ABB Relion SAM600-IO User manual

Relion® SAM600
Switchgear control unit SAM600-IO
Version 2.2
Installation manual

Document ID: 1MRK 514 030-UEN
Issued: June 2021
Revision: C
Product version: 2.2
© 2017 - 2021 Hitachi Power Grids. All rights reserved

Copyright
This document and parts thereof must not be reproduced or copied without written permission from
Hitachi Power Grids, and the contents thereof must not be imparted to a third party, nor used for any
unauthorized purpose.
The software and hardware described in this document is furnished under a license and may be used
or disclosed only in accordance with the terms of such license.
This product includes software developed by the OpenSSL Project for use in the OpenSSL Toolkit.
(https://www.openssl.org/) This product includes cryptographic software written/developed by: Eric
Young ([email protected]) and Tim Hudson ([email protected]).
Trademarks
ABB is a registered trademark of ABB Asea Brown Boveri Ltd. Manufactured by/for a Hitachi Power
Grids company. 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 nearest Hitachi Power Grids representative.

Disclaimer
This document has been carefully checked by Hitachi Power Grids but deviations cannot be
completely ruled out. 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 Hitachi Power
Grids be responsible or liable for any loss or damage resulting from the use of this manual or the
application of the equipment.

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 2004/108/EC) and concerning electrical equipment for use within specified voltage limits
(Low-voltage directive 2006/95/EC). This conformity is the result of tests conducted by Hitachi Power
Grids 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 international standards of the IEC 60255 series.

Table of contents
Section 1 Introduction....................................................................................................3
1.1 This manual...........................................................................................................................3
1.2 Intended audience.................................................................................................................3
1.3 Product documentation......................................................................................................... 3
1.3.1 Product documentation set..................................................................................................3
1.3.2 Document revision history...................................................................................................4
1.3.3 Related documents............................................................................................................. 5
1.4 Document symbols and conventions.....................................................................................5
1.4.1 Symbols...............................................................................................................................5
1.4.2 Document conventions........................................................................................................5
Section 2 Safety information......................................................................................... 7
2.1 Symbols on the product.........................................................................................................7
2.2 Warnings............................................................................................................................... 7
2.3 Caution signs.........................................................................................................................8
Section 3 Environmental aspects................................................................................. 9
3.1 Sustainable development......................................................................................................9
3.2 Disposing of the IED..............................................................................................................9
Section 4 Unpacking, inspecting and storing............................................................ 11
4.1 Removing transport packaging............................................................................................11
4.2 Inspecting the product......................................................................................................... 11
4.2.1 Identifying the product....................................................................................................... 11
4.2.2 Checking delivery items.....................................................................................................11
4.2.3 Inspecting the IED............................................................................................................. 11
4.2.4 Returning an IED damaged in transit................................................................................ 11
4.3 Storing................................................................................................................................. 11
Section 5 Mounting.......................................................................................................13
5.1 Required tools..................................................................................................................... 13
5.2 Checking environmental conditions and mounting space................................................... 13
5.3 Mounting the IED.................................................................................................................13
5.3.1 19” panel rack mounting....................................................................................................14
5.3.1.1 Overview...................................................................................................................... 14
5.3.1.2 Mounting procedure for 19” panel rack mounting........................................................ 15
5.3.2 Wall mounting....................................................................................................................15
5.3.2.1 Overview...................................................................................................................... 15
5.3.2.2 Mounting procedure for wall mounting......................................................................... 16
5.3.3 Side-by-side 19” rack mounting.........................................................................................17
5.3.3.1 Overview...................................................................................................................... 17
5.3.3.2 Mounting procedure for side-by-side rack mounting.................................................... 17
1MRK 514 030-UEN Rev. C Table of contents
Switchgear control unit SAM600-IO 1
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

Section 6 Connecting...................................................................................................19
6.1 Making the electrical connection......................................................................................... 19
6.1.1 IED connectors..................................................................................................................19
6.1.1.1 Overview...................................................................................................................... 19
6.1.1.2 Rear side connectors................................................................................................... 20
6.1.2 Connecting to protective earth ......................................................................................... 25
6.1.3 Connecting the power supply module............................................................................... 26
6.1.4 Connecting the binary input and output signals................................................................ 27
6.2 Making of Ethernet connections..........................................................................................29
6.2.1 Connecting station communication interfaces...................................................................29
Section 7 Checking installation...................................................................................31
7.1 Identifying hardware and software version..........................................................................31
7.2 Checking mounting..............................................................................................................31
7.3 Checking the power supply................................................................................................. 31
7.4 Energizing the IED.............................................................................................................. 31
Section 8 Removing, repairing and exchanging........................................................33
8.1 Product lifecycle.................................................................................................................. 33
8.2 Checking IED information....................................................................................................33
8.3 Removing the IED............................................................................................................... 34
8.4 Sending the IED for repair...................................................................................................34
8.5 Exchanging the IED.............................................................................................................34
Section 9 Technical data.............................................................................................. 35
9.1 Dimensions..........................................................................................................................35
9.1.1 Case without protective cover........................................................................................... 35
9.1.2 Case with protective cover................................................................................................ 36
9.1.3 Wall mounting dimensions................................................................................................ 37
Section 10 Glossary....................................................................................................... 39
Table of contents 1MRK 514 030-UEN Rev. C
2Switchgear control unit SAM600-IO
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

Section 1 Introduction
1.1 This manual GUID-AB423A30-13C2-46AF-B7FE-A73BB425EB5F v20
The installation manual contains instructions on how to install the IED. The manual provides
procedures for mechanical and electrical installation. The chapters are organized in the chronological
order in which the IED should be installed.
1.2 Intended audience GUID-C9B8127F-5748-4BEA-9E4F-CC762FE28A3A v11
This manual addresses the personnel responsible for installing the product hardware.
The installation personnel must have basic knowledge of handling electronic equipment.
1.3 Product documentation
1.3.1 Product documentation set GUID-3AA69EA6-F1D8-47C6-A8E6-562F29C67172 v16
IEC07000220-4-en.vsd
Planning & purchase Engineering Installing Commissioning Operation Maintenance Decommissioning Deinstalling & disposal
Application manual
Operation manual
Installation manual
Engineering manual
Communication
protocol manual
Cyber security
deployment guideline
Technical manual
Commissioning manual
IEC07000220 V4 EN-US
Figure 1: The intended use of manuals throughout the product lifecycle
1MRK 514 030-UEN Rev. C Section 1
Introduction
Switchgear control unit SAM600-IO 3
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

The engineering manual contains instructions on how to engineer the IEDs using the various tools
available within the PCM600 software. The manual provides instructions on how to set up a PCM600
project and insert IEDs to the project structure. The manual also recommends a sequence for the
engineering of protection and control functions, as well as communication engineering for IEC 61850.
The installation manual contains instructions on how to install the IED. The manual provides
procedures for mechanical and electrical installation. The chapters are organized in the chronological
order in which the IED should be installed.
The commissioning manual contains instructions on how to commission the IED. The manual can
also be used by system engineers and maintenance personnel for assistance during the testing
phase. The manual provides procedures for the checking of external circuitry and energizing the IED,
parameter setting and configuration as well as verifying settings by secondary injection. The manual
describes the process of testing an IED in a substation which is not in service. The chapters are
organized in the chronological order in which the IED should be commissioned. The relevant
procedures may be followed also during the service and maintenance activities.
The operation manual contains instructions on how to operate the IED once it has been
commissioned. The manual provides instructions for the monitoring, controlling and setting of the
IED. The manual also describes how to identify disturbances and how to view calculated and
measured power grid data to determine the cause of a fault. The manual provides information related
to the need of LHMI service kit to monitor diagnostics and make configuration changes.
The application manual contains application descriptions and setting guidelines sorted per function.
The manual can be used to find out when and for what purpose a typical protection function can be
used. The manual can also provide assistance for calculating settings.
The technical manual contains operation principle descriptions, and lists function blocks, logic
diagrams, input and output signals, setting parameters and technical data, sorted per function. The
manual can be used as a technical reference during the engineering phase, installation and
commissioning phase, and during normal service.
The communication protocol manual describes the communication protocols supported by the IED.
The manual concentrates on the vendor-specific implementations.
The cyber security deployment guideline describes the process for handling cyber security when
communicating with the IED. Certification, Authorization with role based access control, and product
engineering for cyber security related events are described and sorted by function. The guideline can
be used as a technical reference during the engineering phase, installation and commissioning
phase, and during normal service.
1.3.2 Document revision history GUID-7099E1DB-1CD6-4037-A418-92AB57FA9462 v5
Document
revision
Date Product revision History
A 2017-12 2.2.1 First release for product version 2.2
B 2019-05 2.2.1 PTP enhancements and corrections
2.2.2 Document not released
2.2.3 Document not released
2.2.4 Document not released
C 2021-06 2.2.5 Minor document enhancements and corrections.
Section 1 1MRK 514 030-UEN Rev. C
Introduction
4Switchgear control unit SAM600-IO
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

1.3.3 Related documents GUID-67D1F667-746E-4B71-875A-4CBEAB6EC5E1 v1
Documents related to SAM600–IO Document numbers
Application manual 1MRK 511 445-UEN
Commissioning manual 1MRK 511 447-UEN
Product guide 1MRK 511 448-BEN
Technical manual 1MRK 511 446-UEN
Type test certificate 1MRK 511 448-TEN
Operation manual 1MRK 500 131-UEN
Engineering manual 1MRK 511 442-UEN
Installation manual 1MRK 514 030-UEN
Communication protocol manual, IEC 61850 Edition 1 1MRK 511 440-UEN
Communication protocol manual, IEC 61850 Edition 2 1MRK 511 441-UEN
Accessories guide 1MRK 514 012-BEN
Cyber security deployment guideline 1MRK 511 443-UEN
1.4 Document symbols and conventions
1.4.1 Symbols GUID-2945B229-DAB0-4F15-8A0E-B9CF0C2C7B15 v13
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. It might indicate the presence of a hazard which could result in
corruption of software or damage to equipment or property.
The information icon alerts the reader of important facts and conditions.
The tip icon indicates advice on, for example, how to design your project or how to
use a certain function.
Although 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. It is important that the user fully complies with all
warning and cautionary notices.
1.4.2 Document conventions GUID-96DFAB1A-98FE-4B26-8E90-F7CEB14B1AB6 v9
• Abbreviations and acronyms in this manual are spelled out in the glossary. The glossary also
contains definitions of important terms.
• Parameter names are shown in italics.
1MRK 514 030-UEN Rev. C Section 1
Introduction
Switchgear control unit SAM600-IO 5
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

For example, the function can be enabled and disabled with the Operation setting.
• Each function block symbol shows the available input/output signal.
• the character ^ in front of an input/output signal name indicates that the signal name may
be customized using the PCM600 software.
• the character * after an input signal name indicates that the signal must be connected to
another function block in the application configuration to achieve a valid application
configuration.
• Dimensions are provided both in inches and millimeters. If it is not specifically mentioned then
the dimension is in millimeters.
Section 1 1MRK 514 030-UEN Rev. C
Introduction
6Switchgear control unit SAM600-IO
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

Section 2 Safety information
2.1 Symbols on the product GUID-E48F2EC3-6AB8-4ECF-A77E-F16CE45CA5FD v4
All warnings must be observed.
Read the entire manual before doing installation or any maintenance work on the
product.
Class 1 Laser product. Take adequate measures to protect your eyes and do not
view directly with optical instruments.
2.2 Warnings IP1504-1 v2
Observe the warnings during all types of work related to the product.
GUID-C9B6638A-57E7-4E05-9A33-A60E359C54AF v1
Only electrically skilled persons with the proper authorization and knowledge of any
safety hazards are allowed to carry out the electrical installation.
M2366-2 v2
National and local electrical safety regulations must always be followed. Working in a
high voltage environment requires serious approach to avoid human injuries and
damage to equipment.
M2362-2 v1
Do not touch circuitry during operation. Potentially lethal voltages and currents are
present.
M2364-2 v1
Always use suitable isolated test pins when measuring signals in open circuitry.
Potentially lethal voltages and currents are present.
M2370-2 v1
Never connect or disconnect a wire and/or a connector to or from a IED during
normal operation. Hazardous voltages and currents are present that may be lethal.
Operation may be disrupted and IED and measuring circuitry may be damaged.
GUID-BEDD698E-356C-4CF9-9DAE-64DB3CEADEAD v1
Dangerous voltages can occur on the connectors, even though the auxiliary voltage
has been disconnected.
1MRK 514 030-UEN Rev. C Section 2
Safety information
Switchgear control unit SAM600-IO 7
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

M2369-2 v3
Always connect the IED to protective earth, regardless of the operating conditions.
This also applies to special occasions such as bench testing, demonstrations and
off-site configuration. This is class 1 equipment that shall be earthed.
M2372-2 v1
Never remove any screw from a powered IED or from a IED connected to powered
circuitry. Potentially lethal voltages and currents are present.
SEMOD168311-3 v1
Take adequate measures to protect the eyes. Never look into the laser beam.
GUID-11CCF92B-E9E7-409C-84D0-DFDEA1DCBE85 v2
The IED with accessories should be mounted in a cubicle in a restricted access area
within a power station, substation or industrial or retail environment.
2.3 Caution signs IP1503-1 v1
GUID-5D1412B8-8F9D-4D39-B6D1-60FB35797FD0 v3
Whenever changes are made in the IED, measures should be taken to avoid
inadvertent tripping.
GUID-F2A7BD77-80FB-48F0-AAE5-BE73DE520CC2 v1
The IED contains components which are sensitive to electrostatic discharge. ESD
precautions shall always be observed prior to touching components.
M2695-2 v2
Always transport PCBs (modules) using certified conductive bags.
M2696-2 v1
Do not connect live wires to the IED. Internal circuitry may be damaged
M2697-2 v2
Always use a conductive wrist strap connected to protective earth when replacing
modules. Electrostatic discharge (ESD) may damage the module and IED circuitry.
M2698-2 v2
Take care to avoid electrical shock during installation and commissioning.
M2693-2 v2
Changing the active setting group will inevitably change the IED's operation. Be
careful and check regulations before making the change.
Section 2 1MRK 514 030-UEN Rev. C
Safety information
8Switchgear control unit SAM600-IO
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

Section 3 Environmental aspects
3.1 Sustainable development GUID-573C2931-CBB2-4E7D-A067-D8246CC7A52F v7
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
IED.
Operational reliability and long life time have been assured 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 environmental system. The
effectiveness of the environmental system is constantly evaluated by an external auditing body. We
follow environmental rules and regulations systematically to evaluate their effect on our products and
processes.
3.2 Disposing of the IED AMU0600460 v6
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. When disposing of an IED or its parts contact a local
waste handler who is authorized and specialized in disposing electronic waste. These handlers can
sort the material by using dedicated sorting processes and dispose of the product according to the
local requirements.
GUID-09CAB180-6D53-45E3-99EF-1AF5E357F41E v3
Table 1: Materials of the IED parts
IED Parts Material
Unit Metallic plates, parts and screws Steel and aluminum
Plastic parts PC1), LCP2)
Package Box Cardboard
Attached material Manuals Paper
1) Polycarbonate
2) Liquid crystal polymer
1MRK 514 030-UEN Rev. C Section 3
Environmental aspects
Switchgear control unit SAM600-IO 9
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

10

Section 4 Unpacking, inspecting and storing
4.1 Removing transport packaging AMU0600514 v5
IEDs require careful handling.
1. Examine the delivered products to ensure that they have not been damaged during the
transport.
2. Remove the transport packing carefully without force.
The cardboard packaging material is 100% recyclable.
4.2 Inspecting the product
4.2.1 Identifying the product AMU0600513 v5
1. Locate the IED's order number from the label attached to the IED's case.
2. Compare the IED's order number with the ordering information to verify that the received
product is correct.
4.2.2 Checking delivery items GUID-2A6D8F5A-470F-40D1-9EAE-60DE4DD85EE6 v1
Check that all items are included in the delivery in accordance with the delivery documents.
4.2.3 Inspecting the IED GUID-F6333353-F05D-4B41-BE44-5CE5274E788E v2
• Check the IED to see if any damage occurred during transportation.
4.2.4 Returning an IED damaged in transit GUID-966A05ED-CD30-4F66-957E-00FF38943A73 v5
If damage has occurred during transport, appropriate actions must be taken against the latest carrier.
Please inform the nearest Hitachi Power Grids office or representative. Notify Hitachi Power Grids
immediately if there are any discrepancies in relation to the delivery documents.
4.3 Storing GUID-1DC9D33D-DC62-438B-9333-3BB354164CBC v7
Storing of the IED before installation must be done in the original transport packaging in a dry and
dust free place. Storage temperature must be within the range of -40° C to +70° C. The average high
temperature is recommended to be less than +40° C, to minimize component ageing.
1MRK 514 030-UEN Rev. C Section 4
Unpacking, inspecting and storing
Switchgear control unit SAM600-IO 11
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

12

Section 5 Mounting
5.1 Required tools GUID-B9478208-286B-4CFF-9C47-074D641A6F71 v2
Generally, all the screws included in delivered mounting kits are of Torx type and a torque
screwdriver of the same type is needed (Tx10, Tx15, Tx20, Tx25 and Tx30).
Use only the screws included in the mounting kit when mounting the plates and the
angles on the IED. Screws with wrong dimension may damage the PCBs inside the
IED.
5.2 Checking environmental conditions and mounting
space GUID-2AF46E8C-25B3-4606-A768-E4B70E3D6B0A v12
The mechanical and electrical environmental conditions at the installation site must be within the
limits described in the technical manual and IEC60255-1, normal environment.
• Avoid installation in dusty, damp places and where combustible materials are present near the
IED
• Check that sufficient space is available.
Sufficient space is needed at the front and rear of the IED to allow access to wires and optical
fibers and to enable maintenance and future modifications.
• Ensure convection cooling around the case to minimize the heating effect within the IED.
5.3 Mounting the IED M11978-3 v12
The IED can be rack and wall mounted with the use of different mounting kits, see figure 2.
An additional box of type RHGS can be mounted to one side of a 1/2.
The different mounting kits contain all parts needed including screws and assembly instructions. The
following mounting kits are available:
• 19” Panel (rack) mounting kit
• Wall mounting kit
• Side-by-side mounting kit
The mounting kits are ordered with the IED from the ordering sheet in the Product
guide. They are also available for ordering in the Accessories guide.
1MRK 514 030-UEN Rev. C Section 5
Mounting
Switchgear control unit SAM600-IO 13
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved

A B C
IEC17000051-1-en.vsdx
GUID-B1BFADED-7460-4CE6-A992-93B77DCD1105 V1 EN-US
Figure 2: Different mounting methods
Description
A 19” Panel rack mounting
B Wall mounting
C Side-by-side rack mounting
5.3.1 19” panel rack mounting IP10313-1 v1
5.3.1.1 Overview SEMOD127656-5 v4
All IED sizes can be mounted in a standard 19” cubicle rack by using a suitably sized mounting kit
consisting of two mounting angles, their fastening screws and washers.
The mounting angles are reversible which enables mounting of IED size 1/2 x 19” either to the left or
the right side of the cubicle.
A separately ordered rack mounting kit for side-by-side mounted IEDs or IEDs
together with RHGS cases should be selected so that the total size equals 19”.
Use only the screws included in the mounting kit when mounting the plates and the
angles on the IED. Screws with wrong dimension may damage the PCBs inside the
IED.
Section 5 1MRK 514 030-UEN Rev. C
Mounting
14 Switchgear control unit SAM600-IO
Installation manual
© 2017 - 2021 Hitachi Power Grids. All rights reserved