ABB SS822

Description

Detailed parameter table

ABB SS822

Product introduction

The SS822 is a high-integrity safety relay module from ABB, designed to monitor and control safety functions in industrial automation systems. As a core component of machine safety architectures, it acts as a critical intermediary between safety sensors (e.g., emergency stops, light curtains) and actuators (e.g., contactors, valves), ensuring hazardous machinery stops or enters a safe state when dangerous conditions are detected.

Engineered to meet SIL 3 requirements, the SS822 provides redundant safety monitoring with 4 input channels for connecting multiple safety devices in series or parallel configurations. Its compact 22.5 mm width allows dense mounting in control cabinets, making it ideal for space-constrained environments. Whether protecting operators in automotive assembly lines or ensuring safe shutdowns in packaging machinery, the SS822 delivers reliable safety monitoring, preventing accidents and ensuring compliance with global safety standards.

Core advantages and technical highlights

SIL 3 safety certification

The SS822 achieves SIL 3, the second-highest safety integrity level, making it suitable for high-risk applications where failure could result in serious injury. In a robotic welding cell, it monitors light curtain inputs—any breach triggers the SS822 to cut power to the robot within 15 ms, faster than human reaction time. This certification ensures the module meets rigorous reliability metrics, with a probability of dangerous failure below 1 in 100 million hours of operation.

Flexible input configuration

With 4 safety inputs, the SS822 supports diverse safety device combinations. A single SS822 can monitor an emergency stop button, two guard door interlocks, and a pressure-sensitive mat—all critical safety elements in a plastics injection molding machine. Inputs can be wired in series (for AND logic) or parallel (for OR logic), adapting to specific machine safety requirements without additional hardware.

Compact design with high functionality

At just 22.5 mm wide, the SS822 maximizes control cabinet space. In a food processing line with multiple safety zones, six SS822 modules can fit in the space of a single standard safety relay, reducing cabinet size by up to 70%. Despite its small footprint, it maintains robust 3 kV isolation, preventing electrical interference from compromising safety signals.

ABB SS822

Typical application scenarios

In an automotive stamping plant, the SS822 forms the safety backbone of a 500-ton press. It monitors:

• Two emergency stop buttons (one at each operator station)
• A safety interlock on the press access door
• A light curtain guarding the material loading area

When any safety device activates—such as an operator breaking the light curtain while the press is cycling—the SS822 immediately de-energizes its output contacts, dropping the main contactor and stopping the press. Its 15 ms response time prevents crushing hazards, while redundant internal monitoring ensures the SS822 itself cannot fail silently.

In a pharmaceutical packaging line, the SS822 protects operators adjusting label applicators. It monitors guard door interlocks and a 双手启动装置 (two-hand control station), ensuring the machine only operates when doors are closed and both operator hands are clear of moving parts. The module’s wide temperature range allows reliable operation in climate-controlled cleanrooms.

Related model recommendations

• SS821: A 2-input version of the SS822, ideal for simpler safety loops requiring fewer sensors.
• SS823: A 6-input upgrade from the SS822, supporting more complex safety architectures in large machinery.
• OT25F3: ABB contactor paired with the SS822, providing high-current switching for machinery main power.
• MSR127: ABB safety relay with built-in timer functions, complementing the SS822in time-delayed safety applications.
• CL200: Light curtain system that connects directly to the SS822’s safety inputs, providing perimeter protection.
• CE4T-10: Emergency stop button designed for use with the SS822in industrial environments.

Installation, commissioning and maintenance instructions

Installation preparation

Before installing the SS822, ensure the power supply is disconnected. Mount the module on a 35 mm DIN rail, leaving 10 mm clearance on both sides for cooling. Use 0.5-1.5 mm² wires for input/output connections, stripping 6-8 mm of insulation. Connect safety sensors to input terminals 1-8 (observing polarity for 24 V DC devices) and load contacts to output terminals 9-12. Verify all safety devices are NC (normally closed) as required by the SS822’s monitoring logic.

Maintenance suggestions

Daily checks of the SS822 involve verifying the green power LED and absence of red fault LEDs. Test safety functions weekly by activating each input device and confirming the outputs de-energize. Annual maintenance includes cleaning terminals with a dry cloth and tightening screws to 0.5 Nm torque. If a red fault LED illuminates, check for broken input wires or short circuits—reset by cycling power after correcting the issue. Replace the SS822 with an ABB-approved spare if faults persist, ensuring the replacement is identically wired to maintain safety functionality.

Service and guarantee commitment

The SS822 is backed by a 5-year warranty, reflecting ABB’s confidence in its safety-critical design. This coverage includes defects in materials and workmanship under normal operating conditions. ABB’s safety technical team provides 24/7 support for installation verification, including help with wiring diagrams and safety loop validation to ensure SIL 3 compliance.

Customers receive access to TÜV-certified documentation and application notes for proper implementation. ABB offers factory calibration services for critical applications, ensuring the SS822 maintains its 15 ms response time over its lifecycle. With global distribution, replacement modules are available for rapid delivery, minimizing downtime in safety-critical systems. Trust the SS822 to protect your workforce, backed by ABB’s expertise in industrial safety.