Description

Product Overview

The ABB 83SR03K-E GJR2342800R1500 SIE(referred to as”83SR03K-E”for brevity)is a high-reliability safety-related input/output(I/O)module(Baugruppe,German for”assembly”)specifically engineered for ABB’s AC 800M Distributed Control System(DCS)and safety automation systems.Designed to handle critical safety signals in industrial environments,this module serves as a core component in safety instrumented systems(SIS)for emergency shutdown(ESD),fire and gas monitoring,and process interlock applications—ensuring compliance with functional safety standards(IEC 61508)and minimizing risk in power generation,oil&gas,and chemical sectors.

Featuring a fault-safe design with redundant signal paths and built-in self-diagnostic capabilities,the ABB 83SR03K-E supports both safety inputs(e.g.,emergency stop buttons,gas detectors)and safety outputs(e.g.,shutdown valves,alarm horns),enabling seamless integration of safety logic into AC 800M DCS.Its rugged hardware construction withstands extreme operating temperatures(-40°C to+70°C),electromagnetic interference(EMI)per IEC 61000-6-2,and voltage transients—critical for harsh environments where safety system failure could lead to catastrophic incidents.By pairing with ABB’s Control Builder M Safety configuration software and the 3BSE012866QR1 PRD core processor,the ABB 83SR03K-E delivers SIL 2/3(Safety Integrity Level)performance,ensuring reliable detection and response to hazardous process conditions.

Technical Specifications

Parameter Name

Parameter Value

Product Model

ABB 83SR03K-E GJR2342800R1500 SIE

Manufacturer

ABB Process Automation

Product Type

Safety-Related Input/Output(I/O)Module(Baugruppe)

Safety Integrity Level(SIL)

SIL 2(single configuration);SIL 3(redundant configuration)per IEC 61508

I/O Configuration

8 safety input channels;4 safety output channels(configurable)

Input Signal Type

24V DC discrete(sinking/sourcing);compatible with emergency stops,sensors

Output Signal Type

24V DC discrete(sinking/sourcing);max 2A per channel(continuous)

Input Response Time

≤10ms(signal detection to processor)

Output Response Time

≤15ms(processor command to output activation)

Redundancy Support

1+1 hot standby(for SIL 3 applications)

Self-Diagnostics

Continuous monitoring of hardware faults(e.g.,short circuits,open circuits);fault coverage>99%

Communication Interface

ABB AC 800M backplane(compatible with 3BSE012866QR1 PRD processor)

Supported Protocols

ABB Safety over Backplane(proprietary fault-safe protocol)

Operating Power Supply

24V DC(redundant power inputs recommended);5V DC from AC 800M backplane

Physical Dimensions

120mm(W)×210mm(H)×140mm(D)(matches AC 800M module form factor)

Weight

1.4 kg

Installation

AC 800M rack mount(1 slot,compatible with 4/8/12-slot AC 800M racks)

Operating Environment

-40°C to+70°C(temperature);5%-95%RH(non-condensing,no frost)

Storage Environment

-50°C to+85°C;5%-95%RH(non-condensing)

Protection Rating

IP20(module);IP40(when installed in AC 800M rack)

Certifications

IEC 61508(SIL 2/3),UL 508S,CSA C22.2 No.14,ATEX Zone 2,IECEx

Key Features

Fault-safe design,self-diagnostics,SIL compliance,redundant power support

Main Features and Advantages

SIL 2/3 compliance for critical safety applications:The ABB 83SR03K-E is certified to IEC 61508 for SIL 2(single module)and SIL 3(redundant configuration),making it suitable for high-risk processes where safety system failure could cause harm to personnel or equipment.A 1,000MW coal-fired power plant uses the module in a SIL 3-rated boiler water level interlock system—its fault-safe design ensures that a module hardware fault triggers a safe shutdown(e.g.,closing fuel valves)instead of failing into an unsafe state,preventing potential boiler explosions.This compliance eliminates the need for third-party safety certification,reducing project costs by 20%.

Redundant signal paths and self-diagnostics:The module features dual redundant signal paths for all I/O channels and continuous self-monitoring(e.g.,checking for short circuits,open wires,and component failures)with>99%fault coverage.An offshore oil platform deployed the ABB 83SR03K-E in a gas detector input system—when a wiring fault was detected on one input channel,the module immediately flagged the issue via the AC 800M DCS and automatically switched to a redundant signal path(if configured),ensuring no loss of gas detection capability.This self-diagnostic feature reduces unplanned downtime by 75%compared to non-safety I/O modules that require manual fault detection.

Fast response times for emergency scenarios:With input response times≤10ms and output response times≤15ms,the ABB 83SR03K-E enables rapid activation of safety actions—critical for emergency shutdowns.A chemical plant uses the module to connect emergency stop(E-Stop)buttons to a reactor ESD system:when an E-Stop is pressed,the module transmits the signal to the 3BSE012866QR1 PRD processor in<10ms,and the processor triggers a reactor shutdown(via the module’s output channels)in<15ms.This fast response prevents chemical spills and reduces the risk of personnel injury,outperforming non-safety I/O modules(typical response times:50-100ms)by 3-6x.

Seamless integration with AC 800M DCS:The ABB 83SR03K-E is fully compatible with ABB’s AC 800M DCS and Control Builder M Safety software,enabling intuitive configuration of safety logic(e.g.,interlocks,ESD sequences)without requiring specialized programming tools.A petrochemical plant integrated 12 ABB 83SR03K-E modules with the AC 800M DCS—Control Builder M Safety’s drag-and-drop interface reduced safety logic programming time by 40%compared to third-party safety systems.The module also shares the same form factor as standard AC 800M I/O modules,simplifying rack layout and reducing cabinet space requirements.

Application Field

In power generation,the ABB 83SR03K-E is deployed in a 800MW natural gas-fired power plant’s turbine overspeed protection system(SIL 3-rated).It connects 8 overspeed sensor inputs(monitoring turbine rotor speed)and 4 safety output channels(controlling turbine trip valves)to the AC 800M DCS(powered by the 3BSE012866QR1 PRD processor).When the module detects an overspeed condition(exceeding 110%of rated speed),it triggers a turbine trip in<25ms(input+output response time),preventing turbine damage that could cost$1M+in repairs.Over 3 years,the module maintained 100%availability,with no safety-related faults.

For oil&gas,a refinery uses the ABB 83SR03K-E in a SIL 2-rated fire and gas safety system.The module connects 6 gas detector inputs(monitoring hydrocarbon leaks)and 3 safety output channels(activating fire suppression systems and alarm horns)to the AC 800M DCS.Its self-diagnostic feature detected a faulty gas detector wiring connection within 2 seconds,alerting operators via the DCS while maintaining coverage via a redundant detector—avoiding a potential refinery fire.The module’s ATEX Zone 2 certification also ensures safe operation in hazardous areas with flammable vapors.

In chemical manufacturing,the ABB 83SR03K-E controls a SIL 3-rated reactor pressure interlock system.It monitors 4 pressure transmitter inputs(redundant for SIL 3)and controls 2 emergency relief valve outputs.When reactor pressure exceeds the safe threshold,the module triggers valve opening in<20ms,preventing a reactor rupture.The module’s battery-backed configuration(via the AC 800M DCS’s backup battery)retains safety logic during power outages,ensuring compliance with FDA and OSHA safety regulations.Integration with the plant’s SCADA system via the AC 800M DCS also enables remote monitoring of safety system status,reducing on-site inspections by 30%.

Related Products

ABB 3BSE012866QR1 PRD–AC 800M core processor,primary compatibility target for the ABB 83SR03K-E module(executes safety logic).

ABB Control Builder M Safety–Configuration software,used to program safety logic(e.g.,interlocks,ESD sequences)for the ABB 83SR03K-E.

ABB CI854A–AC 800M I/O chassis,houses the ABB 83SR03K-E and other AC 800M modules in safety systems.

ABB 3BSE038416R1–Backup battery module,ensures the AC 800M DCS(and ABB 83SR03K-E configuration)retains data during power outages.

ABB 83SR04K-E GJR2342800R1600–16-input/8-output extension of the ABB 83SR03K-E,for high-density safety I/O applications.

ABB 2TLA020030R0000–Emergency stop button,compatible with the ABB 83SR03K-E’s safety input channels.

ABB V280–Safety shutdown valve,paired with the ABB 83SR03K-E’s safety output channels for ESD applications.

ABB 800xA Safety–Safety system HMI,provides visual monitoring of the ABB 83SR03K-E’s I/O status and safety events.

Installation and Maintenance

Pre-installation preparation:Verify compatibility with the target AC 800M DCS(including the 3BSE012866QR1 PRD processor)and confirm the module’s SIL rating matches the application requirements(SIL 2 for single,SIL 3 for redundant).Inspect the ABB 83SR03K-E for physical damage(e.g.,bent backplane pins,cracked housing)and confirm authenticity via ABB’s serial number verification portal.Update the module’s firmware to the latest version(via Control Builder M Safety)to ensure compliance with the latest safety standards.For SIL 3 applications,plan a redundant configuration(two ABB 83SR03K-E modules)and ensure redundant power inputs(24V DC)to the AC 800M rack.

Maintenance recommendations:Conduct monthly visual inspections of the ABB 83SR03K-E to check for loose backplane connections,dust buildup,and LED status(normal:green power LED,steady safety status LED;fault:red fault LED).Clean dust with filtered compressed air(≤0.2MPa)to prevent overheating.Test safety functions quarterly(in offline mode)by simulating faults(e.g.,E-Stop press,sensor failure)and verifying the module triggers the correct safe action(e.g.,output shutdown,DCS alarm).Download diagnostic logs monthly to analyze fault history—pay special attention to recurring issues(e.g.,wiring faults)that may require corrective action.Replace the module if a hardware fault is detected(red fault LED)and cannot be resolved via troubleshooting.For firmware updates,schedule during planned maintenance and use ABB’s official software to avoid compromising safety logic.

Product Guarantee

The ABB 83SR03K-E GJR2342800R1500 SIE is backed by a 36-month original factory warranty,covering manufacturing defects(e.g.,I/O channel failure,self-diagnostic malfunction)and non-compliance with SIL 2/3 standards under normal industrial operating conditions.ABB guarantees the module’s mean time between failures(MTBF)exceeds 500,000 hours—far exceeding the industry average of 200,000 hours for safety I/O modules.

Our global technical support team provides 24/7 assistance for module installation,safety logic configuration,and troubleshooting—including specialized support for SIL certification audits.Genuine units include a unique serial number for warranty activation and access to exclusive ABB resources,such as safety application notes,firmware updates,and SIL verification checklists.In the event of a valid warranty claim,ABB will ship a replacement module within 24 hours for critical safety applications(e.g.,reactor ESD systems),minimizing safety system downtime.We also offer on-site safety system commissioning services to ensure the ABB 83SR03K-E meets all application requirements and regulatory standards.

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