ABB SAFT110 Advanced Safety Termination Module

ABB SAFT110 Advanced Safety Termination Module

Product Overview

ABB SAFT110 is an advanced safety terminal module that complies with international safety standards. Its core positioning is the "signal hub and safety barrier" of industrial safety control systems, focusing on the acquisition, processing, transmission, and fault diagnosis of safety related signals (such as emergency stop, safety door, and grating), providing SIL 2/PLd level safety protection for machinery and production processes. It integrates core functions such as safety signal isolation, short circuit detection, and wire breakage monitoring. It can be used as an independent safety terminal to adapt to standalone devices, and can also be integrated into the safety control system of large-scale production lines through safety bus expansion. It is a key safety component in areas with strict safety requirements such as automotive manufacturing, mechanical processing, logistics and warehousing.

Compared to the RVC6-5A module that focuses on motor drive regulation, SAFT110 focuses more on the reliability processing and risk prevention of safety signals. Through redundant design and fault self diagnosis mechanism, it solves problems such as signal interference and difficult fault location in traditional safety circuits, ensuring that hazardous energy can be quickly cut off in dangerous working conditions and safeguarding personnel and equipment safety.

Specification parameters

（1） Core Security and Technical Parameters

Security certification

Compliant with IEC 61508 (SIL 2), IEC 62061 (SIL 2), EN ISO 13849-1 (PLd, Cat. 3) standards

Signal acquisition capability

Supports 8 secure input signals (24V DC, compatible with PNP/NPN), each with independent isolation design

Signal output characteristics

2-channel safety relay output (normally open contacts, rated current 6A/250V AC, 5A/30V DC), supporting redundant output

Fault detection function

Support input signal short circuit detection (response time<10ms), disconnection detection (response time<20ms), overvoltage protection (30V DC withstand)

Power supply parameters

24V DC wide power supply (18~32V DC), power consumption ≤ 8W, with reverse polarity protection and overcurrent protection (2A)

Environmental adaptability

Working temperature -25 ℃~+60 ℃, humidity 5%~95% RH (no condensation), vibration level IEC 60068-2-6 (50Hz, 10m/s ²)

（2） System adaptation parameters

Communication interface: Supports Safety over Profinet (optional) and Modbus RTU (non safety signal communication) for easy interaction with upper level safety controllers

Signal isolation: Isolation voltage between input and output, input and power supply ≥ 2.5kV AC (1min) to avoid signal interference

Physical specifications: Dimensions 12.5mm × 100mm × 120mm (ultra-thin design), compatible with standard 35mm DIN rail installation, weight ≤ 150g

Diagnosis and indication: Each input/output corresponds to an LED status indicator light (green: normal; red: fault; yellow: signal not activated), supporting the upload of fault codes through the communication interface

Performance characteristics

High level safety protection: Through SIL 2/PLd safety certification, adopting a "dual channel+cross monitoring" design, even if a single channel fails, the other channel can still ensure normal safety functions, with an average time from failure to failure (MTTFd) of ≥ 100000 hours, meeting strict safety requirements.

Comprehensive fault diagnosis: Real time monitoring of input signal faults such as short circuit, disconnection, overvoltage, etc. Each input is independently diagnosed with a fault response time of less than 20ms. At the same time, fault information is synchronously output through LED indicator lights and communication interfaces, which can accurately locate the fault channel and shorten the fault investigation time.

Signal isolation and anti-interference: Optoelectronic isolation technology is used between input and output, input and power supply, with an isolation voltage of up to 2.5kV AC, effectively suppressing electromagnetic interference in industrial sites (such as interference generated by frequency converters and motors), ensuring the stability of safe signal transmission, and signal transmission error<0.1%.

Flexible signal adaptation: compatible with both PNP/NPN types of safety sensor signals, it can be connected to different types of safety devices such as emergency stop buttons, safety door switches, and safety gratings without additional hardware adjustments, reducing the variety of spare parts and inventory costs.

Convenient system integration: The ultra-thin 12.5mm design saves control cabinet installation space, supports "plug and play" wiring (using spring terminals, reducing wiring time by 40%), and can seamlessly connect with ABB AC500-S safety PLC and other equipment through Safety over Profinet, simplifying safety system configuration.

Working principle

Safety signal acquisition: Eight safety input interfaces are used to collect signals from safety devices such as emergency stop buttons and safety doors. Each signal is processed by an independent isolation circuit to remove interference noise and converted into a standard digital signal for transmission to the safety control unit.

Safety logic judgment: The safety control unit compares and analyzes the signals collected from two redundant channels based on the "dual channel cross monitoring" logic. If the two signals are consistent and meet the safety status (such as the signal being "1" when the emergency stop is not triggered), then the signal is judged to be normal; If the deviation of the two signals exceeds the threshold or a short circuit or disconnection fault is detected, a safety response will be triggered immediately.

Safety output control: When it is determined that there is a dangerous working condition (such as emergency stop triggering, safety door opening) or signal failure, the safety control unit will cut off the output of the safety relay within<10ms, disconnect the power circuit of the dangerous equipment (such as motor, frequency converter power supply), and at the same time, light up the red fault light through the LED indicator light, and upload the fault information (such as fault channel, fault type) to the upper system through the communication interface.

Fault reset mechanism: After troubleshooting, the module needs to be manually reset (with a built-in reset button) or remotely reset by the upper system command to restore normal operation. Before resetting, the safety output should always remain in the "disconnected" state to prevent the equipment from starting incorrectly under dangerous working conditions.

Precautions

Installation specifications:

It needs to be installed in a control cabinet that meets the IP20 protection level, with a distance of ≥ 15cm from strong interference equipment such as frequency converters and high-power contactors, to avoid electromagnetic interference affecting safety signal acquisition;

The input/output wiring should use multi stranded copper core cables with a cross-sectional area of 0.5~2.5mm ². It is recommended to use twisted pair shielded wires for critical signals such as emergency stop and safety doors, with a single end grounding of the shielding layer (grounding resistance ≤ 4 Ω).

Debugging points:

Before the first power on, it is necessary to check the power supply voltage (ensure it is 24V DC) and wiring polarity to avoid module damage caused by reverse polarity power supply;

During debugging, it is necessary to test the triggering and resetting functions of each input signal one by one to verify whether the safety output can respond accurately (such as immediately disconnecting the safety output when pressing the emergency stop button). At the same time, short circuit and disconnection faults should be tested to confirm that the fault diagnosis function is normal.

Maintenance requirements:

Check the wiring terminals for looseness every 3 months, clean the surface dust of the module, and ensure good ventilation;

Conduct safety function verification once a year, simulate emergency stop triggering, safety door opening, signal short circuit and other scenarios, test the safety output response time (should be<10ms) and fault alarm accuracy, and check whether the safety certification mark is intact.

Safety Warning:

Module maintenance and debugging must be carried out by personnel with safety system operation qualifications. Before operation, the module power supply and upstream safety circuit power supply must be cut off, and a "no operation" sign must be hung;

It is prohibited to put the module into use without passing the safety function verification, modify the internal parameters of the module or disassemble the module, otherwise it may lead to a decrease in safety level and cause safety accidents.