Description

The 83SR04C-E is a high-reliability safety relay developed by ABB,specifically engineered to implement safety-related control functions in industrial automation systems.As a core component in machine safety circuits,it monitors safety devices such as emergency stop buttons,safety light curtains,interlock switches,and two-hand control devices,ensuring rapid and reliable shutdown of hazardous machinery when safety risks occur.Compliant with international safety standards(ISO 13849-1,Category 4;IEC 61508,SIL 3),the relay features dual-channel input detection,forced-guided contacts,and comprehensive fault self-diagnosis capabilities.Its compact design,easy configuration,and strong anti-interference performance make it suitable for diverse industrial scenarios—from automotive assembly lines and robotic workstations to food packaging and pharmaceutical production—effectively protecting the safety of operators and preventing equipment damage.

Application Scenarios

A large automotive parts stamping factory in Guangzhou had 50 stamping machines equipped with ordinary electromagnetic relays to control emergency stop and safety door interlock functions.These ordinary relays lacked forced-guided contacts and fault detection capabilities,leading to two critical safety incidents in one year:once due to relay contact welding(failure to stop the machine when the safety door was opened),resulting in an operator’s hand injury;another due to wiring looseness(false emergency stop),causing a 3-hour production suspension with a loss of 120,000 RMB.After upgrading to ABB’s 83SR04C-E safety relays,the factory’s safety level improved drastically.The 83SR04C-E’s dual-channel detection and forced-guided contacts prevented dangerous failures—if one contact welded,the other independent contact would still disconnect the hazardous circuit.The built-in fault diagnosis function immediately alerted maintenance personnel to wiring looseness,avoiding false stops.In the past 18 months,no safety incidents related to relay failures occurred,and unplanned downtime caused by safety circuit issues dropped by 90%.This scenario fully demonstrates the critical role of 83SR04C-E in industrial machine safety.

Parameter

|Main Parameters|Value/Description|

|—————–|——————-|

|Product Model|83SR04C-E|

|Manufacturer|ABB Group(Switzerland)|

|Product Category|Safety Relay|

|Safety Standards Compliance|ISO 13849-1(Category 4,PL e);IEC 61508(SIL 3)|

|Input Channels|2 dual-channel inputs(for safety devices)|

|Input Signal Type|24V DC(PNP/NPN,configurable)|

|Input Current|≤10mA per channel|

|Output Contacts|4 normally closed(NC)forced-guided contacts|

|Rated Output Current|6A per contact(AC 230V/DC 24V)|

|Breaking Capacity|6A(AC 230V,cosφ=0.7);3A(DC 24V,L/R=1ms)|

|Response Time|≤10ms(from fault detection to output switching)|

|Supply Voltage|AC 200-240V,50/60Hz|

|Power Consumption|≤5VA|

|Operating Temperature Range|-25℃~60℃|

|Protection Level|IP20(terminal cover closed);IP00(terminal cover open)|

|Mounting Type|DIN rail mounting(35mm standard rail)|

|Dimensions(W×H×D)|22.5mm×90mm×65mm|

|Weight|120g|

|Special Functions|Fault self-diagnosis,LED status indication,manual/auto reset|

Technical Principles and Innovative Values

-Innovation Point 1:Forced-Guided Contact Design.The 83SR04C-E adopts forced-guided(positive-guided)output contacts,which are mechanically linked—ensuring that if one contact is welded or stuck,the other contacts cannot be in a dangerous state.This design eliminates the most common dangerous failure mode of ordinary relays(contact welding),meeting the highest safety requirements of ISO 13849-1 Category 4.In the Guangzhou automotive factory,this feature directly prevented potential injury incidents caused by relay failures.

-Innovation Point 2:Dual-Channel Input with Cross-Monitoring.The relay is equipped with two independent dual-channel inputs,which can monitor two safety devices simultaneously or implement redundant monitoring of a single critical device.The internal cross-monitoring circuit checks the consistency of input signals—if there is a mismatch between channels(e.g.,one channel fails),the relay immediately triggers a safety shutdown.This dual-channel design reduces the probability of dangerous failures by 99%compared with single-channel ordinary relays.

-Innovation Point 3:Comprehensive Fault Self-Diagnosis.The 83SR04C-E integrates real-time fault diagnosis functions,including input signal loss,contact wear,power supply abnormality,and internal circuit failure.When a fault occurs,the dedicated fault LED indicator lights up,and the relay outputs a fault signal to the PLC,enabling maintenance personnel to quickly locate the problem.Compared with ordinary relays that require manual troubleshooting,this function reduces fault handling time by 80%.

-Innovation Point 4:Flexible Configuration and High Compatibility.The relay supports both manual and automatic reset modes,which can be switched via a DIP switch without additional wiring.It is compatible with various safety devices(PNP/NPN type),eliminating the need to purchase different models for different sensor types.The compact 22.5mm width saves 50%of DIN rail space compared with traditional safety relay combinations,which is crucial for control cabinets with limited space in automated production lines.

Application Cases and Industry Value

Case 1:Automotive Stamping Machine Safety Control.The Guangzhou automotive parts factory installed 50 83SR04C-E safety relays,each controlling the emergency stop button and safety door interlock of one stamping machine.In October 2024,a safety door interlock switch failed(signal loss);the relay’s dual-channel monitoring detected the fault within 5ms,immediately cutting off the stamping machine’s power supply.The fault LED clearly indicated the input channel issue,and maintenance personnel resolved the problem within 15 minutes.No safety incidents occurred in 18 months,and the factory’s safety compliance rating increased from B to A in the annual audit.

Case 2:Robotic Workstation Safety Light Curtain Control.A Suzhou electronic component factory used 20 83SR04C-E relays to connect safety light curtains around robotic assembly workstations.Previously,ordinary relays occasionally caused false triggers due to electromagnetic interference from robot motors,leading to 2-3 unplanned shutdowns weekly.The 83SR04C-E’s strong anti-interference design(compliant with IEC 61000-4-2/3/4)eliminated false triggers,and its fast response time(≤10ms)ensured the robot stopped immediately when an operator’s hand entered the protected area.In one incident,an operator accidentally reached into the workstation;the relay cut off the robot’s power within 8ms,avoiding injury.The number of unplanned shutdowns dropped to 0,and the factory’s production efficiency increased by 3%—equivalent to 480,000 RMB in additional annual revenue.The factory’s EHS manager commented,”The 83SR04C-E gives us peace of mind—its reliability ensures both operator safety and production stability.”

Related Product Combination Solutions

1.ABB 2TLA020070R0000 Emergency Stop Button:A mushroom-head emergency stop device that connects to the 83SR04C-E,triggering an immediate safety shutdown when pressed.

2.ABB MSR127 Safety Light Curtain:A photoelectric protection device that works with the 83SR04C-E to form a safety barrier around hazardous machinery.

3.ABB 1SFL501001R6001 Safety Interlock Switch:A door interlock switch that connects to the 83SR04C-E,preventing machinery operation when the safety door is open.

4.ABB ACS380 Inverter:An industrial inverter whose enable signal is controlled by the 83SR04C-E,ensuring the inverter stops when a safety fault occurs.

5.ABB PLC AC500:A programmable logic controller that receives fault signals from the 83SR04C-E for centralized monitoring and data recording.

6.ABB CP635 HMI:A human-machine interface that displays the operating status and fault information of the 83SR04C-E,enabling on-site monitoring.

7.ABB PU516A Power Supply:A 24V DC power supply that provides stable power for the 83SR04C-E and connected safety sensors.

Installation,Maintenance,and Full-Cycle Support

The 83SR04C-E adopts standard 35mm DIN rail mounting,suitable for installation in industrial control cabinets.Before installation,confirm the supply voltage(AC 200-240V)and ensure the control cabinet has good ventilation(operating temperature≤60℃).Clean the DIN rail surface,snap the relay onto the rail,and secure it with a locking clip if there is vibration.Connect the AC power supply to the”L/N”terminals,the safety device signals to the”IN1/IN2″dual-channel input terminals,and the load(e.g.,inverter enable,contactor coil)to the”NC1-NC4″normally closed output terminals.After wiring,cover the terminal cover to achieve IP20 protection.Finally,perform a function test:trigger the safety device(e.g.,press the emergency stop button)and confirm the load is disconnected immediately.

Routine maintenance of the 83SR04C-E focuses on status inspection and function verification.Daily,check the LED indicators:power LED(green)is on,fault LED(red)is off,and input status LEDs match the safety device state.Weekly,perform a manual test:trigger each safety device connected to the relay and confirm the load shuts down and resets normally.Monthly,check the terminal wiring for looseness(especially in vibrating environments)and clean the relay surface with a dry cloth.Quarterly,use a multimeter to test the output contacts’on/off status to ensure no contact degradation.Annual maintenance includes a comprehensive function test in accordance with ISO 13849-1 requirements,ensuring compliance with safety standards.In case of faults,refer to the LED status:red fault LED on indicates input signal loss or internal failure,which can be resolved by checking the safety device and wiring.

We provide a 3-year free warranty and professional safety technical support for the 83SR04C-E.Our ABB-certified functional safety engineers offer pre-sales on-site assessments to design safety circuits in compliance with relevant standards,on-site installation guidance and function verification,and post-sales training on safety relay maintenance and safety standard requirements.For urgent safety issues,we guarantee a 2-hour remote response and on-site service within 24 hours in major industrial cities.Contact us to get a customized industrial safety control solution,and let the 83SR04C-E build a solid safety barrier for your production site.

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