09 N/A (250 A) 51 25104-348-06 N/A (175 A) 52 25104-348-09 N/A (250 A) 208V AC, 3-Phase, 60 Hz 48 25104-348-09 N/A (250 A) 240V AC, 3-Phase, 60 Hz 49 25104-369-10 N/A (300 A) 25104-369-10 N/A (300 A) 208V AC, 3-Phase, 60 Hz 0110 240V AC, 3-Phase, 60 Hz 46 480V AC, 3-Phase, 60 Hz 49 600V AC, 3-Phase, 60 Hz 208V AC, 3-Phase, 60 Hz 240V AC, 3-Phase, 60 Hz 0180 480V AC, 3-Phase, 60 Hz 600V AC, 3-Phase, 60 Hz 0210 52 600V AC, 3-Phase, 60 Hz 53 208V AC, 3-Phase, 60 Hz 49 240V AC, 3-Phase, 60 Hz 0300 51 480V AC, 3-Phase, 60 Hz 600V AC, 3-Phase, 60 Hz 54 50 50 25103-406-01 51 53 25107-447-04 25107-447-05 25104-369-12 N/A (400 A) 56 25103-406-01 25107-447-05 56 25104-369-12 N/A (400 A) 57 25103-406-01 25107-447-04 54 Publication 2030-UM003A-EN-P - May 2006 E-6 Replacement Parts Table E.3 (23…1200 A) Replacement Thermal-magnetic Circuit Breaker (Continued) 0420 0630 208V AC, 3-Phase, 60 Hz 51 240V AC, 3-Phase, 60 Hz 52 480V AC, 3-Phase, 60 Hz 57 600V AC, 3-Phase, 60 Hz 58 208V AC, 3-Phase, 60 Hz 240V AC, 3-Phase, 60 Hz 480V AC, 3-Phase, 60 Hz 600V AC, 3-Phase, 60 Hz 0860 52 25103-406-01 25107-447-05 25103-462-01 25107-456-04 25103-406-01 25107-447-05 53 25103-462-01 25107-456-05 54 25103-506-01 25107-504-04 54 25103-462-01 25107-456-05 56 25103-506-01 25107-504-04 25103-462-01 25107-456-05 61 25103-506-01 25107-504-04 60 25103-406-01 25107-447-05 61 25103-462-01 25107-456-05 62 25103-506-01 25107-504-04 25103-506-01 25107-504-06 53 58 59 59 60 208V AC, 3-Phase, 60 Hz 56 240V AC, 3-Phase, 60 Hz 57 480V AC, 3-Phase, 60 Hz 62 600V AC, 3-Phase, 60 Hz 63 208V AC, 3-Phase, 60 Hz 2033-*1200*H-57 25107-604-04 2033-*1200*H-58 25107-604-05 2033-*1200*H-59 25107-604-06 2033-*1200*H-60 1200 Publication 2030-UM003A-EN-P - May 2006 240V AC, 3-Phase, 60 Hz 2033-*1200*A-58 2033-*1200*A-59 25103-603-01 25107-604-03 25107-604-04 2033-*1200*A-60 480V AC, 3-Phase, 60 Hz 2033-*1200*B-66 600V AC, 3-Phase, 60 Hz 2033-*1200*C-66 25107-604-05 25107-604-04 Replacement Parts E-7 Table E.4 (23...85 A) Replacement Thermal-Magnetic Circuit Breaker Circuit Breaker Frame Size (A) 150 250 Rating Plug (A) Part Number 15 25105-265-01 20 25105-265-02 30 25105-265-04 40 25105-265-06 50 25105-265-07 60 25105-265-08 70 25105-265-09 100 25105-265-11 125 25105-265-12 150 25105-265-13 125 25104-348-04 Publication 2030-UM003A-EN-P - May 2006 E-8 Replacement Parts Table E.5 Replacement Control Circuit Transformer System Rating 23…85 A 110 A … 1200 A Line Voltage Control Transformer Part No. 208V/60 Hz 1497-F-HXDX-0-N 240V 60 Hz / 220V 50 Hz 1497-F-BASX-0-N 380…400V 50 Hz 1497-F-M4-0-N 400…415V 50 Hz 1497-F-M4-0-N 480V 60 Hz / 440V 50 Hz 1497-F-BASX-0-N 500V 50 Hz 1497-Custom 600V 60 Hz / 550V 50 Hz 1497-F-CXSX-0-N 208V 60 Hz 1497-H-HXDX-0-N 240V 60 Hz / 220V 50 Hz 1497-H-BASX-0-N 380…400V 50 Hz 1497-H-M4-0-N 400…415V 50 Hz 1497-H-M4-0-N 480V 60 Hz / 440V 50 Hz 1497-H-BASX-0-N 500V 50 Hz 1497-H-MXDX-0-N 600V 60 Hz / 550V 50 Hz 1497-H-CXSX-0-N Table E.6 Replacement Pilot Devices (for Power Panel Door) For Type 1, 4, 12 or IP30, IP54 Enclosure Function Part Number “System On” Pilot Light 800T-PT16R “System Ground Connected” Pilot Light 800T-PT16G “System On” Push button 800T-A1D1 “System Off” Push button 800T-B6D2 “Coast-To-Stop” Push-Pull Operator 800T-FXT9A5 For Type 4X or IP65 enclosure, change from Bulletin 800T- to 800H- in the Part No. Publication 2030-UM003A-EN-P - May 2006 Replacement Parts Replacement Control Modules E-9 The Control Module is factory-sealed to maintain the integrity of the safety system. Order as follows: Table E.7 Replacement Control Modules Control Module Description Part Number No optional functions 2030-CH1200OR 2030-CH0085 Pneumatic Ready 2030-CH1200-1PN OR 2030-CH0085-1PN With 30 second factory set time delay 2030-CH1200-1TD OR 2030-CH0085-1 TD Pneumatic Ready with 30 second factory set time delay 2030-CH1200-1PN-1TD OR 2030-CH0085-1PN-1TD Part no. is incomplete as shown. Select the required line voltage code letter from the chart below Input Line Voltage Code The part number as listed is incomplete. Select an Input Line Voltage Code from the table below. Example: Part No. 2030-CH1200 becomes Part No. 2030-CH1200B for a 480V, 60 Hz, 3 input line voltage application. Table E.8 Input Line Voltage Code for Control Modules. Input Line Voltage 220…240V 50…60 Hz, 3 440…480V 50…60 Hz, 3 550…600V 50…60 Hz, 3 400…415V 50 Hz, 3 208V 60 Hz, 3 500V 50 Hz, 3 380…400V 50 Hz, 3 Input Line Voltage Code A B C G H M N Publication 2030-UM003A-EN-P - May 2006 E-10 Replacement Parts Replacement Remote Lockout Station System Isolated Light LED Lamps If the LED lamp in the System Isolated light is burned out, it can be ordered as follows: Table E.9 LED Lamps Description LED lamp for System Isolated light Replacement Remote Lockout Station Load Switch Assemblies Part No. 800T-N319A 800T-N319G If the switch assembly in the remote lockout station needs to be replaced, it can be ordered as follows: Table E.10 Replacement Remote Lockout Station Switch Assemblies Function Switch Assembly Publication 2030-UM003A-EN-P - May 2006 Color White Green Part No. 2030-RSA1 Appendix F Glossary Category 4: The most stringent safety category identified within International Standard EN 954-1/ISO 13849-1. In order to achieve a Category 4 rating, the system design must be such that a single fault does not lead to the loss of the safety function and the accumulation of faults shall be prevented. Control Module: ElectroGuard® SIS assembly housing the power supply, safety relays, safety control relays, voltage sensing relays, and terminal blocks/ connector plugs required for the RLS ports supported by the Control Module and system interconnections. The Control Module can communicate status information regarding the overall system status, the status of each RLS, and the status of the optional Pneumatic Isolation Module. Control Module with Time Delay: Control module featuring an adjustable 30-second time delay for applications where the machine or process requires a controlled stop. Connection Point: The location where a wire is terminated (see Figure F.1). Figure F.1 Wiring Nomenclature Terminal Block 1 2 3 4 5 6 7 8 9 10 11 12 Connector Plug Connection Point Connector Plug: A removable plug that includes the connection point for one or more wires. The connector plug is inserted into a stationary terminal block to complete the circuit connection (see Figure F.1). 1 Publication 2030-UM003A-EN-P - May 2006 F-2 Glossary DeviceNet Communication Module: Allen-Bradley Flex modules used to communicate status information from the ElectroGuard® SIS Control Module to a remote PLC or other device via a communication protocol. Dual RLS: Rotary operated, enclosed switch with two system Isolated verification lights and an operating handle that can be locked in the OFF position to provide Lockout/Tagout. The dual Remote Lockout Station is used to initiate the isolation sequence simultaneously in separate ElectroGuard® units by sending signals to each Control Module. ElectroGuard® : The Allen-Bradley trademarked name used to identify the Bulletins 2030, 2031, 2032, and 2033 family of SIS products. ElectroGuard® Power Panel: Enclosure housing the Control Module, isolation contactors, grounding contactor, dedicated control transformer, the optional branch circuit protection, and status Communication Modules. Expansion Module: ElectroGuard® SIS module used in applications requiring more than the maximum number of RLSs for an ElectroGuard® Control Module (four for 23...85 A, six for 110...1200 A), or where the total wire lengths for the RLSs supported by the Control Module has been exceeded. The Expansion Module is available with four or ten ports, as open type or enclosed. Expansion Module with Time Delay: An Expansion Module featuring an adjustable 1…30 second time delay for applications where the machine or process requires a controlled stop. Grounding Contactor (GC): Power contactor housed in the ElectroGuard® power panel that grounds any residual voltages or back-EMF from the machine. Isolation Contactors (1IC and 2IC): Power contactors housed in the ElectroGuard® power panel that isolate the electrical energy to the machine. Two contactors are used for redundancy. The isolation contactors and grounding contactor are electrically and mechanically interlocked. Lockout/Tagout (LOTO): The process of isolating the energy source to the machine or process and placing a padlock on the operating handle of the isolation device in order to help prevent someone from inadvertently turning the energy sources back on. LOTO has been a requirement in Occupational Safety Hazards Act (OSHA) since 1990. Pneumatic Isolation Module: ElectroGuard® SIS module used in applications requiring the isolation of the electrical and pneumatic energy to the machine or process. The Pneumatic Isolation Module is to be used only with an ElectroGuard® SIS that is ordered pneumatic-ready. Publication 2030-UM003A-EN-P - May 2006 Glossary F-3 Power Contactor Assembly: The assembly consisting of the two isolation contactors (1IC) and (2IC), the grounding contactor (GC), their associated interlocks, and control and power wires. Qualified ElectroGuard® Service Technician: A technician who has been trained by Allen-Bradley personnel on the proper servicing procedures for the SIS. The names of all authorized ElectroGuard® service technicians are entered into Allen-Bradley’s database after successful completion of training. Remote I/O Communication Module: Allen-Bradley Flex modules used to communicate status information from the ElectroGuard® SIS Control Module to a remote PLC or other device via the Remote I/O communication protocol. Remote Lockout Station (RLS): Rotary-operated, enclosed switch with System Isolated verification light and operating handle that can be padlocked in the OFF position to provide Lockout/Tagout. The RLS initiates the isolation sequence via the Control Module after the machine operator uses the proper stopping means of the machine or process. Safety Isolation System (SIS): Used to describe the functionality of the Bulletins 2030, 2031, 2032, and 2033 family of products. In this publication, this term is used primarily to indicate the entire ElectroGuard® family of products. System Isolated Light: The light that illuminates on the RLS to indicate that the energy fed through the ElectroGuard® SIS to the machine or process has been isolated. If the RLS System Isolated light does not illuminate, service personnel must not begin work on the machine or process. Tamper-indicating seal: To protect the integrity of the SIS design, critical modules are originally sealed at the factory for tamper-resistance. A qualified ElectroGuard® service technician may reseal the modules using tamper-indicating seals and following the recommission directions. The RLSs must be sealed with a wire seal by the end user after commissioning. Publication 2030-UM003A-EN-P - May 2006 F-4 Glossary Terminal Block: A stationary wiring block that includes the connection points for one or more wires. The terminal block may or may not be designed to accept a connector plug (see Figure F.2). Figure F.2 Terminal Block Terminal Block 1 2 3 4 5 6 7 8 9 10 11 12 Connector Plug Connection Point Verification Module: Optional add-on module for the ElectroGuard® SIS that links a customer-supplied remote device to the ElectroGuard® Control Module. The Verification Module provides a set of redundant contacts to the remote device that close when the ElectroGuard® system has safely isolated energy to the machine or process. The Verification Module can also monitor the state of the remote device and not reapply energy until the remote device is in the proper state. The Verification Module uses a standard RLS port on a Control Module or Expansion Module and its safety outputs are analogous to an RLS System Isolated light. Publication 2030-UM003A-EN-P - May 2006 Appendix G Product Information Labels Product Safety Labels Figure G.1 Hazardous Voltage, Part Number. 31035-090-01 Figure G.2 Hazardous Voltage Part Number. 31035-091-01 Figure G.3 Pneumatic Energy Present Part Number. 31035-092-01 Figure G.4 Heavy Object Part Number. 31035-093-01 1 Publication 2030-UM003A-EN-P - May 2006 G-2 Product Information Labels Figure G.5 Heavy Object Part Number. 31035-094-01 Product Information Labels Figure G.6 Tamper-indicating Seal, Part Number 32005-383-02 Figure G.7 Tamper-indicating Seal, Part Number 32005-384-02 Publication 2030-UM003A-EN-P - May 2006 Product Information Labels G-3 Figure G.8 Factory Seal Part Number. 32005-386-02 (on modules shipped from the factory) Figure G.9 Seal Part Number 32005-386-03 (modules repaired by Rockwell repair facilities or field service personnel) Publication 2030-UM003A-EN-P - May 2006 G-4 Product Information Labels Figure G.10 Seal Part Number 32005-386-04 (modules serviced by non-Rockwell personnel) Publication 2030-UM003A-EN-P - May 2006 Product Information Labels G-5 Publication 2030-UM003A-EN-P - May 2006 Trademark List ElectroGuard is a registered trademark and Flex is a trademark of Rockwell Automation. DeviceNet and the DeviceNet logo are trademarks of the Open Device Vendors Association (ODVA). Teflon is a registered trademark of E.I. du Pont de Nemours and Co. CrossMirror is a registered trademark of ROSS CONTROLS Publication 2030-UM003A-EN-P May 2006 Copyright ©2006 Rockwell Automation, Inc. All Rights Reserved. Printed in USA. ">

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Key features
- Enhanced LOTO
- Electrical & Pneumatic Isolation
- Redundancy & Feedback
- Remote Lockout Stations
- System Isolation Light
- Ground Fault Monitoring
- Control Module
- Time Delay Option
- Communication Modules
- Expansion Modules
Frequently asked questions
The ElectroGuard 85...1200 A uses remote lockout stations to initiate isolation. When a station is turned off, it commands the power panel to open contactors, breaking the electrical circuit and removing the hazardous energy. If equipped with the pneumatic isolation module, the system also isolates pneumatic lines. Once isolation is complete, the lockout station’s system isolated light illuminates.
The ElectroGuard 85...1200 A system must be installed in accordance with local electrical codes and the National Electrical Code (NEC) in the US or the Canadian Electrical Code in Canada. It’s also important to follow relevant OSHA or OH&S regulations for safety requirements and guidelines.
The control module controls and verifies the overall function of the ElectroGuard 85...1200 A system. It sends and receives signals from the power panel, the pneumatic isolation module, and the remote lockout stations to ensure proper isolation and verification.