Ross Asia Electro guard Energy Separation Systems – Electric, Pneumatic, Hydraulic | Kouei Japan Trading

Made in Japan
Manufacturer : Ross Asia
Model : Electro guard

ElectroGuard ® Plus Energy Isolation System for Single- or Multi-Zone Machines

Standardize on a New Level for Machine Energy Isolation ElectroGuard ® Plus

The ROSS ElectroGuard ® Plus , provides a new level of machine operator safety and can contribute to enhanced productivity. The flexibility and capabilities make it ideal in virtually any application where operators work within the machine. This system integrates world-class products to offer a system you can trust and the highest level of safety available.

The ElectroGuard ® Plus system has the ability to isolate electrical, pneumatic, and hydraulic energy for a whole machine or by zone in a multi-zone machine system.

The ElectroGuard ® Plus system takes signals from the individual Remote Lockout Stations (RLS) and performs the entire energy isolation procedure, including verification, after which a lock is applied by the operator or maintenance worker. This simple procedure eliminates the downtime that is normally wasted on traveling to and from the isolation devices and locking out every energy source on the machine (or in the zone). Of course, this time savings is realized when res tarting as well – all of which makes for a rapid return on investment. Furthermore, the ability to control multiple zones separately provides the added benefit of not always having to shut down the entire machine which can also contribute to the rapid return on investment.

ElectroGuard ® Plus – A System Approach to Machine Energy Isolation

The ElectroGuard ® Plus system sets a new standard for hazardous energy isolation by greatly easing the task of the machine operator or maintenance personnel to properly perform Lockout/Tagout procedures consistently. Which, in turn, can offer greater assurance of compliance along with the added value of improved productivity.

ElectroGuard ® Plus systems use a modular approach for maximum scalability and flexibility. ElectroGuard ® Plus systems include low- voltage remote lockout stations and modular control panels, factory-sealed and certified to Category 4/PL e (pending), with options for pneumatic and hydraulic isolation to provide the complete solution in a flexible, scalable, maintainable, and cost effective system.

ElectroGuard ® Plus provides many features to benefit your business:

Helps reduce workplace injuries resulting from complicated Lockout/Tagout procedures
A cost-effective solution to conform with OSHA requirements for control of hazardous energy
Simplifies operator Lockout/Tagout procedures to help improve productivity
Modular, pre-wired for quick installation
Improves Safety by eliminating errors and omission of steps during complex lockout/tagout procedures
Higher cycle life than mechanical disconnects, for reduced downtime

With ElectroGuard ® Plus you benefit from:

Fewer lost time accidents
Improved productivity
A standard procedure throughout your facility
Greater plant operation accuracy due to downtime communication
Ease of specifying, purchasing, setup and maintenance

ElectroGuard ® Plus is ideal for applications where machines have:

Multiple access locations requiring operator travel time to the disconnecting devices
Frequent interruptions due to jams, lubrication, etc., causing loss of productivity during the time of proper isolation
Multiple sources of energy requiring a complex Lockout/ Tagout procedure
Maintenance personnel operating electrical disconnects within the hazardous zone

Safety Features	BENEFITS
System approach to simplify hazardous energy isolation procedures	When the energy sources are controlled by the ElectroGuard ® Plus system, it enhances safety by eliminating the need for locking multiple locations, helping reduce the chances of an energy source being overlooked
Remote Lockout Stations (RLS)	The operator switches a low power device, without the flash hazard associated with typical electrical disconnect switches.
“System Isolated” light on RLS	he “System Isolated” light is a positive indication of the ElectroGuard ® Plus sources’ zero energy state, notifying the operator it is safe to enter the machine.
Certified to ISO 13849-1 Category 4, PL e (pending)	Highest functional safety performance possible to help improve workplace safety
Redundant, independent, self monitoring, functional design	ElectroGuard ® Plus faults are detected in time to prevent loss of the safety function
Grounding contactor	Safety features to guard against capacitive coupling, inertial regeneration or other sources that may cause residual voltage
Ground loss monitor	Additional safety features to detect the loss of system ground
Electrical interlock devices on isolation contactors	Multiple technologies used for fault protection
Factory-sealed panels	Tamper evident seals for system integrity
ROSS CONTROLS ® energy isolation valves DM 2 Pneumatic HBB Hydraulic	Maintain system integrity with control-reliable pneumatic and hydraulic valve isolation systems
Conformity to UL standards (reference page 3 for complete industry standards list	Pre-engineered conformity to meet industry standards

Productivity Features	BENEFITS
Single Point Lockout/Tagout	Isolate electrical, pneumatic, and hydraulic energy in a single action, reducing the time to put the machine into a safe mode
Low-voltage Remote Lockout Station	Easy to operate device
Multiple Remote Lockout Stations (RLS)	Allows placement of lockout device near every access point
Standardized System	Similar lockout/tagout procedure between machines, throughout the facility
Status Communication	Use to measure # cycles, cycle time, location of lockout/tagout occurrences
Multi-Zone Control	Increase productivity by only locking out the appropriate zone where access is needed instead of the whole machine

Maintenance Features	BENEFITS
Electrical isolation using power contactors	Dramatically increased cycle life compared with mechanical disconnects
Modular design	Ease of trouble-shooting to the panel/module level
Removable, factory sealed panels	Quick replacement of failed panels
System approach	Common look and feel to each system in the facility
Safety PLC-based system with HMI for advanced troubleshooting	Ease of troubleshooting

Installation Features	BENEFITS
Low voltage Remote Lockout Stations	Low install cost
Compact size Remote Lockout Station	Easy to locate on machine
Expandable	Simple to add more options after installation

Here’s an example of a typical machine having energy isolation devices located on a wall, close to the machine, and a single start/stop station.

When a process jam occurs the operator must travel around between the start/stop station and the energy isolation devices (LOTO) and the jam to get production running again. The clearing of the jam is only a small portion of the production down time; the remaining time is spent on the proper LOTO procedure. Operator travel time and manually locking of two isolation devices is a large portion of the total recovery time.

Time: 70 seconds.

The ElectroGuard ® Plus system is installed in place of the manual isolation devices, while multiple Remote Lockout Stations are installed near the machine access locations. With this simplified LOTO procedure and close proximity of the Remote Lockout Stations, the clearing of a jam is now the largest percentage of the downtime.

Time: 35 seconds

Flexibility in Packaging

The ElectroGuard ® Plus and optional panels are available with standard enclosure ratings of NEMA type 1, 4, and 12. In addition, the system configuration is available in the following styles, to meet your requirements.

Standard ElectroGuard ® Plus configuration as a wall mounted or floor standing panel
Motor Control Center style enclosure, available with power bus structure

Ease of Maintenance

The ElectroGuard ® Plus modular design allows for trouble-shooting to a factory sealed panel, and replacement of the failed panel. Flexibility for “Behind the Seal” maintenance includes the following:

Return to repair services
Purchase on-site start-up services from ROSS CONTROLS ®

ElectroGuard ® Plus – Unsurpassed Advantages

The main goal of the ElectroGuard ® Plus Energy Isolation System is to optimize Lockout & Tagout procedures in order to enhance safety and productivity.

All ElectroGuard ® Plus systems utilize an AB Compact Guardlogix 5380 Safety PLC with 5069 Safety IO and certified SafetyInstructions that are used in ROSS Controls’ Add-On Instructions (AOI’s). The AOI’s are locked and uneditable by users of the ElectroGuard ® Plus system.

 Provides simple, and quickly accessible lockout devices wherever needed, reducing the tendency of machine operators to take an unsafe shortcut

 When the energy sources are controlled by the ElectroGuard ® Plus system, it provides a single point lockout for multiple sources of energy, helping reduce the chances of an energy source being overlooked

 Third party certified conformity to the highest safety category – when ElectroGuard ® Plus faults occur the safety function is always performed (pending certification)

 Modular for quick and easy maintenance

 Factory sealed panels for system integrity

 Establish uniform energy isolation process for all stations & all sites

 HMI module for advanced, rapid troubleshooting ElectroGuard ® Plus –

Single-zone ElectroGuard ® PlusSystem Overview

Single-zone ElectroGuard ® Plus systems can isolate up to six energy sources (any combination of electrical, pneumatic, & hydraulic), and can utilize as many as thirteen remote lockout stations (RLS).\

Potential capacity could be:

1 zone
Up to 6 RLS Stations or up to 13 with external RLS Interface Panel (RIP)
Controls up to 6 Energy Sources (combination of EIP, PIP, & HIP

Single-zone ElectroGuard ® Plus Systems include:

Multi-Zone ElectroGuard ® Plus System Overview

(8 Zones, 69 Remote Lockout Stations, and 32 Energy Sources)

The ElectroGuard ® Plus main Control Panel can be extended to include an 8 port or 16 port Ethernet Switch to expand system capacity.

Potential capacity could be:

8 zones (Base + 7 remote)
69 RLS Stations (Base + 7 RIP)
32 Energy Sources (Base + 8 OCP)

Multi-zone ElectroGuard ® Plus Systems include Base System Capabilities and the following:

Branch Circuit Protection

Application Rated

None – incoming line lugs only
Fusible disconnect
Circuit Breaker

Remote Lockout Station

Provision for top or bottom conduit entry
Rotary lockable disconnect or trapped key options
White or green isolation status indicator light
Multiple enclosure materials/ IP ratings available

Selectable Time Delay

Provision to incorporate a machine cycle stop with the actuation of the Remote Lockout Station

Adjustable 1 to 30 seconds

Pneumatic Isolation Module

Isolates the pneumatic energy
30 to 120 psig (2 to 8 bar)
3/4″ or 1″ valve port

Cover Mounted Metering

Single- or three-phase voltmeter
Single- or three-phase ammeter

Hydraulic Isolation Module

Isolates the hydraulic energy
Up to 5000 psig (344 bar)
1″ valve port

Safety Interface Signals

Provision to incorporate a machine cycle stop with the actuation of the Remote Lockout Station

Two machine status inputs
Two ElectroGuard ® Plus status outputs

Operation

The ElectroGuard ® Plus system is installed between the energy sources and the machine.

The Control Module controls and verifies the ElectroGuard ® Plus system functions. Every function is commanded and monitored for proper completion, and is comprised of the safety PLC, electromechanical devices, and safety control relays. The Control Module sends and receives signals from the Electrical, Pneumatic, Hydraulic, and Motor Isolation modules and panels as well as the Remote Lockout Stations.

If the ElectroGuard ® Plus Main Control Panel ground is broken, or a fault occurs within the isolation system, the

ElectroGuard ® Plus system will isolate all energy sources. Under a fault or shutdown condition of the ElectroGuard ® Plussystem, the “system isolated” light will not be illuminated. No light means no entry.

The ElectroGuard ® Plus system is powered by a 120V AC control transformer in the Main Control Panel and 24V DC power supply within the Control Module.

Sequence of Isolation Operation

1. The operator initiates the isolation sequence by turning the handle on the Remote Lockout Station from the ON to OFF position.

2. The control module responds by commanding all isolation modules & panels – electrical, pneumatic, and hydraulic – to isolate and verify isolation.

The Electrical Isolation Module opens the series contactors, the voltage sense circuit monitors the isolated voltage, and, when safe, the grounding contactor connects the isolated electrical lines to the isolated ground. Electrical isolation is completed and verified by the Control Module.
The Motor Isolation Module opens the contactor (in series with a VFD with Safe Torque Off functionality), the voltage sense circuit monitors the isolated voltage, and, when safe, the grounding contactor connects the isolated electrical lines to the isolated ground. Electrical isolation is completed and verified by the Control Module.
The Pneumatic and Hydraulic Isolation Panels switch off the pneumatic and hydraulic valves, and redundant pressure sensors verify isolation has been completed. Pneumatic and hydraulic isolation is completed and verified by the Pneumatic and Hydraulic Control Panels.

3. After successful isolation, the Control Module illuminates the operator’s Remote Lockout Station “system isolated” light.

4. The operator then applies a LOTO lock to the Remote Lockout Station handle, and it is safe to work on the machine.

Voltage Range	208 to 600V AC, 50/60 Hz
Rated Electrical Isolation	Current Range – 43 to 1250 A
Rated Pneumatic Isolation	Pressure Range – 30 to 120 psig (2 to 8 bar)
Rated Hydraulic Isolation	Pressure Range – 500 to 5000 psig (35 to 344 bar)
Remote Lockout Station	Low Voltage 24V DC, supplied from ElectroGuard® Plus Main Control Panel
Expansion Module	Low Voltage 24V DC, supplied from ElectroGuard ® Plus Main Control Panel
Enclosure Ratings	NEMA Type 1, 4, or 12
Enclosure Styles	Wall-mount or Free-standing MCC-style Enclosure

Conformity to Industry Standards

UL508A with cULus listing (pending)
Certified to ISO 13849-1 Category 4, PL e (pending)
Designed to conform to OSHA for control of hazardous energy

Japan, Ross Asia