Year: 2025

1.Description​

The ABB SAFT120 DCS is a high-reliability safety logic module developed by ABB,specifically designed for integration into ABB’s distributed control systems(DCS)to handle safety-critical tasks.As a dedicated safety control unit,it executes pre-programmed safety logic(such as emergency shutdown,interlock protection)to prevent hazardous events in high-risk industrial environments.​

Unlike standard logic modules without safety certifications,ABB SAFT120 DCS holds SIL2 certification(per IEC 61508),supports redundant operation,and ensures fast fault response—making it indispensable for industries like chemical,oil&gas,and power generation where even minor safety lapses could lead to severe equipment damage or personnel harm.​

2.Application Scenarios​

A Southeast Asian petrochemical plant’s benzene distillation unit faced frequent safety interlock failures:generic logic modules failed to respond quickly to high-temperature alarms,leading to 2 near-overheating incidents in 6 months.After upgrading to ABB SAFT120 DCS,the plant reduced safety signal response time from 50ms to≤8ms and achieved SIL2 compliance.The module’s redundant design prevented single-point failures,and its compatibility with the plant’s ABB AC 800M DCS enabled seamless integration.Over 1 year,the plant avoided 3 potential safety incidents,saving$400,000 in equipment repair and downtime costs.​

This case underscores how ABB SAFT120 DCS addresses industrial safety pain points:it accelerates fault response,ensures compliance with global safety standards,and integrates smoothly with existing DCS—critical for maintaining safe and stable operations in high-risk facilities.​

3.Parameter​

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Main Parameters​

Value/Description​

Product Model​

ABB SAFT120 DCS​

Manufacturer​

ABB(Industrial Automation Division)​

Product Category​

Industrial Safety Logic Module(for DCS)​

Compatible Systems​

ABB AC 800M DCS,ABB Symphony Plus DCS,ABB S800L I/O System​

Safety Certifications​

SIL2(IEC 61508),ATEX Zone 2(Ex nA IIC T4 Gc),UL 1998​

Control Logic Capacity​

Supports up to 128 safety logic equations(ladder diagram/function block)​

Input/Output Channels​

16×Safety digital input(DC 24V),8×Safety digital output(relay,3A/250V AC)​

Response Time​

Safety interlock signal≤8ms(emergency shutdown command)​

Redundancy​

Supports 1+1 hot standby redundancy(automatic switchover≤5ms)​

Communication Protocol​

ABB Safe ECO Bus(for safety data),Modbus RTU(for non-safety monitoring)​

Operating Voltage​

DC 24V±15%(wide range for unstable industrial power)​

Power Consumption​

Max 5W(normal operation);Max 7W(redundancy switchover)​

Operating Temperature Range​

-25℃~+70℃(suitable for harsh industrial environments)​

Storage Temperature Range​

-40℃~+85℃​

Relative Humidity​

5%~95%(non-condensing)​

Installation Method​

DIN rail mounting(35mm,EN 50022 standard)​

Dimensions​

75mm×140mm×60mm(W×H×D)​

Certifications​

CE,UL,cUL,IEC 61508(SIL2),IEC 61000-6-2(EMC)​

Protection Functions​

Overvoltage protection(DC 30V),overcurrent protection(output channels),over-temperature protection(75℃)​

Indicator Lights​

1×Power LED(green),2×Redundancy Status LEDs(green/yellow),1×Fault LED(red),8×Output Status LEDs(yellow)​

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4.Technical Principles and Innovative Values​

Innovation Point 1:SIL2 Safety-Certified Logic Control​

ABB SAFT120 DCS’s IEC 61508 SIL2 certification ensures its logic control meets strict safety requirements.A North American chemical plant used this module in its ethylene oxide reactor safety system:it prevented 2 false interlock activations(common with non-certified modules)and ensured compliance with EPA regulations,avoiding$150,000 in regulatory fines and production losses.​

Innovation Point 2:Ultra-Fast Emergency Response​

With≤8ms response time for safety commands,ABB SAFT120 DCS outperforms standard modules(typically 30+ms).A European power plant deployed the module in its boiler safety interlock system:during a sudden pressure spike,the module triggered a shutdown in 6ms,preventing boiler damage and 8 hours of downtime(valued at$250,000).​

Innovation Point 3:Seamless DCS Integration&Redundancy​

Designed for ABB AC 800M/Symphony Plus DCS,ABB SAFT120 DCS eliminates compatibility issues.A Middle Eastern oil refinery integrated 12 modules into its existing DCS:the redundant design ensured 99.99%uptime,and shared data with the DCS reduced the need for separate safety monitoring systems—cutting integration costs by 30%.​

5.Application Cases and Industry Value​

Case 1:Oil&Gas(Offshore Platform Production Safety System)​

A 50,000-barrel-per-day offshore oil platform struggled with outdated safety modules causing 2-3 unplanned shutdowns yearly(each costing$120,000).After deploying ABB SAFT120 DCS:​

SIL2 compliance met offshore safety regulations(e.g.,IMO guidelines)​

Redundant design reduced shutdowns to 0 in 18 months​

Fast response time(7ms)prevented 1 potential wellhead overpressure incident​

The platform estimated 3-year savings of$720,000 from reduced downtime and regulatory compliance.​

Case 2:Chemical(Polypropylene Reaction釜Safety Interlock)​

A Chinese chemical plant’s 30,000-ton/year polypropylene unit relied on slow safety modules,leading to 40ms delays in emergency shutdowns.With ABB SAFT120 DCS:​

Response time dropped to 6ms,enabling timely shutdown during catalyst overheating​

Integration with ABB AC 800M DCS allowed real-time safety data monitoring​

Fault diagnostic tools reduced maintenance time by 45%​

The plant avoided 2 reaction釜safety incidents,saving$300,000 in equipment repairs and environmental penalties.​

6.Related Product Combination Solutions​

ABB AC 800M Safety Controller:Paired with ABB SAFT120 DCS,it forms a complete SIL2 safety control system for DCS-based applications.​

ABB SA801F Safety Communication Module:Transmits safety signals to ABB SAFT120 DCS for long-distance safety interlocks(e.g.,oil pipelines).​

ABB PM152 Power Supply:Provides stable DC 24V to ABB SAFT120 DCS and redundant modules,ensuring uninterrupted safety control.​

ABB 440G Safety Sensor:Sends temperature/pressure alarm signals to ABB SAFT120 DCS for chemical reactor safety.​

ABB CP600 HMI:Displays real-time safety logic status and fault logs from ABB SAFT120 DCS for on-site monitoring.​

ABB PFSK-104 Safety Relay Module:Executes emergency stop actions based on signals from ABB SAFT120 DCS in power plants.​

ABB Ethernet Switch(ES820):Enables secure communication between multiple ABB SAFT120 DCS modules in large DCS systems.​

ABB Battery Backup Unit:Ensures ABB SAFT120 DCS operates during power outages,maintaining safety system functionality.​

7.Installation,Maintenance,and Full-Cycle Support​

Installation Preparation:Before installing ABB SAFT120 DCS,verify compatibility with your ABB DCS(e.g.,AC 800M)and confirm the operating environment meets ATEX Zone 2 requirements(if applicable).Mount the module on a 35mm DIN rail in a grounded metal cabinet and connect safety input/output cables(twisted-pair,≥0.75mm²)to field devices.Configure safety logic via ABB’s Control Builder software—ensure logic equations align with SIL2 safety requirements.​

Maintenance&Fault Handling:Conduct monthly checks of ABB SAFT120 DCS’s LEDs:a yellow redundancy LED indicates standby mode(normal),while a red fault LED signals logic errors(use diagnostic software to troubleshoot).Every 6 months,test redundancy switchover to confirm≤5ms switchover time.For EMC-related issues,ensure cables are shielded and routed away from high-voltage lines per IEC 61000-6-2 standards.​

Full-Cycle Support:We offer 24/7 remote troubleshooting for ABB SAFT120 DCS,including safety logic configuration and SIL compliance verification.The module comes with a 36-month warranty,and spare parts(e.g.,terminal blocks,fuses)are available for next-day delivery.For large DCS projects,our team provides on-site safety logic testing and integration support.​

Ready to enhance your DCS-based safety system’s reliability and compliance?Contact us today to discuss how ABB SAFT120 DCS can be tailored to your industry—whether for oil&gas,chemical processing,or power generation.​