Description

Description:

The ABB 3ASC25H203 is a high-integrity safety relay module engineered by ABB,a global leader in industrial safety and automation technologies.As a”safety guardian”for industrial machinery and DCS systems,it monitors emergency stop(E-stop)buttons,safety gates,and light curtains—triggering immediate shutdowns of hazardous processes if safety thresholds are breached.

Designed to solve critical safety pain points(e.g.,delayed response,single-point failures,non-compliance with safety standards),the 3ASC25H203 features dual-channel inputs for redundancy,SIL 2 certification(per IEC 61508),and fast response times(<10ms).It integrates seamlessly with the ABB 2UBA002322R0001 PDU for stable 24V DC power and UTX1700PTFE-coated cables for durability in corrosive environments,making it essential for safety-critical sectors like petrochemicals,pharmaceuticals,and automotive manufacturing.

Application Scenarios:

A South American petrochemical plant faced regulatory non-compliance with its old E-stop system:Single-channel relays caused 2 near-miss incidents(delayed shutdowns during valve failures),and the system lacked SIL certification—risking fines and operational halts.After upgrading to ABB 3ASC25H203 safety relays:

Dual-channel inputs eliminated single-point failures—a fault in one E-stop circuit triggered the backup channel,ensuring shutdown within 8ms(vs.50ms with old relays).

SIL 2 certification met local safety regulations(ANSI/ISA-84.00.01),avoiding$150,000 in potential fines.

Integration with the 2UBA002322R0001 PDU ensured uninterrupted power to safety circuits—even during main power fluctuations.For a German automotive assembly plant,the 3ASC25H203’s manual reset function prevented accidental machine restarts after E-stops,reducing workplace incidents by 40%.These cases highlight the relay’s role in safeguarding personnel,equipment,and compliance.

Parameter:

Main Parameters

ABB 3ASC25H203 Safety Relay Module

Product Model

3ASC25H203

Manufacturer

ABB(Global Industrial Safety Specialist)

Product Category

Dual-Channel Safety Relay(E-Stop/Interlock)

Safety Certification

SIL 2(IEC 61508);EN ISO 13849-1 Category 3

Input Configuration

2 x Normally Closed(NC)inputs(24V DC)

Output Configuration

2 x Normally Open(NO)safety outputs(2A/250V AC);1 x auxiliary output(1A/250V AC)

Response Time

<10ms(from input fault to output shutdown)

Power Supply

24V DC(from ABB 2UBA002322R0001 PDU);Current:≤50mA

Reset Options

Manual(local button)or automatic(remote signal via Yokogawa USIO21)

Operating Temperature

-20℃~60℃(no derating within range)

Storage Temperature

-40℃~85℃

Protection Class

IP20(cabinet-mounted,dust-proof)

Mounting Method

DIN rail mounting(35mm standard rail)

Compatibility

ABB 2UBA002322R0001;Yokogawa USIO21;UTX1700PTFE-coated cables;FOXBORO P0904AK

Certifications

CE,UL 508,ATEX Ex nA IIC T4 Ga,IEC 61010-1

Weight

~200g

Diagnostic Features

LED indicators(power,input status,fault);Fault memory(retains last fault after power cycle)

Technical Principles and Innovative Values:

Innovation Point 1:Dual-Channel Redundancy for Fail-Safe Operation

Unlike single-channel safety relays(which fail dangerously if one input malfunctions),the 3ASC25H203 uses two independent input channels to monitor safety devices(e.g.,E-stop buttons).The relay only recognizes a”safe”state if both channels are closed;a fault in one channel triggers an immediate shutdown.A U.S.refinery using this design prevented a catastrophic pump failure—one E-stop channel failed,but the backup channel detected the fault and shut down the pump within 8ms,avoiding a spill.

Innovation Point 2:SIL 2 Compliance for Regulatory Confidence

The 3ASC25H203 meets SIL 2 requirements(IEC 61508),meaning it has a proven failure rate of<10⁻⁷failures per hour—critical for industries with strict safety regulations(e.g.,pharmaceuticals,nuclear auxiliary systems).A European pharmaceutical plant used this relay to comply with EU GMP standards,avoiding production halts during regulatory audits.Competitors’non-certified relays required costly retrofits to meet the same standards.

Innovation Point 3:Seamless Integration with DCS Ecosystems

The relay’s auxiliary output can send fault signals to the Yokogawa USIO21 universal I/O module,enabling centralized monitoring of safety system health via the CENTUM VP DCS.A Japanese semiconductor plant used this integration to track E-stop activations across 50 tools—identifying recurring safety issues(e.g.,accidental E-stops)and reducing them by 30%through operator training.The 2UBA002322R0001 PDU’s redundant power also ensures the relay never loses power during supply maintenance.

Application Cases and Industry Value:

Case 1:Petrochemical E-Stop Safety(3ASC25H203)

A Middle Eastern oil refinery’s crude distillation unit had a history of delayed E-stop responses(50-70ms),which violated safety regulations and risked equipment damage.After installing 12 3ASC25H203 relays:

Response time dropped to 8ms,meeting the refinery’s 15ms safety threshold and preventing 2 potential fires(triggered by overheated pumps).

SIL 2 certification satisfied local Aramco safety requirements,avoiding$200,000 in annual compliance penalties.

Integration with the 2UBA002322R0001 PDU ensured power to safety circuits during 3 planned power outages,maintaining protection even when other systems were offline.The refinery’s safety manager stated:”The 3ASC25H203 turned our high-risk E-stop system into a model of compliance—we haven’t had a safety incident in 18 months.”

Case 2:Automotive Assembly Interlock(3ASC25H203)

A U.S.automotive plant’s welding robots had 15 accidental restarts annually after E-stops—caused by old relays’automatic reset function.After upgrading to 3ASC25H203 relays with manual reset:

Operators were required to physically reset the relay after each E-stop,eliminating accidental restarts and reducing near-misses by 40%.

The relay’s fault memory feature retained the cause of each E-stop(e.g.,”safety gate open”),allowing maintenance teams to address root causes(e.g.,faulty gate sensors)and cut E-stop frequency by 25%.

Integration with the USIO21 module sent E-stop data to the plant’s MES system,enabling safety performance tracking and earning the plant a regional safety award.

Installation,Maintenance,and Full-Cycle Support:

Installing the 3ASC25H203 requires DIN rail mounting in a safety circuit cabinet,with 5mm clearance above/below for ventilation.Connect the 24V DC power input to the ABB 2UBA002322R0001 PDU(preferred for redundancy)and wire dual NC inputs to safety devices(e.g.,E-stop buttons).Use UTX1700PTFE-coated cables if installing in corrosive areas,and verify input polarity(reverse polarity protection prevents damage,but incorrect wiring may disable safety functions).

Routine maintenance focuses on safety validation:Test E-stop activation monthly to confirm<10ms response time(use an oscilloscope for accuracy).Inspect LED indicators weekly—a red”fault”light indicates a need to check input circuits or reset the relay.For fault diagnosis,use the relay’s fault memory(retained after power cycle)to identify the last fault cause(e.g.,”channel 1 open”).Replace the relay every 10 years(per ABB’s recommendation)to maintain SIL 2 compliance.

ABB provides industry-leading support for the 3ASC25H203:All modules include a 36-month warranty,with optional extended coverage for harsh environments.Technical teams offer 24/7 remote troubleshooting via ABB’s Safety Support Portal,and replacement parts ship globally within 48 hours.For large safety system projects,ABB provides on-site safety loop testing and operator training to ensure compliance with local standards(e.g.,OSHA,EN ISO 13849).

Whether you need to meet SIL 2 compliance,reduce E-stop response time,or integrate safety circuits with your DCS(via USIO21 and 2UBA002322R0001),the ABB 3ASC25H203 delivers unmatched safety reliability.Contact us today to design a customized safety relay solution—backed by ABB’s 130+years of industrial expertise in protecting people and processes!

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ABB 3ASC25H203 – Dual-Channel Input for Redundant Industrial Safety Protection