ABB RELION REX640 Installation Manual
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ABB RELION REX640 Installation Manual

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RELION® PROTECTION AND CONTROL
REX640
Installation Manual

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Summary of Contents for ABB RELION REX640

  • Page 1 — RELION® PROTECTION AND CONTROL REX640 Installation Manual...
  • Page 3 Document ID: 1MRS759115 Issued: 2018-12-14 Revision: A Product version: 1 © Copyright 2018 ABB. All rights reserved...
  • Page 4 Copyright This document and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party, nor used for any unauthorized purpose. The software or hardware described in this document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such license.
  • Page 5 In case any errors are detected, the reader is kindly requested to notify the manufacturer. Other than under explicit contractual commitments, in no event shall ABB be responsible or liable for any loss or damage resulting from the use of this manual or the application of the equipment.
  • Page 6 Conformity This product complies with the directive of the Council of the European Communities on the approximation of the laws of the Member States relating to electromagnetic compatibility (EMC Directive 2014/30/EU) and concerning electrical 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.
  • Page 7 Safety information Dangerous voltages can occur on the connectors, even though the auxiliary voltage has been disconnected. Non-observance can result in death, personal injury or substantial property damage. Only a competent electrician is allowed to carry out the electrical installation. National and local electrical safety regulations must always be followed.

  • Page 9: Table Of Contents

    Table of contents Table of contents Section 1 Introduction...............3 This manual..................3 Intended audience................3 Product documentation...............4 Product documentation set............4 Document revision history............. 4 Related documentation..............4 Symbols and conventions..............5 Symbols..................5 Document conventions..............5 Section 2 Environmental aspects............. 7 Sustainable development..............7 Disposal of a protection relay.............
  • Page 10 Table of contents Mounting grounding bar kit............49 Mounting lens sensors for an arc protection system....53 Arranging ventilation..............55 Section 5 Connecting..............57 Required tools.................. 57 Connecting wires................57 Connecting wires to screw-compression type connectors...58 Connecting wires to ring-lug type connectors......58 Connecting wires to push-in type connectors......59 Connecting protective earthing............59 Connecting protective earthing to relay........

  • Page 11: Section 1 Introduction

    Section 1 1MRS759115 A Introduction Section 1 Introduction This manual The installation manual contains instructions on how to install the protection relay. The manual provides procedures for mechanical and electrical installation. The chapters are organized in the chronological order in which the relay should be installed.

  • Page 12: Product Documentation

    The intended use of documents during the product life cycle 1.3.2 Document revision history Document revision/date Product connectivity level History (PCL) A/2018-12-14 First release 1.3.3 Related documentation Download the latest documents from the ABB Web site www.abb.com/relion. REX640 Installation Manual...

  • Page 13: Symbols And Conventions

    Section 1 1MRS759115 A Introduction Symbols and conventions 1.4.1 Symbols The electrical warning icon indicates the presence of a hazard which could result in electrical shock. The warning icon indicates the presence of a hazard which could result in personal injury. The caution icon indicates important information or warning related to the concept discussed in the text.
  • Page 14 Section 1 1MRS759115 A Introduction When the function starts, the START output is set to TRUE. • This document assumes that the parameter setting visibility is "Advanced". • Protective earthing is indicated in figures with the symbol REX640 Installation Manual...

  • Page 15: Section 2 Environmental Aspects

    Section 2 1MRS759115 A Environmental aspects Section 2 Environmental aspects Sustainable development Sustainability has been taken into account from the beginning of the product design including the pro-environmental manufacturing process, long life time, operation reliability and disposing of the protection relay. The choice of materials and the suppliers have been made according to the EU RoHS directive (2011/65/EU).

  • Page 17: Section 3 Unpacking, Inspecting And Storing

    Section 3 1MRS759115 A Unpacking, inspecting and storing Section 3 Unpacking, inspecting and storing Removing transport packaging Protection relays require careful handling. Examine the delivered products to ensure that they have not been damaged during the transport. Remove the transport packaging carefully without force. Attach the protective cover (supplied with the relay) on the top side of the relay for the installation phase.

  • Page 18: Inspecting Product And Delivery Items

    If damage has occurred during transport, 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. Storing If the protection relay is stored before installation, it must be done in the original transport packaging in a dry and dust-free place.

  • Page 19: Section 4 Mounting

    Section 4 1MRS759115 A Mounting Section 4 Mounting Required tools • TX25 and TX30 screwdrivers for installing the protection relay with mounting kits • TX25 and TX20 screwdrivers for mounting the LHMI Checking environmental conditions and mounting space The mechanical and electrical environmental conditions at the installation site must be within the limits described in the technical manual.
  • Page 20 Section 4 1MRS759115 A Mounting GUID-AFEE05C5-676A-40BF-9F06-14F2C2C21D96 V1 EN Figure 3: Making a cutout A 188 ±1 mm B 151 ±1 mm Mount the LHMI to the cutout with the installation brackets and screws. REX640 Installation Manual...
  • Page 21 Section 4 1MRS759115 A Mounting GUID-A3C022EE-B254-4102-9039-2B059391757E V1 EN Figure 4: Mounting the LHMI to the cutout 1 LHMI 2 Installation brackets 3 Screws Tighten the screws evenly to 3.5 Nm ±5%. REX640 Installation Manual...
  • Page 22 Section 4 1MRS759115 A Mounting GUID-7FD722FB-3479-46A6-AA8E-DF431FEF9022 V1 EN Figure 5: Tightening the screws 1 Screws REX640 Installation Manual...

  • Page 23: Surface Mounting Local Hmi

    Section 4 1MRS759115 A Mounting GUID-9FEE663E-146E-4569-9E15-D13CD5EC1236 V1 EN Figure 6: Flush mounted LHMI A 212.5 mm B 177.5 mm C 50.0 mm D 7.6 mm 4.3.1.2 Surface mounting local HMI Make a cutout for the LHMI and drill holes for the raising frame according to the dimensional drawing.
  • Page 24 Section 4 1MRS759115 A Mounting GUID-3D3534C1-72DB-480F-8F49-6A822193C20A V1 EN Figure 7: Making a cutout and drilling holes A 197 ±1 mm B ∅ 6.0 mm C 209 ±1 mm D 179 ±0.4 mm E 213 ±0.4 mm Mount the raising frame to the panel with the M5 screws. REX640 Installation Manual...
  • Page 25 Section 4 1MRS759115 A Mounting GUID-419A4D24-95C5-4FF3-ABC3-6CA78596E8BD V1 EN Figure 8: Mounting the raising frame 1 Raising frame 2 M5 screws Tighten the screws to 4 Nm ±5%. Mount the LHMI with the installation brackets REX640 Installation Manual...
  • Page 26 Section 4 1MRS759115 A Mounting GUID-88E9C676-983D-4F0F-94FC-ED8E04EB7311 V1 EN Figure 9: Mounting the LHMI 1 Installation brackets REX640 Installation Manual...

  • Page 27: Tilt/Inclined Mounting Local Hmi

    Section 4 1MRS759115 A Mounting GUID-3432796D-4ADE-4864-B1B7-900FA25412E1 V1 EN Figure 10: Surface mounted LHMI A 230.0 mm B 235.0 mm C 56.0 mm D 3.5 mm 4.3.1.3 Tilt/inclined mounting local HMI Make a cutout for the LHMI and drill holes for the raising frame according to the dimensional drawing.
  • Page 28 Section 4 1MRS759115 A Mounting GUID-DDC6B2ED-4E31-415A-8C98-5B2B0BB9E7CC V1 EN Figure 11: Making a cutout and drilling holes A 197 ±1 mm B ∅ 6.0 mm C 209 ±1 mm D 179 ±0.4 mm E 213 ±0.4 mm Mount the tilt frame to the panel with M5 screws. REX640 Installation Manual...
  • Page 29 Section 4 1MRS759115 A Mounting GUID-D791986C-1481-4A1E-A17E-703DED85A38B V1 EN Figure 12: Mounting the raising frame 1 Tilt frame 2 M5 screws Tighten the screws to 4 Nm ±5%. Mount the LHMI with the installation brackets REX640 Installation Manual...
  • Page 30 Section 4 1MRS759115 A Mounting GUID-07B890E5-7918-4257-B0A8-B6D762D6291B V1 EN Figure 13: Mounting the LHMI 1 Installation brackets REX640 Installation Manual...

  • Page 31: Mounting Protection Relay

    Section 4 1MRS759115 A Mounting GUID-815EEFFD-9E87-4D34-BD16-956B7BC8D17F V1 EN Figure 14: Tilt mounted LHMI A 230.0 mm B 25° C 236.0 mm D 3.5 mm E 108.0 mm 4.3.2 Mounting protection relay 4.3.2.1 Wall mounting protection relay Drill four M5 screw holes according to the dimensional drawing. REX640 Installation Manual...
  • Page 32 Section 4 1MRS759115 A Mounting GUID-D2F1BE8A-CA14-4B27-8993-C1246B7AF72E V1 EN Figure 15: Drilling screw holes A 322 ±0.4 mm 1 M5 hole B 237 ±0.4 mm Mount the M5 screws in the upper holes, but do not tighten them. Leave them 3...4 mm open. REX640 Installation Manual...
  • Page 33 Section 4 1MRS759115 A Mounting GUID-92E4D4FF-B868-4AA8-9813-CB4ABA0BD3A7 V1 EN Figure 16: Mounting M5 screws in the upper holes 1 M5 screws Attach the mounting bracket to the protection relay with M6 screws and tighten the screws to 9 Nm ±5%. REX640 Installation Manual...
  • Page 34 Section 4 1MRS759115 A Mounting GUID-12FC0EB6-09DB-441C-BDCB-542F832A679A V1 EN Figure 17: Mounting M6 screws 1 Mounting bracket 2 M6 screws Lift the protection relay to its place on the existing screws on the panel. Mount the M5 screws in the bottom holes. Tighten all the M5 screws.
  • Page 35 Section 4 1MRS759115 A Mounting GUID-2967487D-D71A-4808-9D40-B7DA128BF898 V1 EN Figure 18: Mounting and tightening the M5 screws 1 M5 screws REX640 Installation Manual...

  • Page 36: Roof Mounting Protection Relay

    Section 4 1MRS759115 A Mounting GUID-AF6297BF-FAE9-425B-9C7C-2883B908DA81 V1 EN Figure 19: Wall mounted protection relay A 338.0 mm B 265.0 mm C 255.7 mm with compression type CT/VT connectors 276.6 mm with ring lug type CT/VT connectors 287.5 mm with grounding bar A minimum of 50 mm space is needed between two kits.
  • Page 37 Section 4 1MRS759115 A Mounting A minimum of 50 mm space is needed from the back wall. GUID-3C469764-29DA-4A63-AC72-9F6FC6A9B3B0 V1 EN Figure 20: Drilling screw holes A 387.0 ±0.4 mm 1 M5 screw B ∅ 6.0 mm C 175.0 ±0.4 mm D 140.0 ±0.4 mm E min.
  • Page 38 Section 4 1MRS759115 A Mounting GUID-85004054-486A-49FC-B096-1387FDBDE6C1 V1 EN Figure 21: Mounting M5 screws 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 Attach the mounting bracket to the protection relay with M6 screws and tighten the screws to 9 Nm ±5%.
  • Page 39 Section 4 1MRS759115 A Mounting GUID-7396CC77-7604-4AF0-8F03-7743F75AF4B7 V1 EN Figure 22: Mounting M6 screws 1 Mounting bracket 2 M6 screws Lift the protection relay to its place on the existing screws on the roof mounting bracket. Mount the M5 screws in the bottom holes. Tighten the four M5 screws on the roof mounting bracket to 4 Nm ±5%.
  • Page 40 Section 4 1MRS759115 A Mounting GUID-287B9ADA-B09B-402A-93CD-7ACFFADCAE4E V1 EN Figure 23: Mounting and tightening the M5 screws 1 M5 screws REX640 Installation Manual...

  • Page 41: Door Mounting Protection Relay

    Section 4 1MRS759115 A Mounting GUID-71C15788-9F45-4C95-B80C-6189B7EAB581 V1 EN Figure 24: Roof mounted protection relay A 417.0 mm B 306.5 mm C 357.0 mm D 273.5 mm with compression type CT/VT connectors 285.4 mm with ring lug type CT/VT connectors 305.3 mm with grounding bar 4.3.2.3 Door mounting protection relay Drill holes according to the dimensional drawing.
  • Page 42 Section 4 1MRS759115 A Mounting GUID-C2D8F7B2-87FE-44CD-B7CC-37D7BC6E7E53 V1 EN Figure 25: Drilling holes A 249 ±0.4 mm B ∅ 7.0 mm C 245 ±0.4 mm Mount the protection relay to the door or panel with the M6 screws. REX640 Installation Manual...
  • Page 43 Section 4 1MRS759115 A Mounting GUID-9F70D60E-5072-417A-82C6-736CD455EE60 V1 EN Figure 26: Mounting the protection relay to the door 1 M6 screws Tighten the four M6 screws to 9 Nm ±5%. REX640 Installation Manual...
  • Page 44 Section 4 1MRS759115 A Mounting GUID-3B394264-DFDA-43D5-A7C1-CFA848476506 V1 EN Figure 27: Tightening the M6 screws 1 M6 screws REX640 Installation Manual...

  • Page 45: Rack Mounting Protection Relay

    Section 4 1MRS759115 A Mounting GUID-77F9CCBF-A58D-4FBA-91FE-96A8D67EB453 V1 EN Figure 28: Door mounted protection relay A 264.8 mm B 304.0 mm C 242.2 mm with compression type CT/VT connectors 254.1 mm with ring lug type CT/VT connectors 274.0 mm with grounding bar 4.3.2.4 Rack mounting protection relay Attach the protection relay to a 7U rack plate with M6 screws.
  • Page 46 Section 4 1MRS759115 A Mounting GUID-FA19B824-A1E9-47BC-8E3D-CFD1E4EC7A80 V1 EN Figure 29: Mounting the protection relay to the rack plate 1 7U rack plate 2 M6 screws 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.

  • Page 47: Mounting Protection Relay With Local Hmi

    Section 4 1MRS759115 A Mounting GUID-04470FB7-636C-4E71-AF40-FED6B9BD3F9D V1 EN Figure 30: Rack mounted protection relay A 482.60 mm (19”) B 310.35 mm (7U) C 242.20 mm with compression type CT/VT connectors 254.10 mm with ring lug type CT/VT connectors 274.00 mm with grounding bar Check the allowed minimum bending radius from the optical cable manufacturer.
  • Page 48 Section 4 1MRS759115 A Mounting GUID-17FD88B3-3889-4346-81AD-5D65AC2B0A53 V1 EN Figure 31: Drilling holes A 188 ±1 mm B ∅ 6.0 mm C 151 ±1 mm D 230 ±0.4 mm E 322 ±0.4 mm Mount the LHMI and the mounting bracket to the door panel. 2.1.
  • Page 49 Section 4 1MRS759115 A Mounting GUID-B12F5813-0FCA-42CB-B8CA-4D11C49DC708 V1 EN Figure 32: Mounting the LHMI and mounting brackets 1 M5 screws 2 LHMI installation brackets 3 Mounting bracket Attach the mounting bracket to the protection relay with the M6 screws. REX640 Installation Manual...
  • Page 50 Section 4 1MRS759115 A Mounting GUID-3E3D8C5A-C66F-4F68-A358-D131A8C1D0DC V1 EN Figure 33: Attaching the mounting bracket to the protection relay 1 Mounting bracket 2 M6 screws Tighten the M6 screws to 9 Nm ±5%. Lift the protection relay to its place on the existing screws on the bracket. Mount the M5 screws in the bottom holes.
  • Page 51 Section 4 1MRS759115 A Mounting GUID-A8704737-BAC1-4ED2-B391-7CCC4D6FA292 V1 EN Figure 34: Mounting and tightening the M5 screws 1 M5 screws REX640 Installation Manual...

  • Page 52: Rack Mounting Protection Relay With Local Hmi

    Section 4 1MRS759115 A Mounting GUID-04690139-3A2F-4E59-A54F-7DF46B251BA1 V1 EN Figure 35: Door mounted protection relay with LHMI A 265.0 mm B 339.0 mm C 313.2 mm with compression type CT/VT connectors 325.1 mm with ring lug type CT/VT connectors 345.0 mm with grounding bar D 7.6 mm E 212.5 mm 177.5 mm...
  • Page 53 Section 4 1MRS759115 A Mounting GUID-36E3AAF1-DF3B-4B71-8D74-EE39725B7722 V1 EN Figure 36: Mounting the LHMI and mounting bracket 1 M5 screws 2 7U rack plate 3 LHMI installation brackets 4 Mounting bracket Install the RJ-45 coupler with a cable to the panel cutout and connect the cable to the LHMI service port X1.2.
  • Page 54 Section 4 1MRS759115 A Mounting GUID-D13608DE-A717-4EA0-B2FE-45D4B36388CA V1 EN Figure 37: Installing the RJ-45 coupler 1 RJ-45 coupler Attach the mounting bracket to the protection relay with M6 screws. Tighten the M6 screws to 9 Nm ±5%. REX640 Installation Manual...
  • Page 55 Section 4 1MRS759115 A Mounting GUID-28150EB1-8747-4B64-A019-4C4B07242554 V1 EN Figure 38: Mounting M6 screws 1 Mounting bracket 2 M6 screws Lift the protection relay to its place on the existing screws on the mounting bracket. Mount the M5 screws in the bottom holes. Tighten the four M5 screws on the mounting bracket to 4 Nm ±5%.
  • Page 56 Section 4 1MRS759115 A Mounting GUID-3346C113-B70D-40B9-AF45-9C13B5C7FE4C V1 EN Figure 39: Mounting and tightening the M5 screws 1 M5 screws REX640 Installation Manual...

  • Page 57: Mounting Grounding Bar Kit

    Section 4 1MRS759115 A Mounting GUID-114D4B02-C219-4A7C-A01D-32D623A64748 V1 EN Figure 40: Rack mounted protection relay with LHMI 482.6 mm (19”) 310.35 mm (7U) C 265.0 mm D 7.6 mm 19 mm 313.2 mm with compression type CT/VT connectors 325.1 mm with ring lug type CT/VT connectrors 345.0 mm with grounding bar G 339 mm 4.3.4...
  • Page 58 Section 4 1MRS759115 A Mounting GUID-52F79904-C482-4CC5-BFC5-047479232344 V1 EN Figure 41: Mounting grounding bar 1 Module 2 Grounding bar 3 M3 screws and washers 4 Edge with chamfer towards the module's collar screw Tighten the M3 screws to 0.8 Nm ±5%. Install the module back to the same slot in the protection relay.
  • Page 59 Section 4 1MRS759115 A Mounting GUID-F664BEF9-EF9F-4E87-8600-2841653DBF35 V1 EN Figure 42: Installing the module Install connectors with cables to the module. Use peeled cables to get contact to the grounding bar. REX640 Installation Manual...
  • Page 60 Section 4 1MRS759115 A Mounting GUID-8078F871-0FED-4C58-8BB6-0AEE4A0DFAD8 V1 EN Figure 43: Installing connectors 1 Connectors with cables Install shield clamps to connect the cable sheathing to the grounding bar. REX640 Installation Manual...

  • Page 61: Mounting Lens Sensors For An Arc Protection System

    Section 4 1MRS759115 A Mounting GUID-B4DE4C5B-7594-47D6-9446-68CB7502FB33 V1 EN Figure 44: Installing shield clamps 1 Shield clamp See also Shielding RTD mA instrument cables. 4.3.5 Mounting lens sensors for an arc protection system Arc protection is used to detect arc situations in air-insulated metal-clad switchgear. Drill a hole (Ø...
  • Page 62 Section 4 1MRS759115 A Mounting GUID-1757716F-9739-4361-BCE0-2B5E847313EA V1 EN Figure 45: Dimensions of the lens sensor A 3.5 mm B 10 mm C ∅ 9.5 mm D 19 mm Fit the lens sensor into the hole and fasten it with a self-tapping M3 screw. Alternatively, the lens sensor can be fastened with a cable tie.

  • Page 63: Arranging Ventilation

    Section 4 1MRS759115 A Mounting GUID-204F3D72-7019-4F72-98CA-61B2B25EF51B V1 EN Figure 46: Mounting the lens sensor Make sure that the cable tie lies in the groove of the sensor to prevent it from blocking the light. 4.3.6 Arranging ventilation • Reserve sufficient space round the protection relay to ensure adequate ventilation.

  • Page 65: Section 5 Connecting

    Section 5 1MRS759115 A Connecting Section 5 Connecting Required tools Table 2: Tools for connector installation Connector type Tool for anchoring connector Tool for connecting wire Slotted head (DIN 5264) ISO 8764/2 Slotted head (DIN 5364) (mm) (mm) CT/VT connectors Compression 0.6x3.5 0.6x3.5...

  • Page 66: Connecting Wires To Screw-Compression Type Connectors

    Section 5 1MRS759115 A Connecting See the technical manual for product-specific terminal diagrams. 5.2.1 Connecting wires to screw-compression type connectors Terminal blocks of screw-compression type are used for electrical connections. Open the screw terminal before inserting a wire into it for the first time. To open the screw terminal, turn the fixing screw anti-clockwise until the terminal hole is wide open (the inside of the terminal hole is surrounded by metal).

  • Page 67: Connecting Wires To Push-In Type Connectors

    Section 5 1MRS759115 A Connecting Table 4: Wire specifications for ring-lug type connectors Connector type Wire size Stripping length Contact screw Anchoring Stranded Crimp ferrule (mm) tightening screw tightening torque (Nm) torque (Nm) (mm²) (mm²) CT/VT 0.5...6 1.2...1.5 1)2) connectors Signal 1.13 0.35...

  • Page 68: Connecting Protective Earthing To Local Hmi

    Section 5 1MRS759115 A Connecting GUID-38B534BA-2733-44B0-AF98-C964FCF6D323 V1 EN Figure 47: Location of the protective earth pin Each protection relay must have its own earth lead connected to the earth circuit connector. Connect the earth lead to the earth bar. Thread the copper cable on the protective earth. Tighten the protective earth screw to 6 Nm ±5%.

  • Page 69: Connecting Analog Signals

    Section 5 1MRS759115 A Connecting GUID-93E2EC7F-92D8-4AEE-8568-7508EF13D59B V1 EN Figure 48: Loosening protective earth screw T20 Tighten the protective earth screw to 1.5 Nm ±10%. Connecting analog signals A connection diagram is needed to connect the analog signals. • Use the compression type for CT/VT terminals. The wires for the analog signals can be connected to the CT/VT terminals before the connector is connected to the protection relay.
  • Page 70 Section 5 1MRS759115 A Connecting GUID-8E0C4505-14AB-49DD-90B5-750DF82B4FE8 V1 EN Figure 49: Identifying CT/VT color coding 1 Light gray pairs with short circuit facility (CT), RAL7035 2 Dark gray pairs without short circuit facility (VT), RAL7042 GUID-C98AA402-C69C-4820-9E5B-29669F0A366F V1 EN Figure 50: Loose CT/VT connector coding 1 CT connector coding 2 VT connector coding 3 Empty connector...

  • Page 71: Connecting Current And Voltage Inputs

    Section 5 1MRS759115 A Connecting GUID-0F27F3F1-B775-47FD-8940-F66CD1A152DE V1 EN Figure 51: Fixed CT/VT connector coding 1 CT connector coding 2 VT connector coding 3 Empty connector 5.4.1 Connecting current and voltage inputs Each terminal for CTs/VTs is dimensioned for one 0.5...6.0 mm wire or for two wires of maximum 2.5 mm •...
  • Page 72 Section 5 1MRS759115 A Connecting L1 L2 L3 AIM1001 Positive 57-240V Load flow Direction 57-240V 57-240V 57-240V 57-240V 1/5A 1/5A 1/5A 1/5A 0.2/1A CT5 (for residual current only) GUID-A274F38C-5302-4EA9-83F9-5BB17C7672BF V1 EN Figure 52: AIM1001 REX640 Installation Manual...
  • Page 73 Section 5 1MRS759115 A Connecting L1 L2 L3 AIM1002 Positive 57-240V Load flow Direction 57-240V 57-240V 57-240V 1/5A 1/5A 1/5A 1/5A 1/5A 1/5A GUID-E49A0352-50CA-4FE5-9D3D-AD4F09A10F06 V1 EN Figure 53: AIM1002 REX640 Installation Manual...
  • Page 74 Section 5 1MRS759115 A Connecting L1 L2 L3 Positive Current Direction SIM1001 Sensor I Sensor U Sensor I Sensor U Sensor I Sensor U 57-240 0.2/1A (for residual current only) GUID-549B3B87-483B-4411-9790-D4FA8525936B V1 EN Figure 54: SIM1001 REX640 Installation Manual...

  • Page 75: Connecting Rtd And Ma Inputs

    Section 5 1MRS759115 A Connecting L1 L2 L3 Positive Current Direction SIM1001 Sensor I Sensor U Sensor I Sensor U Sensor I Sensor U 57-240 0.2/1A (for residual current only) GUID-D37ABF6A-CE39-4293-8D4B-1DA95A077D27 V1 EN Figure 55: SIM1001 5.4.2 Connecting RTD and mA inputs •...

  • Page 76: Shielding Rtd/Ma Instrument Cables

    Section 5 1MRS759115 A Connecting RTD1001 RTD1 RTD2 RTD3 RTD4 RTD5 RTD6 RTD7 RTD8 RTD9 RTD10 GUID-3EC6FABE-BF3C-4789-AC2F-428C7D177126 V1 EN Figure 56: RTD1001 5.4.2.1 Shielding RTD/mA instrument cables Install connectors with cables to the module. REX640 Installation Manual...
  • Page 77 Section 5 1MRS759115 A Connecting Strip the cables to ensure contact to the grounding bar. The cable position affects the stripping length and position. GUID-28836E17-19C9-4D8A-813F-45F08A18FCC1 V1 EN Figure 57: Installing connectors 1 Connectors with cables A/B Examples of stripping length and position Install shield clamps to connect the cable sheathing to the grounding bar.

  • Page 78: Connecting Binary Signals

    Section 5 1MRS759115 A Connecting GUID-B4DE4C5B-7594-47D6-9446-68CB7502FB33 V1 EN Figure 58: Installing shield clamps 1 Shield clamp Connecting binary signals • Connect the wires for the binary signals to the correct device. Each terminal for binary input and output signal is dimensioned for one 0.5...2.5 wire or for two 0.5...1.0 mm wires.
  • Page 79 Section 5 1MRS759115 A Connecting BIO1001/ BIO1003 BI10 BI11 BI12 BI13 BI14 GUID-2F20AF34-230C-4E35-86AE-A6F930250E3C V1 EN Figure 59: BIO1001/BIO1003 REX640 Installation Manual...
  • Page 80 Section 5 1MRS759115 A Connecting BIO1002/ BIO1004 SPO1 SPO2 SPO3 SPO4 SPO5 SPO6 SPO6_TCS SPO7 SPO8_TCS SPO8 GUID-46FF3F6E-0E8C-4FA7-8964-0480330AC56A V1 EN Figure 60: BIO1002/BIO1004 REX640 Installation Manual...

  • Page 81: Connecting Power Supply

    Section 5 1MRS759115 A Connecting PSM100x Uaux Uaux - /~ SSO1 SSO2 POSP1 POSP2 PODP1 PO1_TCS PODP2 PO2_TCS PODP3 PO3_TCS GUID-6B2AB7B2-D285-4F90-A73D-40603FA7050B V1 EN Figure 61: PSM100x Connecting power supply The permitted auxiliary voltage range is found on the protection relay's sticker. •...

  • Page 82: Connecting Communication

    Section 5 1MRS759115 A Connecting GUID-982F5238-6B8A-44C0-B7C2-F791D8D5871F V1 EN Figure 62: Connecting auxiliary voltage Connecting communication • Before connecting communication, check that the HW module has the correct communication interfaces. The communication module is located in slot A2. See the technical manual for the communication interfaces. Check the allowed minimum bending radius from the optical cable manufacturer.

  • Page 83: Connecting Protection Communication

    Section 5 1MRS759115 A Connecting 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. Remove the dust cap from port X6/LD to expose the SFP socket.
  • Page 84 Section 5 1MRS759115 A Connecting GUID-D53AE6BA-8746-4796-B1C9-13352190FAEA V1 EN Figure 63: LHMI connectors 1 USB port 2 RJ-45 ports REX640 Installation Manual...

  • Page 85: Section 6 Checking Installation

    Section 6 1MRS759115 A Checking installation Section 6 Checking installation Identifying hardware and software version • Check the label on the case of the protection relay for the hardware and software version information. • Check the module labels to identify the modules inside the protection relay. Checking mounting •...
  • Page 86 Section 6 1MRS759115 A Checking installation Energize the power supply of the protection relay and the optional LHMI. This can be done in a number of ways, from energizing a whole cubicle to energizing a single protection relay. The following sequence is expected when the protection relay is energized: •...

  • Page 87: Section 7 Removing, Repairing And Exchanging

    The HW modules submenu contains information about the HW modules. Removing protection relay • Before removing the protection relay, make sure that the auxiliary power is turned off and all wiring is disconnected. Check with your local ABB if the protection relay can be upgraded. REX640 Installation Manual...

  • Page 88: Sending Protection Relay For Repair

    1MRS759115 A Removing, repairing and exchanging Sending protection relay for repair • In case of product problems, contact the nearest ABB office or representative for consultation and instructions. Exchanging protection relay • To exchange the protection relay with another identical unit, remove the protection relay and install the new one.

  • Page 89: Section 8 Technical Data

    Section 8 1MRS759115 A Technical data Section 8 Technical data Local HMI GUID-D53AE6BA-8746-4796-B1C9-13352190FAEA V1 EN Figure 65: LHMI connectors 1 USB port 2 RJ-45 ports REX640 Installation Manual...

  • Page 90: Connector Side

    Section 8 1MRS759115 A Technical data Connector side GUID-5D4C7B10-17CA-4F59-B9E0-8024CB82CDE8 V1 EN Figure 66: Connector side of the protection relay 1 Slot markings in enclosure (top and bottom) 2 Ready LED REX640 Installation Manual...

  • Page 91: Dimensions

    Section 8 1MRS759115 A Technical data Dimensions GUID-F2F41580-05C9-4AC1-8DAB-CFD94F0D545A V1 EN Figure 67: REX640 main dimensions A 304.0 mm B 264.8 mm C 242.2 mm with compression type CT/VT connectors 254.1 mm with ring lug type CT/VT connectors 274.0 mm with grounding bar Table 6: Dimensions of the relay Description...

  • Page 92: Enclosure Class

    Section 8 1MRS759115 A Technical data Table 7: Dimensions of the LHMI Description Value Width 212.5 mm Height 177.5 mm Depth 57.6 mm Weight 1.6 kg Enclosure class Table 8: Degree of protection of flush-mounted protection relay Description Value Front/connector side IP 20 Top and bottom IP 30...
  • Page 93 Section 8 1MRS759115 A Technical data GUID-83EEB0CF-75FB-469C-ACC2-69C496D43C5C V1 EN Figure 68: REX640 sides 1 Side 2 Top 3 Rear 4 Front/connector side 5 Bottom REX640 Installation Manual...

  • Page 95: Section 9 Accessories And Ordering Data

    Section 9 1MRS759115 A Accessories and ordering data Section 9 Accessories and ordering data Table 10: Local HMI Item Order number LHMI 2RCA033008A0001 LHMI, conformal coated 2RCA033008A0901 1 m connection cable for LHMI 1MRS120549-1 2 m connection cable for LHMI 1MRS120549-2 3 m connection cable for LHMI 1MRS120549-3...
  • Page 96 Section 9 1MRS759115 A Accessories and ordering data Item Order number ARC lens sensor cable 15 m 2RCA040290A0015 ARC loop sensor cable 5 m 2RCA041050A0005 ARC loop sensor cable 10 m 2RCA041050A0010 ARC loop sensor cable 15 m 2RCA041050A0015 ARC loop sensor cable 20 m 2RCA041050A0020 ARC loop sensor cable 25 m 2RCA041050A0025...

  • Page 97: Section 10 Glossary

    Section 10 1MRS759115 A Glossary Section 10 Glossary Current transformer Electromagnetic compatibility Human-machine interface Hardware International Electrotechnical Commission Connector type for glass fiber cable, IEC 61754-20 Liquid crystal polymer LHMI Local human-machine interface 1. Personal computer 2. Polycarbonate Product connectivity level RJ-45 Galvanic connector type RoHS Restriction of hazardous substances Resistance temperature detector...
  • Page 100 — ABB Distribution Solutions Distribution Automation P.O. Box 699 FI-65101 VAASA, Finland Phone +358 10 22 11 www.abb.com/mediumvoltage www.abb.com/relion © Copyright 2018 ABB. All rights reserved.

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