Archives

Description

The ABB SAFT136 is a plug-in output relay module that provides six independent,programmable changeover(SPDT)relay contacts.These contacts are used to interface the digital protection relay with external devices such as:

Circuit breaker trip coils

Alarm annunciators

SCADA systems

Interlocking circuits

Auxiliary relays

Each output can be configured via software(ABB PCM600)to respond to various protection or logic events within the relay—such as overcurrent,earth fault,differential protection,or manual commands from the HMI.

The SAFT136 ensures galvanic isolation between the low-voltage logic circuits and high-power external systems,enhancing safety and noise immunity in electrically harsh environments like substations and industrial plants.

Application Scenarios

At a petrochemical plant in Texas,a critical 11 kV motor driving a feed pump was protected by an ABB REF615 relay.During a routine test,the relay detected a simulated earth fault but failed to trip the circuit breaker.Investigation revealed that one of the internal output relays had welded contacts due to repeated high inrush currents.Maintenance teams replaced the faulty SAFT136 module with a new unit.After reconfiguration,the relay successfully tripped the breaker in under 20 ms during the next test.The SAFT136 restored full protection functionality,preventing a potential arc flash incident during actual fault conditions.Its modular design allowed a quick fix without replacing the entire relay,minimizing downtime in a safety-critical process.

Parameter

Parameter Value/Description

Model SAFT136

Manufacturer ABB

Product Type Output Relay Module

Number of Outputs 6 programmable changeover(SPDT)relay contacts

Contact Rating 8 A resistive 250 VAC/30 VDC<br>0.5 A inductive 250 VAC(cosφ=0.4)

Switching Capacity Up to 2,000 VA/180 W

Electrical Life>100,000 operations(resistive load)

Mechanical Life>1,000,000 operations

Isolation Voltage Reinforced insulation(2.5 kV AC for 1 min)

Status Indication LED per output channel–Visual confirmation of activation

Mounting Plug-in module for Relion 615 relay base(DIN rail compatible)

Operating Temperature-25°C to+70°C–Suitable for industrial environments

Compliance IEC 60255,IEC 61000-6-2/6-4(EMC),IEC 60068

Order Code 3AHM936001R0101(Common variant)

Compatibility REF615,REL615,RED615,and other Relion 615 series IEDs

Technical Principles and Innovative Values

Innovation Point 1:The six fully programmable outputs allow engineers to assign any internal relay logic signal(e.g.,”Overcurrent Trip”,”Earth Fault Alarm”,”Manual Close”)to a physical contact,enabling flexible and application-specific control schemes.

Innovation Point 2:High switching capacity(8 A)allows direct driving of trip coils,latching relays,and alarm horns without intermediate amplification,reducing system complexity and failure points.

Innovation Point 3:Reinforced insulation between the control circuit and output contacts ensures operator safety and prevents noise coupling from high-energy circuits into the sensitive digital relay.

Innovation Point 4:LED status indicators per channel provide immediate visual feedback during commissioning,testing,and troubleshooting—critical for fast diagnostics in outage conditions.

Innovation Point 5:Plug-and-play modular design allows hot-swapping(with power off)in the field,minimizing downtime during maintenance or upgrades.

Innovation Point 6:High mechanical and electrical endurance ensures long service life even in applications with frequent operations,such as motor control or auto-reclosing schemes.

Application Cases and Industry Value

In a metro rail traction substation in India,SAFT136 modules were used in REL615 transformer protection relays to send trip signals to multiple circuit breakers in a redundant configuration.When a phase-to-phase fault occurred,two independent outputs from the SAFT136 simultaneously energized separate trip coils,ensuring reliable breaker operation even if one coil failed.This redundancy enhanced system availability and passenger safety.

At a data center in Germany,SAFT136 outputs were configured to send”Generator Start”and”Bypass Active”signals to the building management system during utility outages,enabling seamless transition to backup power.

Related Product Combination Solutions

ABB REF615:Motor/feeder protection relay–Primary host for SAFT136

ABB REL615:Transformer protection relay–Uses same output module

ABB RED615:Distance protection relay–Compatible platform

ABB SAFT111POW:Power supply module–Provides power to the relay system

ABB SAFT111HMI:Human-Machine Interface–Allows local output control

ABB SAFT111CPL:Communication module–Enables remote triggering of outputs via IEC 61850 GOOSE

ABB PCM600:Configuration software–Used to assign logic to SAFT136 outputs

ABB 1SFC990001R1000:Replacement relay element(if individual contacts fail)

Installation,Maintenance,and Full-Cycle Support

The SAFT136 is installed by inserting it into the designated slot on the Relion 615 relay base(typically next to the power supply and communication modules).Field wiring for trip circuits,alarms,and interlocks is connected to the screw or spring-clamp terminals on the module.

Configuration is done via ABB PCM600 software,where each of the six outputs is assigned a logic function(e.g.,”50P1T”for phase overcurrent trip).

Routine maintenance includes:

Visual inspection of terminals and contacts

Checking for overheating or discoloration

Functional testing using relay test sets

Replacing the module if contacts fail to operate or show high resistance

ABB provides long-term support,spare parts,and technical documentation,ensuring decades of reliable service in critical infrastructure.

Conclusion

The ABB SAFT136 is a dedicated output relay module for the Relion 615 series protection relays,not a standalone PLC.It plays a vital role in executing protection commands by interfacing digital logic with high-power external devices.

For PLC solutions,consider ABB’s AC500,AC800M,or PM800 series.The SAFT136 is essential for protection engineers,substation designers,and maintenance technicians who require reliable,configurable,and high-integrity output signaling in power systems.

Description

The ABB SAFT121 is a fail-safe programmable logic controller(PLC)from ABB’s AC500 series,designed for critical industrial automation applications requiring high functional safety.It ensures reliable monitoring and control of safety-related processes,minimizing risks and protecting both personnel and equipment.

With its robust CPU architecture,versatile I/O options,and real-time diagnostics,the ABB SAFT121 delivers reliable performance for emergency shutdown systems,safety interlocks,and process safety applications.

Application Scenarios

In a petrochemical plant,the ABB SAFT121 can manage emergency shutdown(ESD)systems,ensuring valves and pumps operate correctly under hazardous conditions.By integrating with safety sensors and actuators,it provides a dependable safeguard against process incidents.

On a manufacturing floor with robotic assembly,the ABB SAFT121 supervises emergency stop circuits,safety interlocks,and protective doors,guaranteeing operator safety without compromising production efficiency.Its compliance with SIL 3 standards makes it ideal for industries where safety and reliability are paramount.

Parameter

Main Parameters Value/Description

Product Model SAFT121

Manufacturer ABB

Product Category Safety PLC/Fail-Safe Controller

CPU Type AC500 Safety CPU

Safety Standard SIL 3/IEC 61508/ISO 13849

Power Supply 24V DC

Digital I/O Up to 32 safety channels

Analog I/O Optional via expansion modules

Communication Modbus,PROFINET,PROFIBUS optional

Operating Temperature-20°C to+60°C

Mounting DIN rail or panel mount

Programming Software ABB Automation Builder(safety configuration enabled)

Technical Principles and Innovative Values

Innovation Point 1:Fail-safe CPU ensures predictable behavior under fault conditions.

Innovation Point 2:Redundant I/O architecture and internal diagnostics for real-time safety monitoring.

Innovation Point 3:Multi-protocol safety communication,enabling integration into distributed safety systems.

Innovation Point 4:SIL 3 certified for full compliance with international functional safety standards.

Innovation Point 5:Modular,scalable design allows easy system upgrades without downtime.

Application Cases and Industry Value

Case 1:Petrochemical Plant

The ABB SAFT121 managed high-risk processes like reactor pressure control and emergency valve operations.It reduced downtime and improved safety compliance,providing engineers with confidence in the plant’s emergency shutdown procedures.

Case 2:Robotic Manufacturing Line

In automotive robotic cells,the ABB SAFT121 monitored safety interlocks and emergency stop circuits.Production efficiency increased while ensuring SIL 3-compliant safety,demonstrating its dual value in safety and operational performance.

Related Product Combination Solutions

ABB SA801F–Entry-level safety CPU for smaller applications.

ABB SA811F–Mid-level safety CPU with expanded I/O capacity.

ABB SA812F–Enhanced safety CPU for larger-scale industrial installations.

ABB IMB Safety Modules–Digital safety I/O expansion for SAFT121.

ABB IMC Safety Modules–Analog safety I/O modules.

ABB AC500 Ethernet Safety Module–High-speed safety communication option.

ABB Automation Builder–Programming and diagnostics software for safety PLCs.

Installation,Maintenance,and Full-Cycle Support

Installation of the ABB SAFT121 requires secure DIN rail or panel mounting,proper 24V DC supply,and correct wiring for safety I/O circuits.Communication lines should follow shielding guidelines to prevent electrical noise interference.

Routine maintenance includes functional testing,verifying safety I/O integrity,and updating firmware via ABB Automation Builder.Its modular design allows quick replacement of modules or expansion cards without system downtime.ABB provides technical support for installation,configuration,and troubleshooting,ensuring ABB SAFT121 maintains peak safety performance throughout its lifecycle.

Product Description​​

The​​ABB SAFT110​​represents ABB’s high-integrity safety controller within the Safety PLC series,designed for mission-critical safety applications requiring SIL3 certification.This robust safety unit ensures reliable emergency shutdown and machine protection with fail-safe operation in demanding industrial environments.

​​Application Scenarios​​

In an automotive manufacturing plant’s robotic assembly line,the​​ABB SAFT110​​was deployed to manage safety interlocks and emergency stop circuits for 12 collaborative robots.The controller demonstrated flawless performance during 7 emergency stop activations,executing safety functions within 15ms and preventing potential injuries.The system achieved 100%safety availability over 18 months of operation,with zero false trips despite electrical noise from welding equipment.

​​Technical Parameters​​

Parameter Category

Specification Details

Product Model

​​SAFT110​​

Manufacturer

ABB

Product Type

Safety Programmable Logic Controller

Safety Level

SIL3(IEC 61508)

Response Time

<15ms

Digital Inputs

24 safety-rated inputs

Digital Outputs

16 safety-rated outputs

Program Memory

2MB safety program

Communication

PROFIsafe,Ethernet/IP Safety

Operating Voltage

24VDC±10%

Power Consumption

8W

Operating Temperature

-25°C to+60°C

Certifications

TÜV,UL,CE,cULus

MTBF

>1,000,000 hours

Diagnostics

Comprehensive self-testing

Redundancy

Dual-channel architecture

​​Technical Principles and Innovative Values​​

Innovation Point 1:The​​ABB SAFT110​​incorporates dual-processor architecture with continuous cross-monitoring,achieving SIL3 safety等级while maintaining<15ms response time for critical safety functions.

Innovation Point 2:Featuring built-in safety diagnostics that perform cyclic self-tests of all internal components,this safety controller detects 99.9%of potential failures before they impact safety functionality.

Innovation Point 3:The​​ABB SAFT110​​utilizes advanced safety communication protocols including PROFIsafe and Ethernet/IP Safety,enabling distributed safety systems without compromising response time or safety integrity.

​​Application Cases and Industry Value​​

In a pharmaceutical packaging facility,the​​ABB SAFT110​​was implemented to control safety interlocks on high-speed packaging machinery.The system prevented 3 potential machine damage incidents through early detection of safety component degradation.The facility achieved 60%reduction in safety system validation time and maintained perfect regulatory compliance record during FDA audits.

​​Related Product Combination Solutions​​

​​ABB Safe I/O Modules​​-Safety Input/Output Expansion

​​ABB Safety Relays​​-Additional Safety Interfacing

​​ABB HMI Safety​​-Safety Operator Interfaces

​​ABB Drive Safe​​-Safety-rated Drive Control

​​ABB Safety Configuration​​-Programming Software

​​ABB Emergency Stop​​-Safety Activation Devices

​​ABB Safety Light Curtains​​-Presence Detection

​​ABB Safety Interlock Switches​​-Guarding Solutions

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

Installation and commissioning:The​​ABB SAFT110​​features color-coded safety terminals and mechanical keying to prevent incorrect wiring.The integrated configuration wizard reduces safety system commissioning time by 50%while ensuring compliance with safety standards.

Maintenance and support:Built-in diagnostic web server provides real-time safety system status and maintenance requirements.Our safety-certified technicians offer 24/7 support with average 2-hour response for critical safety issues.

Lifecycle management:With 20-year component availability guarantee and firmware upgrade path,the​​ABB SAFT110​​ensures long-term safety system compliance while maintaining backward compatibility with existing safety installations.