ABB Sentry USR22 User manual

SAFETY PRODUCTS
Safety relays
Sentry USR22
Product manual
ORIGINAL INSTRUCTIONS2TLC010073M0201 Rev.G

2TLC010073M0201 Rev.G
Read and understand this document
Please read and understand this document before using the products. Please consult your ABB Electrification
Sweden representative if you have any questions or comments.
Suitability for use
ABB shall not be responsible for conformity with any standards, codes, or regulations that apply to the
combination of products in the customer’s application or use of the product. Third party certificates for the
products are available at https://new.abb.com/low- voltage/products/safety-products. This information by
itself is not sufficient for a complete determination of the suitability of the products in combination with the
end product, machine, system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not
intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses
listed may be suitable for the products:
• Outdoor use uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this document.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
equipment, amusement machines, vehicles, and installations subject to separate industry or government
regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT
ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE ABB
PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT
OR SYSTEM.
Descriptions and examples show how the product works and can be used. It does not mean that it fulfills the
requirements for all types of machines and processes. The buyer/user is responsible for installing and using
the product according to applicable standards and regulations. We reserve the right to make changes to the
product and the documentation without prior notice

2TLC010073M0201 Rev.G
Table of Contents
1 Introduction............................................................................................................................................................ 5
1.1 Purpose of document .......................................................................................................................................... 5
1.2 Intended audience................................................................................................................................................ 5
1.3 Reading prerequisites ......................................................................................................................................... 5
1.4 Special notes ......................................................................................................................................................... 5
2 Safety ...................................................................................................................................................................... 6
2.1 Intended use.......................................................................................................................................................... 6
2.2 Safety precautions ............................................................................................................................................... 6
3 Product description............................................................................................................................................... 7
3.1 Sentry safety relays.............................................................................................................................................. 7
3.2 Sentry product range........................................................................................................................................... 7
3.3 Safety relay overview ........................................................................................................................................... 8
4 Installation.............................................................................................................................................................. 9
4.1 Installing precautions .......................................................................................................................................... 9
4.2 Attaching the safety relay on the DIN rail........................................................................................................ 9
4.3 Removing the safety relay from the DIN rail ................................................................................................... 10
4.4 Resetting the latching device............................................................................................................................. 10
4.5 Connecting precautions...................................................................................................................................... 11
4.6 Connection blocks................................................................................................................................................ 11
4.7 Coding the connection blocks ........................................................................................................................... 11
4.8 Connecting to a screw compression type terminal....................................................................................... 12
4.9 Connecting to a push-in type terminal ............................................................................................................ 12
4.10 Wire properties ..................................................................................................................................................... 12
4.11 Wire length............................................................................................................................................................. 12
5 Functions................................................................................................................................................................. 14
5.1 Function overview ................................................................................................................................................ 14
5.2 Power supply ......................................................................................................................................................... 14
5.3 Relay outputs......................................................................................................................................................... 14
5.4 Safety device interface........................................................................................................................................ 15
5.5 Test, start and reset interface ........................................................................................................................... 15
5.6 Automatic reset .................................................................................................................................................... 15
5.7 Manual reset .......................................................................................................................................................... 16
5.8 Multi-reset.............................................................................................................................................................. 16
6 Connections............................................................................................................................................................ 17
6.1 Connection groups............................................................................................................................................... 17
7 Application connections ....................................................................................................................................... 18
7.1 Connection examples .......................................................................................................................................... 18
7.2 One channel connection...................................................................................................................................... 19
7.3 Two channels connection with equivalent contacts ..................................................................................... 19
7.4 Two channels connection with antivalent contacts ...................................................................................... 20

2TLC010073M0201 Rev.G
7.5 Two channels OSSD connection ........................................................................................................................ 20
7.6 Pressure sensitive device connection .............................................................................................................. 21
7.7 Two-hand device connection ............................................................................................................................. 21
7.8 Reset button connection example .................................................................................................................... 22
8 Configuration ......................................................................................................................................................... 23
8.1 Buttons ................................................................................................................................................................... 23
8.2 Display .................................................................................................................................................................... 24
8.3 Password................................................................................................................................................................ 24
8.4 Timer settings ....................................................................................................................................................... 24
8.5 Factory reset.......................................................................................................................................................... 24
8.6 Output groups....................................................................................................................................................... 24
8.7 Preset ...................................................................................................................................................................... 24
8.8 Settings in preset mode...................................................................................................................................... 24
8.9 Configuration in preset mode ........................................................................................................................... 25
8.10 Settings in custom mode.................................................................................................................................... 26
8.11 Configuration in custom mode.......................................................................................................................... 26
8.12 Operation mode with preset.............................................................................................................................. 27
8.13 Operation mode with custom configuration.................................................................................................. 28
8.14 Delay functions ..................................................................................................................................................... 29
9 Maintenance ........................................................................................................................................................... 31
9.1 Maintaining precautions ..................................................................................................................................... 31
9.2 Scheduled test....................................................................................................................................................... 31
10 Troubleshooting..................................................................................................................................................... 32
10.1 Front LEDs and display........................................................................................................................................ 32
10.2 LED operation indication and error status...................................................................................................... 32
10.3 Display codes......................................................................................................................................................... 34
11 Model overview ...................................................................................................................................................... 36
11.1 Sentry models........................................................................................................................................................ 36
11.2 Accessories and spare parts .............................................................................................................................. 37
12 Dimensions ............................................................................................................................................................. 38
12.1 Sentry ...................................................................................................................................................................... 38
13 Technical data ........................................................................................................................................................ 39
13.1 Technical data ....................................................................................................................................................... 39
14 Declaration of conformity .................................................................................................................................... 45

2TLC010073M0201 Rev.G 5
1 Introduction
1.1 Purpose of document
The purpose of this document is to describe the functions and to provide instructions for
installation, operation, maintenance and troubleshooting of the product.
1.2 Intended audience
This document is intended for authorized personnel.
1.3 Reading prerequisites
It is assumed that the reader of this document has:
• Basic knowledge of ABB safety products.
• Knowledge of machine safety.
• Knowledge of safety devices.
1.4 Special notes
Pay attention to special notes in this document:
Warning! Risk of severe personal injury!
An instruction or procedure which, if not carried out correctly, may
result in injury to the technician or other personnel.
Caution! Risk of damage to the equipment!
An instruction or procedure which, if not carried out correctly, may
damage the equipment.
Note! Important or explanatory information.

6 2TLC010073M0201 Rev.G
2 Safety
2.1 Intended use
The intended use of the Sentry safety relay is to monitor the state of a safety device and
depending on the state, activate or inactivate the outputs within the system response time.
The protective function of the safety device is only safe if the safety relay is correctly
connected and configured. The safety relay is not by itself a complete protective device.
• Use the safety relay as a safety monitoring device.
• Use the safety relay as expansion device of safe outputs
• The safety relay is not intended for use in explosive or easily flammable adjacent air.
• Other use than defined as correct is considered as incorrect use.
2.2 Safety precautions
Warning! The safety precautions must be followed during installation, operation,
maintenance and troubleshooting.
Warning! The safety functions must be tested at start up or at replacement
before the system is put in operation.
Installation shall be conducted by authorized personnel following the Safety regulations,
standards and local legal regulations. Carefully read through the entire original instruction
before using the device.
Make sure that these instructions are included together with the documentation of the
system. Make sure that these instructions always are available for users of the system.
The safety relay must be selected so its safety related capacity meets or exceed the
performance level (PL) or safety integrity level (SIL) that has been estimated in the risk
analysis. The safety relay must only be used after it has been selected according to related
instructions, relevant standards, rules and regulations for protection and safety at work.
The entire dangerous zone must be visible from the position where the reset button is
installed. The reset button must be positioned out of reach from the dangerous zone.
The safety functions must be tested after installation or replacement of components or
cables. The safety relay must be exchanged within 20 years.
Failure to comply with instructions, operation that is not in accordance with the use
prescribed in the instructions, improper installation or handling can affect the safety of people
and the system. Failure to comply with the instructions or standards, excludes any liability.

2TLC010073M0201 Rev.G 7
3 Product description
3.1 Sentry safety relays
Sentry safety relays provide safe stop and start of monitored devices to prevent errors. The
following safety device types are applicable for the Sentry safety relays:
• 1 channel safety device.
• 2 channel safety device with equivalent contacts.
• 2 channel safety device with antivalent contacts.
• Expansion of safety modules.
• Pressure sensitive safety device (short-circuit detection).
• Two-hand safety device.
• OSSD safety device.
Examples of devices for connection to the Sentry safety relays:
• Light beams.
• Light curtains.
• Three position safety device.
• Safety interlock switches.
• Emergency stop buttons.
• Bumpers, contact edges and safety mats.
3.2 Sentry product range
The Sentry product range has the following groups of safety relays:
BSR (Basic function Safety Relay) group
The BSR group include BSR10, BSR11 and BSR23. The safety relays have basic monitoring
functions for 1- and 2-channel safety devices. The safety relay can be used as an expansion of
other safety modules.
SSR (Single function Safety Relay) group
The SSR group includes SSR10, SSR10M, SSR20, SSR20M, SSR32 and SSR42. The safety relays
have single safety device functions and limited configuration possibilities for automatic and
manual reset. SSR32 and SSR42 have a timer function.
TSR (Timer function Safety Relay) group
The TSR group includes TSR10, TSR20 and TSR20M. The safety relays have timer functions and
configuration possibilities. TSR10 is fully configurable with preset selection possibilities and
password protection.
USR (Universal function Safety Relay) group
The USR group include USR10 and USR22. The safety relays have multiple functionalities for
monitoring safety device including timer functions. The USR group is fully configurable with
preset selection possibilities and password protection.

8 2TLC010073M0201 Rev.G
3.3 Safety relay overview
P
M
E
F
A
B
C
D
J
H
G
K
L
N
A. Connection block, top side back.
B. Connection block, top side front.
C. Product name.
D. Display.
E. Increment button.
F. Select button.
G. LEDs for status indication.
H. Print for connection block, top side back.
J. Print for connection block, top side front.
K. Print for connection block, bottom side front.
L. Print for connection block, bottom side back.
M. Connection block, bottom side front.
N. Connection block, bottom side back.
P. DIN rail latching device.

2TLC010073M0201 Rev.G 9
4 Installation
4.1 Installing precautions
Follow the instructions carefully to avoid personal injury or damage to the device.
The safety relay shall be attached on a 35 mm DIN rail in a lockable enclosure that has at least
protection class IP54. Sentry safety relays shall be installed in an upright position.
Make sure there is at least 10 mm distance between the safety relay and other non-Sentry
units to prevent uncontrolled heating. Make sure there is at least 50 mm distance above and
below the safety relay and other units for correct air flow in the venting holes of the safety
relay.
Caution! Sentry safety relays can be installed without distance to other Sentry
safety relays, with exception of BSR23. Make sure there is at least 5 mm
distance between BSR23 and other Sentry safety relays
4.2 Attaching the safety relay on the DIN rail
1. Make sure that the DIN rail latching is reset.
2. Hang the top rear side of the safety relay on the DIN rail.
3. Push the bottom rear side of the safety relay on the DIN rail until a click is heard.

10 2TLC010073M0201 Rev.G
4.3 Removing the safety relay from the DIN rail
1. Use a screwdriver to unlock the DIN relay latching device from the DIN rail.
2. Pull the bottom rear side of the safety relay away from the DIN rail until a click is heard.
3. Lift the top rear side of the safety relay away from the DIN rail.
4.4 Resetting the latching device
• Pull the bottom side of the DIN rail latching device from the safety relay and push it
upwards to release it to its original position.

2TLC010073M0201 Rev.G 11
4.5 Connecting precautions
Warning! Disconnect the power supply before attaching or removing the
connection blocks.
Make sure that connection blocks and wires are clearly marked for correct connections. Use
applicable requirements in IEC 60204‑1 for wire connections. Make sure that the wires are
fitted with crimp terminals or ferrules before connection, unless solid copper conductors are
used.
For connections of relay output contacts: Make sure that all power supplies or signal sources
are connected to one side of the safety relay and that all power consumers or signal receivers
are connected to the opposite side of the safety relay.
Make sure to use at least one of the following methods to ensure correct wire protection
against short circuits for the safety relay outputs:
• The wires are permanently connected and protected against external damage, for example
by wire ducts or other types of covers for protection.
• Use of separate multi-core wires.
• Use of cables with wires being individually shielded with earth connection.
The safety requirement is that fuses shall be used on the relay outputs.
4.6 Connection blocks
The connection blocks on the safety relay are detachable to simplify installation and
replacement. The safety relay can be ordered with two different types of connection blocks,
screw compression type or push-in type.
4.7 Coding the connection blocks
The coding kit is used to make each connection point individual to avoid faulty connection.
Place the coding parts in an specific order on the connection block and match these with the
pin header.
• The risk assessment must include the risk of mistakes when using the connection blocks
without coding.
• If coding is used, a test of the outcome of the coding against the identified risks must be
done.

12 2TLC010073M0201 Rev.G
4.8 Connecting to a screw compression type terminal
Use a screwdriver with slot size 3,5 mm.
1. Open the terminal before inserting a wire.
2. Insert the wire in the correct terminal.
3. Close the terminal and secure the wire with torque 0,7 Nm ±0,1.
4.9 Connecting to a push-in type terminal
1. Press the actuating lever.
2. Insert the wire in the correct terminal.
3. Release the actuating lever.
4.10 Wire properties
Wire area, screw compression type connection block
Wire with crimp sleeve, ferrule or single solid conductor. Two wires with the same area must
be used. Wire strip length 6,5 mm ±0,5.
Minimum 1x24 AWG and Maximum 1x12 AWG
Minimum 1x0,2 mm2 and Maximum 1x3,3 mm2
Minimum 2x24 AWG and Maximum 2x16 AWG
Minimum 2x0,2 mm2 and Maximum 2x1,5 mm2
Wire area, push-in type connection block
Wire with crimp sleeve, ferrule or single solid conductor. Two wires with the same area must
be used. Wire strip length 6,5 mm ±0,5.
Minimum 1x24 AWG and Maximum 1x14 AWG
Minimum 1x0,2 mm2 and Maximum 1x2,5 mm2
Minimum 2x24 AWG and Maximum 2x16 AWG
Minimum 2x0,25 mm2 and Maximum 2x1,5 mm2
4.11 Wire length
The maximum wire length depends on the total resistance and total capacitance in the
transmitter loop for each channel. The model used to determine the maximum allowed wire
resistance and wire capacitance between the transmitter port (T) and the receiver port (R) is
shown in the figure.
Rext is the total wire resistance, and Cext is the total wire capacitance (to ground, or shield).
The switch symbolizes the sensor, placed halfway in the T-R loop (as indicated by having half
of Rext/Cext on each side). Iext is the current drawn by the sensor for its operation and/or
other external loads. The maximum allowed wire resistance, Rext, vs. the externally drawn
current Iext is listed in the table.

2TLC010073M0201 Rev.G 13
The maximal wire length is limited by the resistive loading to the maximum wire resistance
divided with the wire resistance per length of the unit.
The maximal wire length is limited by capacitive loading to (100nF - external capacitive
loading) divided with the wire capacitance per length of unit.
Rext is resistance for the complete wire.
Iext Maximum wire resistance Rext (T–R)
0 mA 850 Ω
5 mA 600 Ω
10 mA 460 Ω
15 mA 370 Ω
20 mA 300 Ω
25 mA 260 Ω
30mA 220 Ω

14 2TLC010073M0201 Rev.G
5 Functions
5.1 Function overview
Power supply, 24 VDC
Relay output
• 2 NO + 2 NO
Safety device interface
• One channel connection
• Two channels with equivalent contacts
• Two channels with antivalent contacts
• Two channels OSSD
• Pressure sensitive device
• Two-hand device
Test, start and reset interface
• Automatic reset
• Manual reset
• Multi reset
Timer function
• Off-delay 0.5 s
• Off-delay 1.5 s
• Off-delay 0 – 999 s
• On-delay 0 – 999 s
• Time bypass 0 – 999 s
• Time reset 0 – 999 s
Features
• Display
• Error status code
• Password
5.2 Power supply
24 VDC
The safety relay and the safety devices are supplied with 24 VDC and common shared ground.
Warning! The power supply must be of type PELV/SELV
5.3 Relay outputs
The safety relay output contacts are opened or closed based on the signals from the safety
device. Each safety relay output has two contacts in series, one contact for each internal
output relay.

2TLC010073M0201 Rev.G 15
A
B
A
4
43
44
A. Connectors: Terminals in connection blocks.
B. NO contact: The NO contact is open when the relay is inactivated and closed when the
relay is activated.
Caution! A relay output is in safe state when the contact is open.
Note! The NO contact is open at all types of internal failures and is a safe
output.
Note! Arc suppression for inductive loads is recommended to get a longer
lifetime for the relay contacts.
5.4 Safety device interface
Sentry safety relays have interfaces with inputs/outputs (I/O:s) for connections of safety
devices.
Inputs/Outputs
T1/T2 detect short circuits to +24 VDC or other OSSD signals and are designed for supplying
signals to different types of safety devices.
Note! It is not necessary to connect T1/T2 to the safety devices. The safety
level may be reduced if T1/T2 are not used. Possible errors in the
connected safety devices and wires may not be identified.
R1/R2 receives the signals from the safety devices.
Warning! The safety relays and the safety devices supplied with 24 VDC must be
connected to PELV/SELV power supply.
5.5 Test, start and reset interface
The safety relay has an interface for test, start and reset functions. The safety relay enters
inactive mode when at least one input is not accepted. The safety relay enters active mode
when the inputs are accepted, and a reset is performed.
5.6 Automatic reset
When at least one input signal is not accepted, the safety relay enters inactivated mode. The
MODE LED light blue and at least one of CH1/CH2 LED will turn OFF. When the safety input
signals are accepted and the test (X1/X4) circuit is closed, an automatic reset is made. The
relay activates and the three LEDs will light green.

16 2TLC010073M0201 Rev.G
5.7 Manual reset
Warning! Always use the manual reset function when a reset button is installed.
When at least one input safety signal is not accepted, the safety relay enters to inactive mode.
The MODE LED is blue and at least one of the CH1/CH2 LEDs will turn OFF and the reset button
light is static on.
When the safety input safety signals are accepted, the CH1 LED and the CH2 LED are green and
the MODE LED is blue. The reset button light is flashing to indicate that a reset is possible. To
reset the safety circuit, press the reset button for 0.05 s to 2 s. The relay goes to active mode
and the button light turns off when the button is released (falling edge).
A reset button light test can be executed by pressing the reset button in active mode.
5.8 Multi-reset
It is possible to use one reset button to reset up to ten safety relays while maintaining the
reset button light function.

2TLC010073M0201 Rev.G 17
6 Connections
6.1 Connection groups
The connections are divided into groups.
A Power supply
T Signal to safety device
R Signal from safety device
X Test/reset/start/indication
13, 23, 14, 24 Safety output group 1, NO
33, 43, 34, 44 Safety output group 2, NO

18 2TLC010073M0201 Rev.G
7 Application connections
7.1 Connection examples
CH1
MODE
CH2
SENTRY USR22
OSSD 1 OSSD 2
CH1 CH2
CH1 CH2 CH1 CH2
CH1 CH2 CH1 CH2
CH1 CH2 CH1 CH2 CH1 CH2 CH1 CH2
D)
A)
C)
E)
B)
H) I) F) G)
J)
A. One signal from T1/T2
B. One signal from T1
C. Two OSSD signals
D. Two signals from +24VDC
E. One Signal from +24VDC
F. Autoreset
G. Antivalent signals from +24VDC
H. Antivalent signals from T1/T2
J. Mat/Bumper/Safety edge
K. Two-hand device
Note! Always use transient suppressors when inductive loads are connected
to the relay outputs.

2TLC010073M0201 Rev.G 19
7.2 One channel connection
The safety device contact must be closed before the safety relay can be set in active mode.
Opening of the safety device contact inactivates the safe outputs.
One channel connection, +24 VDC static signal
One channel connection from T1
7.3 Two channels connection with equivalent contacts
Both contacts must be closed before the safety relay can be set in active mode. Opening one
or both contacts inactivate the safe outputs. Both contacts must be opened and closed before
the outputs can be activated. A short-circuit between the safety inputs is not monitored by the
safety relay if T connections are not used. In this case category 4 can only be achieved if a
safety device with short-circuit monitored outputs is connected.
Two channels connection with equivalent contacts, +24 VDC static signal

20 2TLC010073M0201 Rev.G
Two channels connection with equivalent contacts from T1/T2
7.4 Two channels connection with antivalent contacts
In the example the R1 contact must be closed and the R2 contact must be opened before the
safety relay can be set in active mode. Switching one or both of the contacts inactivates the
safety relay. If T1/T2 are used gives short circuit detection.
Both contacts must switch from their initial position and back again before the outputs can be
activated.
Two channels connection with antivalent contacts, +24 VDC static signal
Two channels connection with antivalent contacts from T1/T2
7.5 Two channels OSSD connection
Safety devices with dual OSSD outputs can be connected to R1 and R2. Short-circuit between
the signals and to 24V DC are detected by the safety device from where the OSSD-signal
originates.