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ABB RELION REX640, Installation Manual

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ABB RELION REX640 Installation Manual Download Page 76

57-240V

N

VT1 (Vab)

57-240V

N

VT2 (Vbc)

57-240V

N

VT3 (Vca)

57-240V

N

VT4

CT1

1/5A

N

CT2

N

CT3

N

CT4

N

CT5

N

CT6 

X1

X2

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1/5A

1/5A

1/5A

1/5A

S1

S2

P2

P1

S1

P1

P2

S2

Positive

Load flow

Direction

AIM1002

L1 L2 L3

1/5A

N

c

a

A

B

C

Figure 70: AIM1002 module (two phase-to-phase VTs)

Connecting

1MRS759115 E

76

REX640

Installation Manual

Summary of Contents for RELION REX640

Page 1: ... RELION PROTECTION AND CONTROL REX640 Installation Manual ...

Page 2: ......

Page 3: ...Document ID 1MRS759115 Issued 2023 02 10 Revision E Copyright 2023 ABB All rights reserved ...

Page 4: ...ed 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 Open Source Software This product contains open source software For license information refer to product documentation at www abb com ...

Page 5: ...ace 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 antivirus programs etc to protect the product and ...

Page 6: ...cal 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 Intertek 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 internat...

Page 7: ...ed to carry out the electrical installation National and local electrical safety regulations must always be followed The frame of the protection relay has to be carefully earthed The protection relay contains components which are sensitive to electrostatic discharge Unnecessary touching of electronic components must therefore be avoided Whenever changes are made in the protection relay measures sh...

Page 8: ...1 Identifying product 16 3 2 2 Checking delivery items 16 3 2 3 Inspecting product 16 3 2 4 Returning a product damaged in transportation 16 3 3 Storing 16 4 Mounting 17 4 1 Required tools 17 4 2 Checking environmental conditions and mounting space 17 4 3 Mounting options 18 4 3 1 Mounting local HMI 18 4 3 2 Mounting protection relay 28 4 3 3 Mounting protection relay with local HMI 42 4 3 4 Mount...

Page 9: ...y signals 85 5 6 Connecting power supply 87 5 7 Connecting communication 88 5 7 1 Connecting protection communication 88 5 8 Connecting external display module 89 6 Checking installation 91 6 1 Identifying hardware and software version 91 6 2 Checking mounting 91 6 3 Energizing protection relay 91 7 Removing repairing and exchanging 93 7 1 Product life cycle 93 7 2 Checking protection relay s info...

Page 10: ...d 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 Introduction 1MRS759115 E 10 REX640 Installation Manual ...

Page 11: ...guideline Hardware modification instructions Modification sales guideline Figure 1 The intended use of documents during the product life cycle 1 3 2 Document revision history Document revision date Product connectivity level History A 2018 12 14 PCL1 First release B 2019 08 15 PCL1 Content updated C 2020 02 13 PCL2 Content updated to correspond to the prod uct connectivity level D 2020 12 09 PCL3 ...

Page 12: ...to use a certain function Although the warning hazards are related to personal injury it is necessary to understand that under certain operational conditions operation of damaged equipment may result in degraded process performance leading to personal injury or death Therefore comply fully with all warning and caution notices 1 4 2 Document conventions A particular convention may not be used in th...

Page 13: ...pressed with a number and an SI unit The corresponding imperial units may be given in parentheses This document assumes that the parameter setting visibility is Advanced Protective earthing is indicated in figures with the symbol 1MRS759115 E Introduction REX640 Installation Manual 13 ...

Page 14: ...body We follow environmental rules and regulations systematically to evaluate their effect on our products and processes 2 2 Disposal of a device Definitions and regulations of hazardous materials are country specific and change when the knowledge of materials increases The materials used in this product are typical for electric and electronic devices All parts used in this product are recyclable ...

Page 15: ...aged during the transport 2 Remove the transport packaging carefully without force 3 Attach the protective cover supplied with the relay on the top side of the relay for the installation phase Figure 2 Attaching the protective cover on the top of the relay The cardboard packaging material is 100 recyclable 1MRS759115 E Unpacking inspecting and storing REX640 Installation Manual 15 ...

Page 16: ...ng transportation If the protection relay has been damaged during transportation make a claim against the transport contractor and notify the local ABB representative 3 2 4 Returning a product damaged in transportation If damage has occurred during transportation appropriate actions must be taken against the latest carrier Inform the nearest ABB office or representative ABB should be notified imme...

Page 17: ...available Sufficient space is needed at the front and rear of the protection relay to allow access to wires and optical fibers to provide 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 If the UL enclosure rating should be higher than Type 1 the HMI ...

Page 18: ... HMI 4 3 1 1 Flush mounting local HMI 1 Make a cutout for the LHMI according to the dimensional drawing A B A 188 1 mm 7 4016 0 03937 in B 151 1 mm 5 9449 0 03937 in Figure 3 Making a cutout Mounting 1MRS759115 E 18 REX640 Installation Manual ...

Page 19: ...ckets and screws 3 2 1 1 LHMI 2 Installation brackets 3 Screws Figure 4 Mounting the local HMI to the cutout 3 Tighten the screws evenly to 3 5 Nm 5 2 5815 ft lb 5 1 1 Screws Figure 5 Tightening the screws 1MRS759115 E Mounting REX640 Installation Manual 19 ...

Page 20: ...B A D C A 212 5 mm 8 3661 in B 177 5 mm 6 9882 in C 50 0 mm 1 9685 in D 7 6 mm 0 2992 in Figure 6 Flush mounted local HMI Mounting 1MRS759115 E 20 REX640 Installation Manual ...

Page 21: ...ing frame according to the dimensional drawing A C B E D A 197 1 mm 7 7559 0 03937 in B Ø 6 0 mm 0 2362 in C 209 1 mm 8 2283 0 03937 in D 179 0 4 mm 7 0472 0 01575 in E 213 0 4 mm 8 3858 0 01575 in Figure 7 Making a cutout and drilling holes 1MRS759115 E Mounting REX640 Installation Manual 21 ...

Page 22: ...e raising frame to the panel with the M5 screws 1 2 1 Raising frame 2 M5 screws Figure 8 Mounting the raising frame 3 Tighten the screws to4 Nm 5 2 9502 ft lb 5 Mounting 1MRS759115 E 22 REX640 Installation Manual ...

Page 23: ...4 Mount the LHMI with the installation brackets 1 1 Installation brackets Figure 9 Mounting the local HMI 1MRS759115 E Mounting REX640 Installation Manual 23 ...

Page 24: ...B A C D A 230 0 mm 9 0551 in B 235 0 mm 9 2520 in C 56 0 mm 2 2047 in D 3 5 mm 0 1378 in Figure 10 Surface mounted local HMI Mounting 1MRS759115 E 24 REX640 Installation Manual ...

Page 25: ...aising frame according to the dimensional drawing A B C E D A 197 1 mm 7 7559 0 03937 in B Ø 6 0 mm 0 2362 in C 209 1 mm 8 2283 0 03937 in D 179 0 4 mm 7 0472 0 01575 in E 213 0 4 mm 8 3858 0 01575 in Figure 11 Making a cutout and drilling holes 1MRS759115 E Mounting REX640 Installation Manual 25 ...

Page 26: ...t frame 2 M5 screws Figure 12 Mounting the raising frame 3 Tighten the screws to 4 Nm 5 2 9502 ft lb 5 4 Mount the LHMI with the installation brackets 1 1 Installation brackets Figure 13 Mounting the local HMI Mounting 1MRS759115 E 26 REX640 Installation Manual ...

Page 27: ...C E D B A A 230 0 mm 9 0551 in B 25 C 236 0 mm 9 2913 in D 3 5 mm 0 1378 in E 108 0 mm 4 2520 in Figure 14 Tilt mounted local HMI 1MRS759115 E Mounting REX640 Installation Manual 27 ...

Page 28: ...nting protection relay 1 Drill four M5 screw holes according to the dimensional drawing A B 1 A 322 0 4 mm 12 6772 0 01575 in B 237 0 4 mm 9 3307 0 01575 in 1 M5 hole Figure 15 Drilling screw holes Mounting 1MRS759115 E 28 REX640 Installation Manual ...

Page 29: ...the M5 screws in the upper holes but do not tighten them Leave them 3 4 mm 0 1181 0 1575 in open 1 1 M5 screws Figure 16 Mounting M5 screws in the upper holes 1MRS759115 E Mounting REX640 Installation Manual 29 ...

Page 30: ...ghten the screws to 9 Nm 5 6 6381 ft lb 5 2 1 1 Mounting bracket 2 M6 screws Figure 17 Mounting M6 screws 4 Lift the protection relay to its place on the existing screws on the panel 5 Mount the M5 screws in the bottom holes Mounting 1MRS759115 E 30 REX640 Installation Manual ...

Page 31: ...6 Tighten all the M5 screws 1 1 M5 screws Figure 18 Mounting and tightening the M5 screws A B C Figure 19 Wall mounted protection relay 1MRS759115 E Mounting REX640 Installation Manual 31 ...

Page 32: ...e optical cable manufacturer 4 3 2 2 Roof mounting protection relay 1 Drill M5 screw holes or through holes to the roof inside the cabinet according to the dimensional drawing A minimum of 50 mm 1 9685 in space is needed from the back wall 1 A C D F E B A 387 0 0 4 mm 15 2362 0 01575 in B Ø 6 0 mm 0 2362 in C 175 0 0 4 mm 6 8898 0 01575 in D 140 0 0 4 mm 5 5118 0 01575 in E min 32 5 mm 1 2795 in F...

Page 33: ...binet 3 Mount the M5 screws in the upper M5 holes of the roof mounting bracket but do not tighten them Leave them 3 4 0 1181 0 1575 in mm open 3 4 1 2 1 Upper M5 hole 2 Roof mounting bracket 3 M5 screws for holes on top of the cabinet 4 M5 screws for holes inside the cabinet Figure 21 Mounting M5 screws 1MRS759115 E Mounting REX640 Installation Manual 33 ...

Page 34: ...e screws to 9 Nm 5 6 6381 ft lb 5 2 1 1 Mounting bracket 2 M6 screws Figure 22 Mounting M6 screws 5 Lift the protection relay to its place on the existing screws on the roof mounting bracket 6 Mount the M5 screws in the bottom holes Mounting 1MRS759115 E 34 REX640 Installation Manual ...

Page 35: ...7 Tighten the four M5 screws on the roof mounting bracket to 4 Nm 5 2 9502 ft lb 5 1 1 M5 screws Figure 23 Mounting and tightening the M5 screws 1MRS759115 E Mounting REX640 Installation Manual 35 ...

Page 36: ...m 14 0551 in D 273 5 mm 10 7677 in with compression type CT VT connectors 285 4 mm 11 2362 in with ring lug type CT VT connectors 305 3 mm 12 0197 in with a grounding bar Figure 24 Roof mounted protection relay Mounting 1MRS759115 E 36 REX640 Installation Manual ...

Page 37: ...ction relay 1 Drill holes according to the dimensional drawing A C B A 249 0 4 mm 9 8032 0 01575 in B Ø 7 0 mm 0 2756 in C 245 0 4 mm 9 6457 0 01575 in Figure 25 Drilling holes 1MRS759115 E Mounting REX640 Installation Manual 37 ...

Page 38: ...2 Mount the protection relay to the door or panel with the M6 screws 1 1 M6 screws Figure 26 Mounting the protection relay to the door Mounting 1MRS759115 E 38 REX640 Installation Manual ...

Page 39: ...3 Tighten the four M6 screws to 9 Nm 5 6 6381 ft lb 5 1 1 M6 screws Figure 27 Tightening the M6 screws 1MRS759115 E Mounting REX640 Installation Manual 39 ...

Page 40: ...onnectors 254 1 mm 10 0039 in with ring lug type CT VT connectors 274 0 mm 10 7874 in with a grounding bar Figure 28 Door mounted protection relay 4 3 2 4 Rack mounting protection relay 1 Attach the protection relay to a 7U rack plate with M6 screws Mounting 1MRS759115 E 40 REX640 Installation Manual ...

Page 41: ... Figure 29 Mounting the protection relay to the rack plate 3 Mount the protection relay and rack plate to a 19 rack The rack plate can also be mounted to the rack before the protection relay is attached to it 4 Tighten the screws 1MRS759115 E Mounting REX640 Installation Manual 41 ...

Page 42: ...254 10 mm 0 0039 in with ring lug type CT VT connectors 274 00 mm 10 7874 in with a grounding bar Figure 30 Rack mounted protection relay Check the allowed minimum bending radius from the optical cable manufacturer 4 3 3 Mounting protection relay with local HMI Mounting 1MRS759115 E 42 REX640 Installation Manual ...

Page 43: ...sion for RTXP 24 test switch 7U 1 1 Mount the LHMI and the mounting bracket to the rack plate a Attach the 6U or 7U rack plate to the rack frame b Mount the LHMI with its own installation brackets to the LHMI cutout 2 Mount the relay a Mount the relay to the door mounting bracket using M5 screws b Mount the relay and door mounting bracket assembly to the rack plate using M6 screws 3 Mount the RTXP...

Page 44: ...pping screw ST3 5x13 4 5 7 8 6 3 2 2 1 1 Door mounting bracket 2 M6 screws 3 6U or 7U rack plate 4 M5 screws 5 M3 screws 6 RTXP 24 mounting part 7 ST3 5 screws 8 RJ 45 coupler with a cable Figure 31 Installation kit contents Mounting 1MRS759115 E 44 REX640 Installation Manual ...

Page 45: ...E 322 0 4 mm 12 6772 0 01575 in Figure 32 Drilling holes 2 Mount the LHMI and the mounting bracket to the door panel a Mount the LHMI with its own installation brackets to the LHMI cutout b Mount the mounting bracket to the door panel with the M5 screws c Tighten the M5 screws to 4 Nm 5 2 9502 ft lb 5 d Mount the M5 screws in the upper holes of the mounting bracket but do not tighten them Leave th...

Page 46: ...ounting bracket to the protection relay with the M6 screws 1 2 1 Mounting bracket 2 M6 screws Figure 34 Attaching the mounting bracket to the protection relay 4 Tighten the M6 screws to 9 Nm 5 6 6381 ft lb 5 5 Lift the protection relay to its place on the existing screws on the bracket Mounting 1MRS759115 E 46 REX640 Installation Manual ...

Page 47: ...6 Mount the M5 screws in the bottom holes 7 Tighten the four M5 screws to 2 9502 ft lb 5 1 1 M5 screws Figure 35 Mounting and tightening the M5 screws 1MRS759115 E Mounting REX640 Installation Manual 47 ...

Page 48: ...HMI 4 3 3 3 Rack mounting protection relay with local HMI 1 Mount the LHMI and the mounting bracket to the rack plate a Attach the 7U rack plate to the rack frame b Mount the LHMI with its own installation brackets to the LHMI cutout c Mount the mounting bracket to the 7U rack plate with M5 screws d Tighten the M5 screws to 4 Nm 5 2 9502 ft lb 5 e Mount the M5 screws in the upper holes of the moun...

Page 49: ... HMI and mounting bracket 2 Install the RJ 45 coupler with a cable to the panel cutout and connect the cable to the LHMI service port X1 2 1 1 RJ 45 coupler Figure 38 Installing the RJ 45 coupler 3 Attach the mounting bracket to the protection relay with M6 screws 1MRS759115 E Mounting REX640 Installation Manual 49 ...

Page 50: ...ift the protection relay to its place on the existing screws on the mounting bracket 6 Mount the M5 screws in the bottom holes 7 Tighten the four M5 screws on the mounting bracket to 4 Nm 5 2 9502 ftlb 5 1 1 M5 screws Figure 40 Mounting and tightening the M5 screws Mounting 1MRS759115 E 50 REX640 Installation Manual ...

Page 51: ...ith compression type CT VT connectors 325 1 mm 12 7992 in with ring lug type CT VT connectors 345 0 mm 13 5827 in with a grounding bar G 339 mm 13 3465 in Figure 41 Rack mounted protection relay with local HMI 4 3 4 Mounting grounding bar kit 1 Detach the module from the protection relay 1MRS759115 E Mounting REX640 Installation Manual 51 ...

Page 52: ...plate with M3 screws and washers 2 2 3 3 2 3 4 1 1 Module 2 Grounding bar 3 M3 screws and washers 4 Edge with chamfer towards the module s collar screw Figure 42 Mounting grounding bar 3 Tighten the M3 screws to 0 8 Nm 5 0 5900 ft lb 5 Mounting 1MRS759115 E 52 REX640 Installation Manual ...

Page 53: ...4 Install the module back to the same slot in the protection relay Figure 43 Installing the module 1MRS759115 E Mounting REX640 Installation Manual 53 ...

Page 54: ...5 Install connectors with cables to the module Use peeled cables to get contact to the grounding bar 1 Figure 44 Installing connectors Mounting 1MRS759115 E 54 REX640 Installation Manual ...

Page 55: ...amps to connect the cable sheathing to the grounding bar 1 1 Shield clamp Figure 45 Installing shield clamps See also Chapter 5 4 2 1 Shielding RTD mA instrument cables 1MRS759115 E Mounting REX640 Installation Manual 55 ...

Page 56: ... situations in air insulated metal clad switchgear 1 Drill a Ø 10 mm 0 3937 in hole in the wall of the supervised space A B C D A 3 5 mm 0 1378 in B 10 mm 0 3937 in C Ø 9 5 mm 0 3740 in D 19 mm 0 7480 in Figure 46 Dimensions of the lens sensor Mounting 1MRS759115 E 56 REX640 Installation Manual ...

Page 57: ...cable tie To do this secure the cable tie to a suitable point of attachment on the cubicle wall and wrap the cable tie tightly around the sensor Figure 47 Mounting the lens sensor 3 Make sure that the cable tie lies in the groove of the sensor to prevent it from blocking the light 1MRS759115 E Mounting REX640 Installation Manual 57 ...

Page 58: ...in REA accessories as three alternative lengths 1MSC 380018 100 ARC sensor fiber delivery length 100 m 1MSC 380018 300 ARC sensor fiber delivery length 300 m 1MSC 380018 500 ARC sensor fiber delivery length 500 m 3 Connector items offered in REX640 accessories as 2RCA056821 ARC fiber spacer sleeve 25 pcs SJG BP05226 02 ARC sensor fiber V pin connector 25 pcs Two spacer sleeves and two V pin connec...

Page 59: ...ot needed as the naked fiber 1MSC 380018 x00 has no jacket to be stripped Step by step procedure 1 Cut with scissors required length of the fiber note that allowed maximum arc loop sensor length with REX640 is 60 meters 2 Install spacer sleeve and then crimp ring Figure 50 Spacer sleeve Figure 51 Crimp ring 1MRS759115 E Mounting REX640 Installation Manual 59 ...

Page 60: ...spacer sleeve using a clockwise turning motion i e screw the crimp ring onto the spacer if necessary Figure 52 Attaching the crimp ring to the spacer sleeve c Holding cable crimp ring and spacer in left hand and crimp tool in right insert small end of crimp ring completely into the front die nest of the crimp tool Figure 53 Using the crimp tool d Squeeze crimp tool handles together until it clicks...

Page 61: ...ing small bristle brush supplied IMPORTANT Pull straight when stripping the fiber buffer The HCS fiber cladding can be damaged if fiber is not pulled straight a Insert the fiber through the guide tube of the fiber stripper until the cable spacer sleeve bottoms out in the tube Figure 54 Using fiber stripper b Holding cable securely squeeze handles to cut buffer and PULL straight to remove buffer 1M...

Page 62: ...iber coating with bare fingers Use of disposable nitrile powder free examination gloves is recommended Once the fiber has been stripped the coating will retain finger oils which can transfer to and damage gripper pads in the cleaver during the last step 4 in the termination process If damage is visible cut off the damaged fiber and repeat the procedure from step 2 with a new spacer and crimp ring ...

Page 63: ...flange of the crimp ring Figure 56 Sliding the ferrule onto the fiber Figure 57 Ferrule in place b Insert the crimp ring completely into the rear die nest of the crimp tool Be sure the ferrule flange is flush against the edge of the die nest 1MRS759115 E Mounting REX640 Installation Manual 63 ...

Page 64: ...ring is being used Black Careful while handling the Cleave Tool Handle as a precision device and do not strike on hard surfaces or drop Keep the cleave tool clean and free from oils including naturally occurring finger oils Gripper pads diamond blade and anvil should be cleaned after every 50 cleaves Use the OFS Cleave Tool Cleaning Kit Part P16247 available separately Do not use alcohol to clean ...

Page 65: ... do so may cause poor cleave quality and or damage to the diamond blade Do not hold onto the connector during the cleave process Doing so may cause poor cleave quality Always follow termination kit manufacturers recommendation for cleave tool service and maintenance c Release the connector in the tool d Using index finger slowly and gently depress trigger to perform the cleave process The cleave p...

Page 66: ...c loop sensor a Cover ready connectors in both ends with dust caps 4 3 7 Mounting RJ 45 coupler for an HMI service port 1 Make a cutout for the RJ 45 coupler according to the dimensional drawing A Ø 22 5 mm 0 8858 in B Ø 45 mm 1 7717 in C 11 9 mm 0 4685 in D R 1 85 mm 0 0728 in 1 Free space behind the panel Figure 61 RJ 45 connector panel cutout 2 Install the RJ 45 coupler with a cable to the pane...

Page 67: ...ions are made on the front of the case No soldering is needed 1 Connect signal connector terminals 2 Connect compression type X1 and X2 terminals for CTs VTs 3 Connect the terminals on the communication module for IRIG B 4 Connect the RTD inputs and mA outputs using shielded stranded cables and connect the cable shield to GND rail 5 Connect all the sensors of the same type to adjacent channels The...

Page 68: ...4 mm AWG 24 12 1 9 mm 0 3543 in 0 6 0 8 Nm 0 4425 0 5900 ft lb 1 2 Nm 0 8851 ft lb Signal connector 0 2 4 mm AWG 24 12 0 2 2 5 mm AWG 24 14 2 7 mm 0 2756 in 0 4 0 5 Nm 0 2950 0 3688 ft lb 0 2 Nm 0 1475 ft lb Serial EIA 485 IRIG B connector 0 2 1 0 mm AWG 24 17 0 13 0 34 mm AWG 26 22 7 8 mm 0 2756 0 3150 in 0 2 Nm 0 1475 ft lb 5 2 2 Connecting wires to ring lug type connectors Terminal blocks of ri...

Page 69: ...cks of push in type are used for electrical connections 1 Connect the wire in one of the alternative ways When using stranded wire without ferrule push the connector s release button while inserting the wire When using wire with end ferrule insert the wire without pushing the release button Table 6 Wire specifications for push in type connectors Connector type Wire size Stripping length Contact sc...

Page 70: ... a gas insulated switchgear 1 Using a TX30 screwdriver loosen the protective earth screw to connect a separate earth protection lead Figure 62 Location of the protective earth pin Each protection relay must have its own earth lead connected to the earth circuit connector 2 Connect the earth lead to the earth bar 3 Thread the copper cable on the protective earth 4 Tighten the protective earth screw...

Page 71: ...analog signals can be connected to the CT VT terminals before the connector is connected to the protection relay The connector features an automatic short circuit mechanism for the current terminals Therefore detaching the connector from the unit does not open the secondary circuit of the CT which otherwise could cause dangerously high voltages To avoid a mismatch between CT and VT connections the...

Page 72: ... Empty connector Figure 65 Loose CT VT connector coding 1 CT connector coding 2 VT connector coding 3 Empty connector Figure 66 Fixed CT VT connector coding 5 4 1 Connecting current and voltage inputs Conventional instrument transformers Each terminal for CTs VTs is dimensioned for one 0 5 6 0 mm2 AWG 20 10 wire or for two wires of maximum 2 5 mm2 AWG 14 Connecting 1MRS759115 E 72 REX640 Installat...

Page 73: ...r pin lay out SIM1901 supporting IEC 60044 SIM1902 supporting IEC 61869 There are a number of sensor interface adapters available which can be used to connect the sensors to the relay supporting different scenarios both in green field and retrofit cases More information can be found in Sensor accessories 57 240V N VT1 57 240V N VT2 57 240V N VT3 57 240V N VT4 57 240V N VT5 1 5A N CT1 N CT2 N CT3 N...

Page 74: ...T2 N CT3 N CT4 N CT5 for residual X1 X2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 5A 1 5A 1 5A 0 2 1A S1 S2 P2 P1 S1 P1 P2 S2 Positive Load flow Direction AIM1001 L1 L2 L3 current only c a A B C Figure 68 AIM1001 module two phase to phase VTs Connecting 1MRS759115 E 74 REX640 Installation Manual ...

Page 75: ... N CT3 N CT4 N CT5 N CT6 X1 X2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 5A 1 5A 1 5A 1 5A S1 S2 P2 P1 S1 P1 P2 S2 Positive Load flow Direction AIM1002 n a da dn A n L1 L2 L3 L1 L2 L3 1 5A N Figure 69 AIM1002 module 1MRS759115 E Connecting REX640 Installation Manual 75 ...

Page 76: ...2 N CT3 N CT4 N CT5 N CT6 X1 X2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 5A 1 5A 1 5A 1 5A S1 S2 P2 P1 S1 P1 P2 S2 Positive Load flow Direction AIM1002 L1 L2 L3 1 5A N c a A B C Figure 70 AIM1002 module two phase to phase VTs Connecting 1MRS759115 E 76 REX640 Installation Manual ...

Page 77: ...IM1901 X1 4 5 7 8 DFF Sensor I Sensor U DFF X2 4 5 7 8 DFF DFF X3 4 5 7 8 DFF DFF 3 4 Sensor I Sensor U Sensor I Sensor U s1 s2 s1 s2 s1 s2 for residual current only Figure 71 SIM1901 module VT primary connection phase to earth 1MRS759115 E Connecting REX640 Installation Manual 77 ...

Page 78: ...IM1901 X1 4 5 7 8 DFF Sensor I Sensor U DFF X2 DFF DFF X3 DFF DFF 3 4 Sensor I Sensor U Sensor I Sensor U s1 s2 s1 s2 s1 s2 for residual current only 4 5 7 8 4 5 7 8 Figure 72 SIM1901 module VT primary connection phase to phase Connecting 1MRS759115 E 78 REX640 Installation Manual ...

Page 79: ...IM1902 X1 1 2 7 8 DFF Sensor I Sensor U DFF X2 1 2 7 8 DFF DFF X3 1 2 7 8 DFF DFF 3 4 Sensor I Sensor U Sensor I Sensor U s1 s2 s1 s2 s1 s2 for residual current only Figure 73 SIM1902 module VT primary connection phase to earth 1MRS759115 E Connecting REX640 Installation Manual 79 ...

Page 80: ...IM1902 X1 1 2 7 8 DFF Sensor I Sensor U DFF X2 DFF DFF X3 DFF DFF 3 4 Sensor I Sensor U Sensor I Sensor U s1 s2 s1 s2 s1 s2 for residual current only 1 2 7 8 1 2 7 8 Figure 74 SIM1902 module VT primary connection phase to phase Connecting 1MRS759115 E 80 REX640 Installation Manual ...

Page 81: ...r one 0 5 2 5 mm2 AWG 20 14 wire or for two 0 5 1 0 mm2 AWG 20 17 wires RTD1001 X1 X2 1 2 mA mA1 4 5 mA mA2 3 Ref RTD1 7 8 9 Ref RTD2 10 11 12 Ref RTD3 13 14 15 Ref RTD4 16 17 18 Ref RTD5 1 2 3 Ref RTD6 4 5 6 Ref RTD7 7 8 9 Ref RTD8 10 11 12 Ref RTD9 13 14 15 Ref RTD10 16 17 18 6 Figure 75 RTD1001 1MRS759115 E Connecting REX640 Installation Manual 81 ...

Page 82: ... 16 17 18 Ref RTD3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Ref RTD1 Ref RTD2 mA mA2 mA mA3 mA mA4 mA mA5 mA mA6 13 14 15 BI3 BI2 BI1 BI4 BI7 BI6 BI5 BI8 BI11 BI10 BI9 BI12 Figure 76 RTD1002 Connecting 1MRS759115 E 82 REX640 Installation Manual ...

Page 83: ...odule Strip the cables to ensure contact to the grounding bar The cable position affects the stripping length and position A B 1 1 Connectors with cables A B Examples of stripping length and position Figure 77 Installing connectors 1MRS759115 E Connecting REX640 Installation Manual 83 ...

Page 84: ...2 Install shield clamps to connect the cable sheathing to the grounding bar 1 1 Shield clamp Figure 78 Installing shield clamps Connecting 1MRS759115 E 84 REX640 Installation Manual ...

Page 85: ...or one 0 5 2 5 mm2 AWG 20 14 wire or for two 0 5 1 0 mm2 AWG 20 17 wires X1 X2 1 1 2 BIO1001 BIO1003 BI14 17 18 BI13 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BI12 BI11 BI10 BI9 BI8 BI7 BI6 BI5 BI4 BI3 BI2 BI1 X2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SO1 SO2 SO3 SO4 SO5 SO6 SO7 SO8 Figure 79 BIO1001 BIO1003 1MRS759115 E Connecting REX640 Installation Manual 85 ...

Page 86: ...8 9 10 11 12 BI9 BI8 BI7 BI6 BI5 BI4 BI3 BI2 BI1 X2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 SPO1 SPO3 SPO2 SPO4 SPO5 SPO6_TCS SPO7 SPO6 SPO8_TCS SPO8 I I Figure 80 BIO1002 BIO1004 Connecting 1MRS759115 E 86 REX640 Installation Manual ...

Page 87: ... 16 17 18 6 7 8 9 10 11 12 13 SO3 4 5 I I PO3_TCS I Figure 81 PSM100x 5 6 Connecting power supply The permitted auxiliary voltage range is found on the protection relay s sticker Connect the protection relay s auxiliary voltage to slot G terminal X1 1 2 Connect the positive lead to terminal X1 1 1MRS759115 E Connecting REX640 Installation Manual 87 ...

Page 88: ...k the allowed minimum bending radius from the optical cable manufacturer 5 7 1 Connecting protection communication Port X6 LD of the communication module is used for protection communication connection As the optional SFP transceiver is not attached to the port at the time of delivery it needs to be installed to port X6 LD if protection communication is used 1 Remove the dust cap from port X6 LD t...

Page 89: ...he permitted auxiliary voltage range from the sticker found at the rear side of the LHMI b Connect the auxiliary voltage leads to the outermost terminals of the LHMI s power connector plug The polarity is marked on the LHMI s rear plate close to connector X3 c Push the power connector plug to the bottom d Turn the locking latches to lock position to secure the connector 2 Connect the LHMI to the p...

Page 90: ...D 1 2 1 USB port 2 RJ 45 ports Figure 83 Local HMI connectors Connecting 1MRS759115 E 90 REX640 Installation Manual ...

Page 91: ...tection relay 6 2 Checking mounting Check that all fixing screws are tight and that all cables are connected 6 3 Energizing protection relay Check all connections to external circuitry to ensure correct installation before energizing the protection relay and carrying out the commissioning procedures Also remove the protective film Figure 84 Removing the protective film 1MRS759115 E Checking instal...

Page 92: ... LHMI show a steady light which indicates a successful start up The start up time depends on the size of the application configuration Application configurations with less functionality have shorter start up times 2 Check the self supervision function via the HMI path Monitoring IED status to verify that the protection relay operates properly If the green Ready LED of the power supply module and t...

Page 93: ...sion and serial number Check the protection relay s information in one of the alternative ways Select Menu bar Device information Product identifiers on the HMI Select Device information Product identifiers on the WHMI The Product identifiers submenu contains product related information including product type serial number order number production date and SW version The HW modules submenu contains...

Page 94: ...ion relay and install the new one The exchangeable units can be found in the PartsOnLine system see www abb com partsonline Use of PartsOnLine requires user registration Check with your local ABB if the protection relay can be upgraded Removing repairing and exchanging 1MRS759115 E 94 REX640 Installation Manual ...

Page 95: ...8 Technical data 8 1 Local HMI D 1 2 1 USB port 2 RJ 45 ports Figure 85 Local HMI connectors 1MRS759115 E Technical data REX640 Installation Manual 95 ...

Page 96: ...8 2 Connector side 1 2 1 Slot markings in enclosure top and bottom 2 Ready LED Figure 86 Connector side of the protection relay Technical data 1MRS759115 E 96 REX640 Installation Manual ...

Page 97: ...igure 87 REX640 main dimensions Table 7 Dimensions of the local HMI Description Value Width 304 0 mm 11 9685 in Height 264 8 mm 10 4252 in Depth With compression type CT VT connectors 242 2 mm 9 5354 in With ring lug type CT VT con nectors 254 1 mm 10 0039 in With grounding bar 274 0 mm 10 7874 in Weight box 6 9 8 8 kg 15 2 19 4 lb Table continues on the next page 1MRS759115 E Technical data REX64...

Page 98: ...8 Degree of protection of the protection relay Description Value Front connector side IP 20 with ring lug signal connectors IP 00 or IP 10 depending on wiring Top and bottom IP 30 Rear IP 40 Table 9 Degree of protection of the local HMI Description Value Front IP 54 Other sides IP 20 Technical data 1MRS759115 E 98 REX640 Installation Manual ...

Page 99: ...3 1 2 1 4 5 1 Side 2 Top 3 Rear 4 Front connector side 5 Bottom Figure 88 REX640 sides 1MRS759115 E Technical data REX640 Installation Manual 99 ...

Page 100: ...3 0 m 9 8 ft connection cable for HMI 1MRS120549 3 5 0 m 16 4 ft connection cable for HMI 1MRS120549 5 RJ 45 coupler for HMI service port SYJ ZBE 8A17 Table 11 Communication Item Order number LC SFP plug in connector for optical multi mode media 100M 2RCA045621 LC SFP plug in connector for optical single mode media 100M 20 0 km 12 4 mi 2RCA045622 LC SFP plug in connector for optical single mode me...

Page 101: ...RCA040290A0001 ARC lens sensor cable 3 0 m 9 8 ft 2RCA040290A0003 ARC lens sensor cable 5 0 m 16 4 ft 2RCA040290A0005 ARC lens sensor cable 7 5 m 24 6 ft 2RCA040290A0007 ARC lens sensor cable 15 0 m 49 2 ft 2RCA040290A0015 ARC loop sensor cable 5 0 m 16 4 ft plastic fiber 2RCA051658A0005 ARC loop sensor cable 10 0 m 32 8 ft plastic fiber 2RCA051658A0010 ARC loop sensor cable 15 0 m 49 2 ft plastic...

Page 102: ...C sensor fiber 100 m delivery length 1MSC 380018 100 ARC sensor fiber 300 m delivery length 1MSC 380018 300 ARC sensor fiber 500 m delivery length 1MSC 380018 500 ARC sensor fiber connector 25 pcs SJG BP05226 02 ARC sensor fiber connector spacer sleeve 25 pcs 2RCA056821 1 2 3 4 1 ARC loop sensor cable glass fiber 2 ARC loop sensor cable plastic fiber 3 Blind extension cable for ARC loop sensors 4 ...

Page 103: ...mpression type connector 2RCA040474A0001 5 VT compression type connector 2RCA040474A0002 1 CT 4 VT compression type connector 2RCA040474A0003 1 CT 1 VT ring lug type connector 2RCA041297A0004 5 CT ring lug type connector 2RCA041297A0001 5 VT ring lug type connector 2RCA041297A0002 1 CT 4 VT ring lug type connector 2RCA041297A0003 RS 485 IRIG B connector SYJ ZRK 44P10 1MRS759115 E Accessories and o...

Page 104: ...ime code format B LC Connector type for glass fiber cable IEC 61754 20 LCP Liquid crystal polymer LHMI Local human machine interface PC 1 Personal computer 2 Polycarbonate RJ 45 Galvanic connector type RoHS Restriction of hazardous substances RS 485 Serial link according to EIA standard RS485 RTD Resistance temperature detector SHMI Switchgear HMI SI Sensor input SW Software USB Universal serial b...

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Page 108: ...voltage www abb com relion www abb com substationautomation ABB Distribution Solutions Digital Substation Products P O Box 699 FI 65101 VAASA Finland Phone 358 10 22 11 1MRS759115 E Copyright 2023 ABB All rights reserved ...

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