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.