ABB 2RCA025057A0001R safety relay

ABB 2RCA025057A0001R safety relay

Product Overview

ABB 2RCA025057A0001R safety relay is a core control component designed by ABB specifically for the safety protection of personnel and equipment in the field of industrial automation. It is widely used in scenarios that require high safety levels of protection, such as mechanical manufacturing, automotive production lines, warehousing and logistics, packaging equipment, etc. This relay strictly complies with international safety standards such as IEC 61508 and EN ISO 13849. Through redundant design, fault detection, and forced guiding contact technology, it achieves rapid response and reliable cut-off to hazardous working conditions, providing key guarantees for safety protection in industrial production processes and effectively reducing equipment misoperation and personnel injury risks.

Core technical parameters

Model identification

2RCA025057A0001R

ABB safety relay series standard coding, including safety level, functional module, and version information

security level

SIL 3（IEC 61508）/ PL e（EN ISO 13849-1）

Meet the security requirements of high-risk scenarios and support the high integrity design of security related systems

input voltage

AC 24V~240V/DC 24V (wide voltage adaptation)

Compatible with mainstream control power sources in industrial sites, enhancing equipment versatility

Contact form

4NO+2NC (forced guiding contact)

The mandatory guiding structure prevents safety failure caused by contact adhesion, and the NO/NC combination satisfies complex safety logic

Contact capacity

AC-15：230V/6A； DC-13：24V/4A

Adapt to different load types to ensure stability during safe shutdown

response time

≤ 5ms (safety signal cut-off time)

Quickly respond to danger signals and minimize exposure time to danger

Fault detection function

Short circuit detection, wire breakage detection, contact adhesion detection

Real time monitoring of self and peripheral circuit faults, triggering safety protection mechanisms

Working temperature range

-25℃~+70℃

Adapt to the temperature requirements of most industrial site environments

Protection level

IP20 (installed inside the control cabinet)

Meet the dust prevention requirements inside the control cabinet and prevent foreign objects from entering and affecting performance

Core performance characteristics

1. High security level redundancy design

This safety relay adopts dual coil redundant control and forced guiding contact structure, which eliminates safety failure caused by single point faults from the hardware level. When any coil or contact experiences an abnormality, the relay can quickly identify and trigger a safe cut-off action, ensuring reliable disconnection of the hazardous circuit. At the same time, the product has passed SIL 3 and PL e-level safety certifications and can be directly applied to safety related control systems without the need for additional safety redundancy modules, simplifying system design.

2. Comprehensive fault diagnosis capability

Equipped with comprehensive self diagnosis and peripheral circuit monitoring functions, it can detect real-time fault states such as input signal disconnection, output contact short circuit, coil overload, etc., and provide feedback on fault information through dedicated fault indicator lights and signal output terminals. Operations personnel can quickly locate problems through fault prompts, shorten troubleshooting time, and improve equipment maintainability. In addition, in the event of a fault, the relay will remain in a safe cut-off state until the fault is resolved and manually reset to prevent the equipment from accidentally starting when the fault is not resolved.

3. Flexible security logic adaptation

Support the integration of various safety components such as emergency stop button, safety door, dual hand control, and light curtain. Common safety control logic such as "safety door+emergency stop" linkage and dual hand interlock can be achieved through external wiring combinations, adapting to the safety protection needs of different devices. The wide voltage input design enables compatibility with various PLCs and control modules, without the need for additional power conversion devices, reducing system integration costs.

4. Stable anti-interference performance

Adopting enhanced electromagnetic compatibility (EMC) design and passing EMC EN 61000-6-2/3 standard testing, it can effectively resist electromagnetic radiation, surge, and voltage fluctuation interference in industrial sites. The coil has a built-in suppression circuit to reduce electromagnetic interference generated during the switching process and avoid affecting surrounding control equipment; The contacts are made of silver nickel alloy material, which enhances the arc extinguishing ability and ensures contact reliability in frequent on-off scenarios.

5. Convenient installation and status monitoring

Adopting the standard 35mm DIN rail installation method, the installation process is simple and efficient, suitable for mainstream industrial control cabinet layouts. The panel is equipped with power indicator lights, operation indicator lights, and fault indicator lights to visually display the working status of the relay; Some models support remote status monitoring signal output and can be connected to the factory MES system to achieve centralized management and traceability of equipment safety status.

Applicable application scenarios

-Mechanical processing equipment: used for emergency stop control and safety door protection of CNC machine tools, stamping machines, bending machines and other equipment. When the operator opens the safety door or triggers an emergency stop, the power circuit of the equipment is quickly cut off to prevent mechanical injury.

-Automotive manufacturing production line: equipped with welding robots and assembly line safety protection systems, achieving dual hand operation interlocking and peripheral safety light curtain linkage control to avoid human casualties caused by robot misoperation.

-Storage and logistics equipment: applied to stacker cranes, conveyor belts, lifting platforms and other equipment, monitoring the operating position of equipment and signals for personnel entering dangerous areas, achieving safe start stop and emergency braking of equipment.

-Packaging and printing equipment: Control the safety protection doors and linkage emergency stop devices of the equipment. In case of equipment maintenance or abnormalities, immediately cut off the drive circuit to ensure the safety of operators.

-Food and pharmaceutical production line: Combining hygiene grade safety components to achieve safety control of the production line, meeting both safety protection requirements and adapting to the clean environment requirements of the food and pharmaceutical industry.

Installation and usage precautions

1. Before installation, it is necessary to confirm that the product safety level matches the safety requirements of the application scenario. It is strictly prohibited to use low safety level products for high-risk scenarios, such as stamping, cutting, and other dangerous processes.

2. When wiring, it is necessary to strictly distinguish between safety input circuits, control circuits, and power output circuits to ensure that the wiring is firm and complies with electrical specifications, and to avoid signal interference between different circuits.

3. Relays should be installed in ventilated and dry control cabinets, avoiding close installation with high-power heating elements (such as contactors and frequency converters) to prevent high environmental temperatures from affecting their performance.

4. During use, it is necessary to regularly check the reliability of safety input components (emergency stop buttons, safety door switches, etc.), and confirm the status of relay fault indicator lights to avoid safety protection failure caused by peripheral component failures.

After troubleshooting, the relay must be manually reset to restore its operation. It is strictly prohibited to use illegal methods such as short circuiting contacts to forcibly start the equipment, ensuring that the root cause of the fault has been completely resolved.

When replacing relays, products of the same model and safety level should be selected. After replacement, safety function testing should be conducted to verify the integrity and reliability of the safety logic.