ABB Relion REX610 Installation Manual Download

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6.5

Exchanging protection relay

•

To exchange the protection relay with another identical unit, remove the
protection relay and install the new one.
The exchangeable units can be found from the PartsOnLine system, see

www.abb.com/partsonline

. Use of PartsOnLine requires user registration.

•

To exchange a protection relay to a different unit, change the case and connect
the wires.

2NGA000821 A

Section 6

Removing, repairing and exchanging

REX610

Installation Manual

Summary of Contents for Relion REX610

Page 1: ... RELION PROTECTION AND CONTROL REX610 Installation Manual ...

Page 2: ......

Page 4: ...ed in this document is furnished under a license and may be used copied or disclosed only in accordance with the terms of such license Trademarks ABB and Relion are registered trademarks of the ABB Group All other brand or product names mentioned in this document may be trademarks or registered trademarks of their respective holders Warranty Please inquire about the terms of warranty from your nea...

Page 5: ...ce which should be connected to a secure network It is the sole responsibility of the person or entity responsible for network administration to ensure a secure connection to the network and to take the necessary measures such as but not limited to installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product and ...

Page 6: ...rical equipment for use within specified voltage limits Low voltage directive 2014 35 EU This conformity is the result of tests conducted by the third party testing laboratory KEMA in accordance with the product standard EN 60255 26 for the EMC directive and with the product standards EN 60255 1 and EN 60255 27 for the low voltage directive The product is designed in accordance with the internatio...

Page 7: ...always be followed The frame of the protection relay has to be carefully earthed When the plug in unit has been detached from the case do not touch the inside of the case The relay case internals may contain high voltage potential and touching these may cause personal injury The protection relay contains components which are sensitive to electrostatic discharge Unnecessary touching of electronic c...

Page 8: ......

Page 9: ...ery items 9 Identifying product 9 Checking delivery items 9 Inspecting product 9 Returning a product damaged in transit 10 Storing 10 Section 4 Mounting 11 Checking environmental conditions and mounting space 11 Detaching and installing plug in unit 11 Detaching plug in unit 11 Installing plug in unit 13 Sealing plug in unit 14 Securing handle 15 Inserting or removing SD card 16 Installing module ...

Page 10: ...necting relay via USB 42 Energizing protection relay 43 Section 6 Removing repairing and exchanging 45 Product lifecycle 45 Checking protection relay information 45 Removing protection relay 46 Sending protection relay for repair 46 Exchanging protection relay 47 Section 7 Technical data 49 Case and HMI display variants 49 Front side of the protection relay 49 Rear side of the protection relay 50 ...

Page 11: ... electrical installation The chapters are organized in the chronological order in which the relay should be installed 1 2 Intended audience This manual addresses the personnel responsible for installing the product hardware The installation personnel must have basic knowledge of handling electronic equipment 2NGA000821 A Section 1 Introduction REX610 3 Installation Manual ...

Page 12: ...Technical manual IEC 61850 engineering guide GUID 36243071 4B06 48B2 B2D9 3CE41B04C031 V1 EN US Figure 1 The intended use of documents during the product life cycle 1 3 2 Document revision history Document revision date Product version History A 2022 04 21 1 0 First release 1 3 3 Related documentation Download the latest documents from the ABB Web site abb com mediumvoltage 1 4 Symbols and convent...

Page 13: ...t conventions A particular convention may not be used in this manual Abbreviations and acronyms are spelled out in the glossary The glossary also contains definitions of important terms Push button navigation in the LHMI menu structure is presented by using the push button icons To navigate between the options use and Menu paths are presented in bold Select Main menu Settings LHMI messages are sho...

Page 14: ...ctional earth terminal is indicated in figures with the symbol Equipment protected throughout by double insulation or reinforced insulation equivalent to class II of IEC 61140 is indicated in figures with the symbol Section 1 2NGA000821 A Introduction 6 REX610 Installation Manual ...

Page 15: ...nyls PBB 1000 ppm RoHS3 0 001 Polybrominated diphenyl ether PBDE 1000 ppm RoHS3 0 001 Operational reliability and long life time have been ensured with extensive testing during the design and manufacturing processes Moreover long life time is supported by maintenance and repair services as well as by the availability of spare parts Design and manufacturing have been done under a certified environm...

Page 16: ...ection relay Parts Material Case Metal plates parts and screws Steel Hard plastic parts Polycarbonate REACH and RoHS compliant Soft plastic parts Silicone UL94 HB Thermoplastic elastomer Electronics modules in case Various Plug in unit Electronic plug in modules Various Electronics HMI module Various Hard plastic parts Polycarbonate REACH and RoHS compliant Soft plastic parts Silicone UL94 HB Ther...

Page 17: ...he protection relay The cardboard packaging material is 100 recyclable 3 2 Inspecting product and delivery items 3 2 1 Identifying product 1 Locate the protection relay s order number from the label on the side of the HMI or the rear of the case 2 Compare the protection relay s order number with the ordering information to verify that the received product is correct 3 2 2 Checking delivery items C...

Page 18: ...ort appropriate actions must be taken against the latest carrier Please inform the nearest ABB office or representative Notify ABB immediately if there are any discrepancies in relation to the delivery documents 3 3 Storing If the protection relay is stored before installation it must be done in the original transport casing in a dry and dust free place Observe the environmental requirements state...

Page 19: ...ide sufficient ventilation to the protection relay and to enable maintenance and future modifications Ensure that flush mounted protection relays can be added and replaced without excessive dismantling Make sure that the ventilation holes are not blocked at any side of the installed protection relay case 4 2 Detaching and installing plug in unit 4 2 1 Detaching plug in unit Before detaching the pl...

Page 20: ...ching the plug in unit does not open the secondary circuit of the CT which could cause dangerously high voltages Do not touch terminals inside the case after removing the plug in unit Live terminals can be inside the case The signal connectors are left open when the plug in unit is detached Section 4 2NGA000821 A Mounting 12 REX610 Installation Manual ...

Page 21: ...y Remove the plug in unit to insert or remove analog cards 1 Rotate the handle 90 to the left and push the plug in unit into the case GUID 136BB778 8F4B 4333 A927 D1C1C488F09C V1 EN US Figure 3 Installing a plug in unit into the case 2 Hold the handle and push the plug in unit into the case as far as it goes The plug in unit stops at a distance of 7 8 mm 0 2756 0 3150 in from the case 2NGA000821 A...

Page 22: ...es to the case and a clicking sound is heard The handle is in the latched position 4 2 3 Sealing plug in unit The front panel of the protection relay has a locking mechanism for sealing the plug in unit Thread a sealing wire through the holes in the locking mechanism and attach a seal Section 4 2NGA000821 A Mounting 14 REX610 Installation Manual ...

Page 23: ...rotection relay has an additional locking mechanism to secure the handle in place A padlock can be fitted to the locking mechanism to prevent the handle from opening By default the handle is locked in place without a padlock For added security use a padlock to lock the handle in place 2NGA000821 A Section 4 Mounting REX610 15 Installation Manual ...

Page 24: ...US Figure 6 Locking mechanism for securing the handle 4 2 5 Inserting or removing SD card 1 Detach the plug in unit from the case 2 Locate the SD card slot on the rear of the plug in unit Section 4 2NGA000821 A Mounting 16 REX610 Installation Manual ...

Page 25: ... the SD card in place The protection relay supports SD and MMC cards It is recommended to use a card of type 16 GB or 32 GB Class 10 The device supports up to 128 GB MMC card 5 Install the plug in unit See the operation manual and the engineering manual for more details on the functionality supported with the SD card 2NGA000821 A Section 4 Mounting REX610 17 Installation Manual ...

Page 26: ...t from the case as shown in Detaching plug in unit GUID 2CC4E199 8C17 4E71 A359 D1D9BA6F5FF8 V1 EN US Figure 8 Plug in unit detached from the case 2 Install a cassette by gradually pushing the cassette into its slot The AIU2001 cassette belongs to slot D which is the leftmost when viewing the relay from the front The AIC2001 and AIC2002 cassettes belong to slot C and are designed so that they cann...

Page 27: ...483 43F1 8B02 A09B6E8F1CF3 V1 EN US Figure 9 Installing AIU2001 GUID 2B68BF02 5240 4A7C BC8E 24FB9C83407D V1 EN US Figure 10 Installing AIC2001 and AIC2002 2NGA000821 A Section 4 Mounting REX610 19 Installation Manual ...

Page 28: ...ssion type and ring lug type terminals 1 Detach the plug in unit from the case as shown in Detaching plug in unit GUID 0A3A896F 71AC 43D6 9A6F 2FD0E1561214 V1 EN US Figure 11 Removing module cassettes If the product supports a ring lug type CT module AIC2002 the cover must be removed from the rear of the relay before removing the cassette from the case Section 4 2NGA000821 A Mounting 20 REX610 Ins...

Page 29: ...22 V1 EN US Figure 12 Removing CT module cover 2 Release the module cassettes by pressing the clip finger at the top or bottom of the module cassette using a flat tip screwdriver 2NGA000821 A Section 4 Mounting REX610 21 Installation Manual ...

Page 30: ...B 4C0E A0D4 DD8B4E2B4D76 V1 EN US GUID 132667CC A8A5 495A 8520 4A3D0FF75B36 V1 EN US Figure 13 Releasing a module cassette 3 Pull the cassette out carefully Section 4 2NGA000821 A Mounting 22 REX610 Installation Manual ...

Page 31: ...Flush mounting protection relay All the mounting elements are integrated in the protection relay Requirements for installation Panel cutout of 129 0 1 139 0 mm 5 0787 0 03937 5 4724 in Depth behind the panel 163 6 mm 6 4409 in 1 Loosen the clamp screws from the top and bottom of the case 2 Detach the fixing clamp assembly 2NGA000821 A Section 4 Mounting REX610 23 Installation Manual ...

Page 32: ...N US Figure 14 Detaching the fixing clamp assembly A 129 0 1 mm 5 0787 0 03937 in B 139 0 mm 5 4724 in 3 Mount the case to the panel cutout 4 Mount the fixing clamp assembly back to the case Section 4 2NGA000821 A Mounting 24 REX610 Installation Manual ...

Page 33: ...Figure 15 Mounting the fixing clamp assembly 5 Tighten the M3 1 5 mm Allen key screws to secure the case The allowed range for the fixing screws tightening torque is 0 7 10 Nm 0 5162 10 ft lb 2NGA000821 A Section 4 Mounting REX610 25 Installation Manual ...

Page 34: ...n unit into the case There is a protective film on the top side of the protection relay Its purpose is to prevent debris falling inside the unit while installing electrical wiring Remove the protective film before energizing the protection relay Section 4 2NGA000821 A Mounting 26 REX610 Installation Manual ...

Page 35: ...ure 17 Flush mounted case and plug in unit A 149 5 mm 5 8858 in B 159 5 mm 6 2795 in C 127 5 mm 5 0196 in D 202 8 mm 7 9842 in E 163 6 mm 6 4409 in F 39 2 mm 1 5433 in G 155 5 mm 6 1220 in H 137 5 mm 5 4133 in 2NGA000821 A Section 4 Mounting REX610 27 Installation Manual ...

Page 36: ... Wall mounting protection relay A mounting kit is needed for wall mounting the protection relay In addition to the detailed mounting instructions the wall mounting kit includes Two side panels and one front panel Screws 1 Drill mounting holes according to the dimensional drawing 2 Mount the two side panels to the wall for example with M6 screws not included in package 3 Mount the front panel with ...

Page 37: ... 14 3700 in 1 Side panels B 7 5 mm 0 2952 in 2 Hexagon socket head cap screw M5x8 4 pieces C 66 5 mm 2 6181 in 3 Front panel D 133 mm 5 2362 in 4 Torx screw M5x10 4 pieces E 66 5 mm 2 6181 in 5 Wall mounting screws 6 pieces 4 Mount the case to the front panel cutout 2NGA000821 A Section 4 Mounting REX610 29 Installation Manual ...

Page 38: ...gure 19 Wall mounted protection relay A 390 mm 15 3543 in B 181 80 mm 7 1574 in C 214 12 mm 8 4299 in 5 Connect the wires A wall mounted protection relay can be released by loosening the fixing clamp Section 4 2NGA000821 A Mounting 30 REX610 Installation Manual ...

Page 39: ...Figure 20 Swinging out the protection relay A 54 mm 2 1259 in 1 Remove the screws before swinging out the frame B 574 mm 22 5984 in 6 Swing the frame back to the wall and insert the removed screws 2NGA000821 A Section 4 Mounting REX610 31 Installation Manual ...

Page 40: ...32 ...

Page 41: ...Thickness CT C1 M3 3 5 mm 0 1377 in Max 0 6 mm 0 02362 in VT D2 M2 5 3 0 mm 0 1181 in Max 0 5 mm 0 01968 in 5 2 Connecting wires All connections are made on the rear of the case No soldering is needed Open the screw compression type terminals before inserting any wires By default the terminals are closed at the time of delivery Use fine wire in door mounting 2NGA000821 A Section 5 Connecting REX61...

Page 42: ...2 AWG 24 12 0 25 4 mm2 AWG 24 12 9 mm 0 3543 in C1 AIC2002 4 mm2 AWG 12 1 0 25 4 mm2 AWG 24 12 0 25 4 mm2 AWG 24 12 D2 AIU2001 0 2 4 mm2 AWG 24 12 0 2 2 5 mm2 AWG 24 14 0 2 2 5 mm2 AWG 24 14 7 mm 0 2755 in 1 Through ring terminal only stud size M3 5 6 max outer size of ring terminal 8 mm 0 3149 in 5 3 Connecting functional earthing The earth lead must be at least 1 5 mm2 AWG 16 If the earth lead i...

Page 43: ...d should be as short as possible but extra length is required for door mounting Each protection relay must have its own earth lead connected to the earth circuit connector 2 Connect the earth lead to the earth bar Use either a stripped wire screwed between a washer cup and the functional earth screw or a ring lug 2NGA000821 A Section 5 Connecting REX610 35 Installation Manual ...

Page 44: ...gnals A connection diagram is needed to connect the analog signals When using the ring lug type for CT VT terminals follow these steps 1 Unscrew the ring lug connector cover to access the ring lug terminals 2 Remove the fixing screw 3 Slide the screw through the terminal lug and screw it back on 5 4 1 Connecting current and voltage inputs Connect the wires from the CTs VTs to the correct device ac...

Page 45: ...clamp is 0 8 Nm 10 0 5900 ft lb 10 CT CT CT CT C1 AIC2001 AIC2002 1 2 3 4 5 6 8 7 1 5 A N 1 5 A N 1 5 A N 1 5 A N GUID A14D08B9 E96F 41BA A8BB 2F0AA0F09D5F V1 EN US Figure 22 AIC2001 AIC2002 card 2NGA000821 A Section 5 Connecting REX610 37 Installation Manual ...

Page 46: ...ch connect the current and voltage transformers directly to the switch 5 5 Connecting binary signals Connect the wires for the binary signals to the correct device according to the connection diagram Each terminal for binary input and output signal is dimensioned for one 2 5 mm2 AWG 14 or 1 5 mm2 AWG 16 wire The allowed tightening torque for the wire clamp is 0 40 0 50 Nm 0 2950 0 3687 ft lb Secti...

Page 47: ...re 24 DIO2001 card 5 6 Connecting power supply The permitted auxiliary voltage range of the protection relay is marked on top of the protection relay s LHMI Connect the relay s auxiliary voltage to terminals A1 1 and A1 2 Connect the positive lead to terminal A1 1 The allowed tightening torque for the wire clamp is 0 40 0 50 Nm 0 2950 0 3687 ft lb 2NGA000821 A Section 5 Connecting REX610 39 Instal...

Page 48: ...ip TCS1 TCS2 4 Func onal earth GUID DD1E7547 C3D4 4F48 BD89 7DED17395353 V1 EN US Figure 25 PSU2001 card GUID 8E3BB97D 85A5 46EB A0C5 90F58C8FA580 V1 EN US Figure 26 Connecting auxiliary voltage Section 5 2NGA000821 A Connecting 40 REX610 Installation Manual ...

Page 49: ...nal B inverted 3 SHIELD AC coupled shield pin 4 GND_485 Common pin for A B Ensure the communication interfaces are properly connected The relay s communication interfaces are located on the lower left side of the protection relay when viewing it from the rear The allowed tightening torque for the RS 485 interface is 0 15 0 20 Nm 0 1106 0 1475 ft lb See the technical manual for product specific com...

Page 50: ...lay can be connected from the front USB using a micro USB type B connector The relay supports USB based power up The relay turns on with limited functionality when it is connected from the front port and it supports USB based connectivity for specific actions Use a standard micro USB cable to connect to the relay Section 5 2NGA000821 A Connecting 42 REX610 Installation Manual ...

Page 51: ...al strip is wired and placed correctly Remove the protective film from the top side of the unit Check that there is no debris visible in the ventilation holes The cover label m ust be rem oved before the relay will be energized GUID 79A04A4C 9540 4E82 BDAB 55902BC65D70 V1 EN US Figure 29 Removing the protective film 1 Green Normal LED starts to flash 2 LCD lights up and IED start up is displayed 3...

Page 52: ...e protection relay detects a diagnostic error during start up the green Normal LED flashes and the internal fault code is displayed on the LCD Section 5 2NGA000821 A Connecting 44 REX610 Installation Manual ...

Page 53: ... information is shown on the display for a few seconds when the device starts up The same information is found also in the protection relay menu 1 Select Main Menu Information 2 Select a submenu with and 3 Enter the selected submenu with 4 Browse the information with and The Product identifiers submenu contains product related information like product type serial number order number production dat...

Page 54: ... DC22 4A32 9E06 16061D36EF15 V1 EN US Figure 30 Loosening the M3 screws 5 Detach the panel fixing clamp from the case 6 Remove the case from the panel cutout 6 4 Sending protection relay for repair In case of product problems contact the nearest ABB office or representative for consultation and instructions Section 6 2NGA000821 A Removing repairing and exchanging 46 REX610 Installation Manual ...

Page 55: ...tall the new one The exchangeable units can be found from the PartsOnLine system see www abb com partsonline Use of PartsOnLine requires user registration To exchange a protection relay to a different unit change the case and connect the wires 2NGA000821 A Section 6 Removing repairing and exchanging REX610 47 Installation Manual ...

Page 56: ...48 ...

Page 57: ...ection relay GUID 8E4EB9A8 0A01 4DD3 A8F3 0E116433B5E4 V1 EN US Figure 31 Display Table 6 Display Character size1 Rows in the view Characters per row Small mono spaced 6 12 pixels 5 20 1 Depending on the selected language 2NGA000821 A Section 7 Technical data REX610 49 Installation Manual ...

Page 58: ...7 1 2 Rear side of the protection relay GUID 24D5F963 9C71 45E6 A4E5 3574A1466AF7 V1 EN US Figure 32 Rear view of the protection relay Section 7 2NGA000821 A Technical data 50 REX610 Installation Manual ...

Page 59: ...1 EN US Figure 33 REX610 main dimensions A 149 5 mm 5 8858 in B 159 5 mm 6 2795 in C 127 5 mm 5 0196 in D 202 8 mm 7 9842 in E 163 6 mm 6 4409 in F 39 2 mm 1 5433 in G 155 5 mm 6 1220 in H 137 5 mm 5 4133 in 2NGA000821 A Section 7 Technical data REX610 51 Installation Manual ...

Page 60: ...163 6 mm 39 2 mm 7 9842 in Weight Protection relay with the four separate connectors 2 5 kg 5 5 lbs 7 3 Enclosure class Table 8 Degree of protection of the protection relay Description Value Front side IP 54 Left and right side IP 20 Top and bottom IP 20 Case inside1 IP 20 1 Plug in unit removed Section 7 2NGA000821 A Technical data 52 REX610 Installation Manual ...

Page 61: ...ries Item Order number Wall mounting kit 2RCA055188A0001 19 rack mounting kit with cutout for one relay 2REA060349A0001 19 rack mounting kit with cutout for two relays 2REA060349A0002 2NGA000821 A Section 8 Accessories and ordering data REX610 53 Installation Manual ...

Page 62: ...54 ...

Page 63: ...chine interface HW Hardware IEC International Electrotechnical Commission LCD Liquid crystal display LED Light emitting diode LHMI Local human machine interface RoHS Restriction of hazardous substances RS 485 Serial link according to EIA standard RS485 SI Sensor input STP Shielded twisted pair SW Software USB Universal serial bus VT Voltage transformer 2NGA000821 A Section 9 Glossary REX610 55 Ins...

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