ElectroGuard® Energy Isolation System – Electric, Pneumatic & Hydraulic Operating Instructions
Overview
The ROSS Controls® ElectroGuard® SIS Plus Safety Isolation System is the state of the art in integrated machine energy isolation. The system isolates electrical, pneumatic, and hydraulic energy sources simultaneously, enabling maintenance personnel and machine operators to safely perform lockout/tagout and energy isolation procedures in compliance with OSHA 29 CFR 1910.147 and international equivalents. Certified to Category 4, Performance Level e (ISO 13849-1:2015) and Safety Integrity Level 3 (IEC 61508), the ElectroGuard® SIS Plus is the highest-rated energy isolation system in the ROSS Controls portfolio.
The ElectroGuard® SIS Plus is a partly completed machine (EU Machinery Directive) placed between energy sources and the machine to provide isolation and verification functionality. The system's Main Control Module (MCM) uses a certified safety PLC, safety control relays, and voltage sensing relays to monitor and control all isolation modules. If the system ground is broken or a fault occurs, the system shuts down and the "system Isolated" light is not illuminated – no light means no entry.
ROSS Controls, founded in 1921 with over 100 years of fluid power and machine safety experience, developed the ElectroGuard® SIS Plus to address multi-energy-source isolation in automated manufacturing. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com for configuration assistance.
Key Features
Highest Safety Certification – Category 4, PL e, SIL 3
The ElectroGuard® SIS Plus is certified to Category 4, Performance Level e per ISO 13849-1:2015 and Safety Integrity Level 3 per IEC 61508. Functional safety validation has been performed by DGUV (HSM 06008 – Sicherheit geprüft / tested safety). These certifications ensure the system meets the most stringent requirements for safety-rated energy isolation in industrial machinery.
Integrated Multi-Energy Source Isolation
The ElectroGuard® SIS Plus uniquely integrates electrical, pneumatic, and hydraulic isolation in a single coordinated system. The Electrical Isolation Module (EIM) uses power contactors for isolation and grounding of three-phase electrical energy. The Pneumatic Isolation Panel (PIP) and Hydraulic Isolation Panel (HIP) provide corresponding isolation for pneumatic and hydraulic energy sources. All modules are coordinated through the Main Control Panel, ensuring simultaneous isolation of all energy types.
Modular Architecture with Remote Lockout Stations
The ElectroGuard® SIS Plus uses a modular design with factory-sealed, replaceable panels and modules: Main Control Panel (MCP), Electrical Isolation Panel (EIP), Pneumatic Isolation Panel (PIP), Hydraulic Isolation Panel (HIP), Control Module (CM), Remote Lockout Stations (RLS), and RLS Interface Panel (RIP). Remote Lockout Stations allow operators to initiate the isolation sequence from any point on the machine, improving both safety and productivity.
Technical Specifications
The following specifications are drawn from the official ROSS Controls ElectroGuard® SIS Plus Operating Instructions (Doc ID 6613):
- Safety Certification: Category 4, Performance Level e per ISO 13849-1:2015
- Safety Integrity Level: SIL 3 per IEC 61508:2001
- Functional Safety: DGUV HSM 06008 (Sicherheit geprüft / tested safety)
- Main Enclosure Power: 120V AC control transformer
- Main Control Module Power: 24 VDC power supply
- Remote Lockout Stations: 24 VDC low voltage signal
- Pneumatic Isolation Modules: 120 VAC
- Hydraulic Isolation Modules: 24 VDC
- Isolation Types: Electrical (contactor-based), Pneumatic (PIP), Hydraulic (HIP)
- Zone Configurations: Single zone or multiple zone
- Enclosure Styles: Wall mount, free-standing MCC-type enclosure
- CE Declaration of Conformity available at www.rosscontrols.com
Applications
Automated Manufacturing and Assembly Systems
The ElectroGuard® SIS Plus is designed for complex automated manufacturing systems where multiple types of energy must be isolated for safe maintenance access. Automotive assembly lines, stamping operations, robotic work cells, and CNC machining centers represent typical applications where electrical, pneumatic, and hydraulic energy are all present. The system's modular design allows configuration for the specific energy mix and zoning requirements of each machine or cell.
Multi-Zone Machine Safety Compliance
For large machines or production lines with multiple access zones, the ElectroGuard® SIS Plus supports multi-zone configurations using a single Main Control Panel with multiple Remote Lockout Stations and isolation panels. This architecture enables zone-by-zone isolation, allowing work to proceed in one zone while other zones remain operational, improving both safety and production efficiency.
Safety and Compliance Standards
The ElectroGuard® SIS Plus is designed for compliance with OSHA 29 CFR 1910.147, ISO 13849-1:2015, IEC 61508, and the EU Machinery Directive. It is a partly completed machine under the Machinery Directive and must be incorporated into a complete machine installation with a Declaration of Incorporation. All systems are factory tested and sealed prior to shipping from ROSS Controls.
Installation and Setup Guide
System Configuration and Module Selection
Identify all energy sources requiring isolation: electrical (voltage, current, phases), pneumatic (pressure/flow), and hydraulic (pressure/flow). Select the appropriate Electrical Isolation Module, Pneumatic Isolation Panel, and/or Hydraulic Isolation Panel. Determine the number of access zones and Remote Lockout Stations needed. Contact ROSS Controls for assistance with system configuration and for a Declaration of Incorporation.
Main Control Panel Mounting
The Main Control Panel is available in wall-mount and free-standing MCC-type enclosure configurations. Mount in a location accessible to operators and maintenance personnel. Some systems may require a separate control power feed rather than drawing from the Main Control Panel. Ensure all Remote Lockout Stations are clearly marked and accessible.
Commissioning and Verification
After installation, commission the ElectroGuard® SIS Plus with qualified safety-rated electrical and pneumatic personnel. Verify the complete isolation sequence for each energy source and each zone. Test the "system Isolated" light indication. Test ground fault detection. Document all test results. Ensure all personnel are trained on the isolation sequence before releasing the system for production use.
Why Choose ROSS Controls
ROSS Controls has been engineering machine safety solutions since 1921. The ElectroGuard® SIS Plus offers the highest available safety certifications (Category 4, PL e, SIL 3) in an integrated, modular system addressing all energy types simultaneously. Factory-sealed, replaceable modules minimize maintenance complexity throughout the product lifecycle. Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.
Download This Document
The official ROSS Controls ElectroGuard® SIS Plus Series Operating Instructions (Doc ID 6613) can be downloaded from the ROSS Controls document library.
PDF Download URL: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/6613/ElectroGuard_SIS_Plus_Series_Operating_Instructions_RC-EG-SIS-Plus_EN.pdf
Related Products and Resources
- e L-O-X® Series Electrical Isolation Devices – Standalone 30A-200A electrical isolation
- L-O-X® Series Pneumatic Energy Isolation Valves – Pneumatic lockout/tagout
- EEZ-ON® Soft-Start/Dump Valves – Controlled pressurization and energy isolation
- MCSE Series Double Valves – Safety exhaust control-reliable valves
- ROSS Machine Safety Solutions – www.rosscontrols.com
Frequently Asked Questions
Q: What safety certifications does the ElectroGuard® SIS Plus hold?
A: Certified to Category 4, Performance Level e per ISO 13849-1:2015, SIL 3 per IEC 61508:2001, and DGUV functional safety validation (HSM 06008 – tested safety). CE declaration of conformity available at www.rosscontrols.com.
Q: What energy types can the ElectroGuard® SIS Plus isolate?
A: The ElectroGuard® SIS Plus can isolate electrical (three-phase), pneumatic, and hydraulic energy sources simultaneously through its modular Electrical Isolation Panel, Pneumatic Isolation Panel, and Hydraulic Isolation Panel.
Q: What does "no light means no entry" mean for the ElectroGuard® SIS Plus?
A: If the "system Isolated" light is not illuminated, the isolation system is not confirmed to be in the isolated state. This indicates a fault, ground fault, or incomplete isolation sequence. Personnel must not enter the isolated zone unless the light is illuminated.
Q: Can the ElectroGuard® SIS Plus support multiple access zones?
A: Yes. Both single-zone and multiple-zone configurations are supported. Multi-zone systems use a single Main Control Panel with multiple Remote Lockout Stations and isolation panels, allowing zone-by-zone isolation.
Q: Is the ElectroGuard® SIS Plus a complete machine?
A: No. The ElectroGuard® SIS Plus is a "partly completed machine" under the EU Machinery Directive. It must be incorporated into a complete machine installation with a Declaration of Incorporation.
Q: What power supply does the ElectroGuard® SIS Plus require?
A: The main enclosure requires 120V AC for the control transformer. The Main Control Module has a 24 VDC power supply. Remote Lockout Stations run on 24 VDC; pneumatic isolation modules on 120 VAC; hydraulic isolation modules on 24 VDC.
Q: What is the Main Control Module function?
A: The MCM houses the safety PLC, safety control relays, and voltage sensing relays that control the system. It communicates with Remote Lockout Stations and all installed isolation modules (EIM, MIM, PIM, HIM) to coordinate the isolation sequence.
Q: Where can I find the CE declaration of conformity for the ElectroGuard® SIS Plus?
A: The Declaration of CE Conformity and certifications for the ElectroGuard® SIS Plus are available for download at www.rosscontrols.com.