Description

Part of the GJR5 series of safety and redundancy modules,the ABB GJR5-250500-R0202 is specifically tailored for use in redundant control architectures and safety instrumented systems(SIS),where system integrity and fault tolerance are paramount.It supports certified safety protocols and is typically used in conjunction with ABB’s Safe PLC CPUs and redundancy managers to implement SIL 2 or SIL 3 compliant safety functions according to IEC 61508 and IEC 62061 standards.The module features dual-channel architecture with diagnostic capabilities that continuously monitor signal integrity,enabling early detection of faults such as wire breaks,short circuits,or unauthorized bypass attempts.Its integration into the AC 500 platform ensures seamless communication via the internal backplane bus,minimizing wiring complexity and enhancing system reliability.With its rugged construction,galvanic isolation,and support for hot-swap operation in redundant configurations,the ABB GJR5-250500-R0202 stands as a cornerstone of dependable automation solutions where operational continuity and personnel safety cannot be compromised.

Technical Specifications

Product Model|GJR5-250500-R0202

Manufacturer|ABB

Product Type|Safety Digital I/O Module

Series/Platform|AC 500(Automation Controller 500)

Number of Channels|2 digital inputs,2 digital outputs(safety-rated)

Input Voltage|24 VDC

Input Current|Typically 8 mA per channel

Output Type|Solid-state relay(semiconductor),safety-isolated

Output Load Current|Up to 0.5 A per channel

Isolation|Reinforced isolation between channels and backplane(2500 VAC RMS)

Safety Certification|Complies with IEC 61508,IEC 62061,ISO 13849-1(up to SIL 3/PL e)

Response Time|<10 ms typical

Operating Temperature|0°C to 60°C(32°F to 140°F)

Storage Temperature|-40°C to 85°C(-40°F to 185°F)

Humidity|5%to 95%RH,non-condensing

Mounting|DIN rail(35 mm)

Power Supply|24 VDC via backplane

Main Features and Advantages

High-level safety integration and system redundancy are at the core of the ABB GJR5-250500-R0202’s design philosophy,making it an essential component in applications where failure could lead to severe consequences.The module is engineered to support dual-channel(redundant)safety circuits,allowing for cross-checking of signals to detect internal faults and ensure fail-safe operation.This dual-architecture design enables the implementation of safety functions such as emergency stops,door interlocks,and two-hand control systems with the highest levels of reliability and diagnostic coverage.

A significant advantage of the ABB GJR5-250500-R0202 is its seamless compatibility with the ABB AC 500 Safety PLC platform,which allows engineers to configure and monitor safety logic using familiar engineering tools like Automation Builder and SafeBuilder.This integration simplifies programming,reduces commissioning time,and ensures consistency across both standard and safety-related control functions.The module’s built-in diagnostics continuously verify the health of input and output circuits,providing real-time feedback to the controller and enabling predictive maintenance strategies.

The ABB GJR5-250500-R0202 also features galvanic isolation rated at 2500 VAC RMS,protecting the control system from electrical transients and ground potential differences that are common in industrial environments.Its compact DIN rail footprint allows for efficient use of cabinet space,while the robust housing ensures resilience against vibration,dust,and temperature fluctuations.Designed for use in redundant configurations,the module supports hot-swap capability,allowing for replacement without shutting down the entire control system—critical in continuous-process industries.With certifications for SIL 3 and PL e,the ABB GJR5-250500-R0202 delivers peace of mind in mission-critical applications,reinforcing ABB’s reputation for engineering excellence in industrial safety automation.

Application Field

The ABB GJR5-250500-R0202 is predominantly deployed in industrial applications where functional safety and system availability are non-negotiable.In automotive manufacturing,it is used to monitor safety gates,robotic cells,and press operations,ensuring that hazardous movements are halted immediately upon activation of an emergency stop or light curtain.Its ability to interface with dual-channel safety sensors makes it ideal for Category 4 and Performance Level e(PL e)compliant machinery as defined by ISO 13849-1.

Within energy and power generation facilities,the ABB GJR5-250500-R0202 plays a crucial role in turbine protection systems,boiler controls,and switchgear monitoring,where rapid and reliable shutdown sequences are essential to prevent equipment damage or environmental incidents.In water and wastewater treatment plants,it helps secure pump stations,chemical dosing units,and confined space access points,ensuring compliance with occupational health and safety regulations.

The module is also widely used in material handling and logistics systems,such as automated storage and retrieval systems(AS/RS),conveyor interlocks,and crane safety circuits.In pharmaceutical and food processing environments,it supports hygienic design requirements while ensuring that safety protocols are maintained during cleaning and maintenance cycles.For system integrators working on brownfield upgrades or greenfield projects involving the AC 500 platform,the ABB GJR5-250500-R0202 offers a proven,certified solution for implementing robust safety logic without compromising on flexibility or scalability.Its presence in these high-stakes applications underscores its role as a trusted enabler of safe and efficient industrial automation.

Related Products

ABB GJR5-250500-R0102–A variant of the same series with different I/O configuration(e.g.,input-only or output-only),used for specialized safety monitoring tasks within the AC 500 platform.

ABB AC500-S–The safety-certified CPU module that works in conjunction with the ABB GJR5-250500-R0202 to execute safety logic programs and manage emergency shutdown sequences.

ABB GJR5-250500-R0302–A related redundancy module used for CPU or communication bus redundancy,often deployed alongside the ABB GJR5-250500-R0202 in high-availability control systems.

ABB CP571–A central processing unit in the AC 500 series for standard control tasks,which can be paired with the ABB GJR5-250500-R0202 in mixed safety and non-safety applications.

ABB DM582–A standard digital I/O module in the AC 500 family,used for non-safety signals,providing contrast to the safety-rated functionality of the ABB GJR5-250500-R0202.

ABB AI533–An analog input module for the AC 500 system,often used in parallel with the ABB GJR5-250500-R0202 for comprehensive process monitoring and control.

ABB Automation Builder–The integrated engineering software suite used to configure,program,and diagnose the ABB GJR5-250500-R0202 and other AC 500 components.

ABB SafeBuilder–A dedicated tool for designing and validating safety logic,essential for commissioning systems utilizing the ABB GJR5-250500-R0202.

Installation and Maintenance

Pre-installation preparation:Before installing the ABB GJR5-250500-R0202,ensure the DIN rail is securely mounted and the control cabinet is de-energized.Verify that the backplane power(24 VDC)is stable and within tolerance,and confirm compatibility with the AC 500 CPU and redundancy configuration.Check that all field wiring for safety inputs and outputs uses shielded,twisted-pair cables with proper grounding to minimize electromagnetic interference.Follow ABB’s wiring guidelines for safety circuits,including the use of separate conduits for safety and non-safety signals to maintain integrity.Ensure that the module’s firmware version is compatible with the controller before commissioning.

Maintenance recommendations:The ABB GJR5-250500-R0202 is designed for long-term,maintenance-free operation,but periodic system diagnostics should be performed using Automation Builder to verify signal status,diagnostic flags,and communication health.Inspect terminal connections annually for tightness and signs of corrosion,especially in humid or corrosive environments.Monitor the module’s LED indicators for normal operation—steady green for active,blinking for diagnostics or faults.If a fault is detected,use the diagnostic data from the CPU to isolate the issue to wiring,field device,or module failure.Due to its safety-critical nature,any replacement of the ABB GJR5-250500-R0202 should be followed by functional safety testing and documentation in accordance with site safety management procedures.

Product Guarantee

We provide a comprehensive product guarantee for every ABB GJR5-250500-R0202 module supplied,reflecting our commitment to quality,authenticity,and performance in industrial automation.Each unit is verified for originality and functionality prior to shipment,ensuring it meets ABB’s exacting standards for safety and reliability.Our guarantee covers defects in materials and workmanship under normal operating conditions and includes full traceability documentation upon request.We support our customers with expert technical assistance for integration,configuration,and troubleshooting,leveraging deep expertise in the AC 500 safety platform.In the event of a verified failure,we offer prompt replacement or repair to minimize downtime in critical operations.By delivering genuine,certified ABB GJR5-250500-R0202 modules backed by rigorous quality assurance and responsive service,we empower engineers and maintenance teams to build and sustain safe,efficient,and resilient control systems.

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