ABB DSTS104 3BSE007285R1

Description

Detailed Parameter Table

ABB DSTS104 3BSE007285R1

Product introduction

The DSTS104 3BSE007285R1 is a high-integrity safety relay module developed by ABB to monitor and control safety-related functions in industrial automation systems. It is designed to ensure the safe operation of machinery by responding to emergency stop signals, safety gate interlocks, and other protective devices, immediately triggering protective actions such as machine shutdown when hazardous conditions are detected.

This safety module integrates seamlessly with ABB’s automation components, including the DC541-CM 1SAP270000R0001 controller module, to form a comprehensive safety system. The DSTS104 3BSE007285R1 operates independently of the standard control system, providing a redundant layer of protection that meets stringent safety standards.

With its SIL 3 and PL e certifications, the DSTS104 3BSE007285R1 is suitable for high-risk applications where human-machine interaction is frequent, such as robotic workcells, packaging lines, and material handling systems. Its compact design and easy integration make it a versatile solution for both new installations and retrofits of existing safety systems.

Core advantages and technical highlights

Enhanced safety performance

The DSTS104 3BSE007285R1 achieves SIL 3 and PL e ratings, ensuring it can handle the most demanding safety applications. Its redundant internal circuitry and self-monitoring capabilities detect faults such as short circuits, open circuits, and power supply issues, triggering a safe state if any anomaly is found. In an automotive stamping plant, for example, it reliably monitors emergency stop buttons and safety light curtains, ensuring the press immediately stops if a worker enters the hazardous area, preventing serious injuries.

Fast response time

With a response time of ≤15 ms, the DSTS104 3BSE007285R1 minimizes the time between a safety event and the machine’s shutdown. This rapid reaction is critical in high-speed applications, such as a bottling line where a jam could cause bottles to shatter— the module quickly stops the conveyor, reducing the risk of operator injury from flying debris.

Flexible configuration

The DSTS104 3BSE007285R1 features 4 inputs and 4 outputs, allowing it to monitor multiple safety devices simultaneously, such as two emergency stop buttons and two safety gates. Its configurable input modes (NC or NO) and output logic (NO/NC combinations) adapt to various safety circuit designs, eliminating the need for additional interface modules. This flexibility simplifies system design in complex machinery with multiple access points, such as assembly robots with multiple maintenance doors.

ABB DSTS104 3BSE007285R1

Typical application scenarios

In a robotic welding cell, the DSTS104 3BSE007285R1 is used to monitor safety gates, light curtains, and an emergency stop button. When an operator opens a safety gate to load parts, the module detects the gate’s interlock signal loss and immediately cuts power to the welding robot’s drive system via its safety outputs. Simultaneously, it sends a fault signal to the DC541-CM 1SAP270000R0001 controller, which logs the event and illuminates a warning light via a DO524 A3 1SAP240700R0001 module.

The DSTS104 3BSE007285R1 resets only after all safety conditions are restored (gate closed, emergency stop released) and a manual reset is performed, preventing accidental machine restart. This ensures compliance with safety standards like ISO 13850 for emergency stops, protecting workers from exposure to moving robots and arc welding hazards.

In a food processing line with high-speed slicing machines, the module monitors emergency stops at each workstation and safety mats at the line’s entrance. If a worker steps on a safety mat while the machine is running, the DSTS104 3BSE007285R1 triggers an immediate stop, halting the slicer and conveyor via its outputs. Its fast response time prevents contact with rotating blades, while its diagnostic LEDs help maintenance teams quickly identify which safety device was activated.

Related model recommendations

• DSTS102 3BSE007284R1: A 2-input/2-output version of the DSTS104 3BSE007285R1, suitable for simpler safety circuits with fewer devices.
• DC541-CM 1SAP270000R0001: Controller module that receives non-safety status signals from the DSTS104 3BSE007285R1for event logging and system monitoring.
• DO524 A3 1SAP240700R0001: Digital output module activated by the DC541-CMto control non-safety indicators (e.g., warning lights) when the DSTS104 3BSE007285R1 triggers a stop.
• TB820V2 3BSE013208R1: Terminal base used to wire field devices (e.g., emergency stops) to the DSTS104 3BSE007285R1, ensuring secure connections.
• SINT4611C: Power supply module that provides stable 24 V DC power to the DSTS104 3BSE007285R1and associated safety devices.
• DSTC100 3BSE018105R1: Safety controller that works with the DSTS104 3BSE007285R1in large-scale systems, coordinating safety functions across multiple machines.
• AI810 3BSE008516R0001: Analog input module that monitors auxiliary signals (e.g., machine speed) for the DC541-CM, which can preemptively reduce speed before the DSTS104 3BSE007285R1triggers a full stop.

Installation, commissioning and maintenance instructions

Installation preparation

Before installing the DSTS104 3BSE007285R1, ensure the control cabinet is clean and free of conductive debris. The ambient temperature must be within -20°C to +60°C, with no condensation. Required tools include a screwdriver (PH2), wire strippers, and a multimeter for voltage checks.

Mount the module on a 35 mm DIN rail, leaving at least 10 mm of space on each side for cooling. Use 0.5-1.5 mm² copper wires for input/output connections, stripped to 6-8 mm. Connect the 24 V DC power supply (from a SINT4611C) to the designated terminals, verifying polarity to avoid damage. All safety circuits must be wired with double-insulated cables, separated from non-safety wiring to prevent interference.

Maintenance suggestions

For daily maintenance of the DSTS104 3BSE007285R1, check the LED indicators: a steady green power LED and illuminated input/output LEDs (when active) indicate normal operation. A red fault LED signals issues like a broken input wire or power loss—refer to the manual to diagnose specific faults.

Test all safety functions monthly by activating each input device (e.g., pressing emergency stops, opening safety gates) and confirming the module triggers the correct output response (machine shutdown). Clean the module with a dry cloth quarterly to remove dust. If a fault persists after checking wiring, replace the DSTS104 3BSE007285R1 with an ABB-approved spare, ensuring the replacement is certified to the same safety standards. Always power down the system before replacing the module to maintain safety integrity.

Service and guarantee commitment

The DSTS104 3BSE007285R1 comes with a 5-year warranty from ABB, covering defects in materials and workmanship under normal operating conditions. This extended warranty reflects ABB’s confidence in the module’s durability and safety performance.

ABB’s technical support team provides specialized assistance for safety system design, including verification of DSTS104 3BSE007285R1 integration with other components like the DC541-CM 1SAP270000R0001. We offer on-site safety audits to ensure compliance with SIL 3 and PL e requirements, as well as training on module diagnostics and maintenance.

In the event of a warranty claim, ABB guarantees fast replacement to minimize safety system downtime. Our global network of service centers ensures timely access to technical resources, helping customers maintain the highest safety standards for their industrial machinery.