ABB SAFT 100 Series Modules: SAFT111POW,

Technical Dossier

Product Details And Specifications

ABB SAFT 100 Series: Comprehensive Module Range and Technical Overview

The ABB SAFT 100 series is a family of modular control and interface boards developed by ABB (formerly Asea Brown Boveri) for use in its ACS and DCS variable-speed AC drive platforms, including the ACS 600, ACS 800, and legacy DCS 400/600 DC drive systems. These modules are installed across heavy industrial sectors including petrochemical refineries, nuclear auxiliary systems, pulp and paper mills, offshore platforms, and large-scale water treatment facilities. The SAFT 100 series defines the control backplane architecture for a generation of ABB drives that remain in active service globally, with installed base units routinely requiring spare board replacements rather than full drive upgrades due to capital cost constraints and process continuity requirements.

The Evolution of SAFT 100 Series Architecture

The SAFT 100 series was introduced in the late 1980s as ABB standardized its modular drive control architecture across European manufacturing sites, primarily in Finland (Pitäjänmäki) and Sweden. The original SAFT 1xx boards used parallel backplane communication with proprietary ABB DDCS (Distributed Drive Control System) fiber-optic links for multi-drive coordination. Early revisions (SAFT 110, SAFT 111) established the power supply and analog I/O baseline. Mid-generation boards (SAFT 120, SAFT 121, SAFT 122) expanded digital I/O density and introduced pulse encoder feedback capability. Later additions (SAFT 130, SAFT 137, SAFT 138) addressed fieldbus integration requirements as Profibus-DP and DeviceNet adoption accelerated in the 1990s. The SAFT 100 series reached end-of-active-production around 2005–2010 depending on the specific board variant, transitioning to the AINT, RDCO, and RMIO board families used in ACS 800 and ACS 880 platforms. Compatibility between SAFT 100 boards and newer ABB drive generations is not direct; firmware and backplane pinout differences require engineering evaluation before any cross-generation substitution. For sites running legacy ACS 600 or DCS 400/600 systems, the SAFT 100 series remains the only compatible spare board family, making long-term inventory sourcing a critical maintenance planning factor.

SAFT 100 Series Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly sourced modules within the ABB SAFT 100 series. Each entry reflects the board's primary functional role within the drive control architecture:

SAFT111POW: Internal power supply board; generates regulated DC voltages for SAFT 100 control backplane.
SAFT110POW: Earlier-revision power supply module; functionally equivalent to SAFT111POW with minor PCB layout differences.
SAFT120AI: Analog input board; 8-channel, ±10 V / 4–20 mA configurable, 12-bit resolution.
SAFT121AI: Analog input expansion; higher-density variant with differential input support for noise-sensitive environments.
SAFT122AO: Analog output board; 4-channel, ±10 V output, used for speed reference and torque signal transmission.
SAFT130DI: Digital input board; 16-channel 24 VDC optoisolated inputs for drive command and status monitoring.
SAFT131DI: Digital input board, extended version; supports higher input voltage range and additional diagnostic functions.
SAFT132DO: Digital output board; 8-channel relay outputs rated for 250 VAC / 30 VDC switching.
SAFT137PB: Profibus-DP adapter board; enables fieldbus communication between SAFT 100 backplane and Profibus master controllers.
SAFT138DN: DeviceNet communication adapter; used in North American installations requiring CAN-based fieldbus integration.
SAFT140CPU: Central processing unit board; executes drive application software and coordinates all SAFT 100 I/O modules.
SAFT141CPU: Upgraded CPU board; faster processor clock, expanded RAM, compatible with later ACS 600 firmware revisions.
SAFT150ENC: Pulse encoder interface board; supports incremental encoders up to 10,000 PPR for closed-loop speed control.
SAFT151ENC: Dual-channel encoder board; supports two independent encoder inputs for master-follower drive configurations.
SAFT160COM: DDCS fiber-optic communication board; connects drive to ABB Master/Follower or DriveWindow PC tool via fiber link.
SAFT161COM: Extended DDCS board; supports longer fiber distances and multi-drop topologies in large drive line configurations.

Sourcing Hard-to-Find & Obsolete SAFT 100 Series Parts

The SAFT 100 series is classified as end-of-life (EOL) by ABB. OEM new-stock availability is effectively zero for most board variants. DriveKNMS maintains a dedicated inventory of tested surplus, refurbished, and new-old-stock (NOS) SAFT 100 series boards sourced through controlled industrial decommissioning projects, authorized distributor closeouts, and direct procurement from facilities undergoing drive platform upgrades. For each board supplied, DriveKNMS provides full traceability documentation including board revision level, firmware version where applicable, and test report. For customers managing multi-year maintenance contracts on legacy ACS 600 or DCS 400/600 installations, DriveKNMS offers reserved stock agreements to guarantee board availability against planned and unplanned outage events. Inquiries for bulk quantities, specific revision levels, or time-critical emergency supply should be directed to the sales team with full drive nameplate data to confirm compatibility.

Quality Control for the SAFT 100 Series Range

SAFT 100 series boards present specific test challenges due to their multi-layer PCB construction, proprietary ASIC components, and backplane-dependent power sequencing. DriveKNMS applies a structured test protocol for each board variant: incoming inspection covers physical condition assessment (capacitor condition, relay contact integrity, connector pin alignment, conformal coating status); functional testing is performed using ABB-compatible drive test rigs that replicate the actual backplane power and communication environment; for CPU boards (SAFT140CPU, SAFT141CPU), firmware boot verification and DDCS communication handshake tests are executed; for I/O boards, all channels are individually stimulated and measured against ABB factory specification tolerances; power supply boards (SAFT111POW, SAFT110POW) undergo load regulation testing across the full output current range. Boards that do not pass all test stages are quarantined and not offered for sale. Test reports are available upon request for critical applications.