ABB REC603 User manual

Wireless Controller
REC601/603
Product Guide

Contents
1. Description.....................................................................3
2. Applications....................................................................4
3. Battery condition monitoring...........................................8
4. Motor overload protection..............................................9
5. Inputs and outputs / Physical interfaces.........................9
6. Communication............................................................13
7. Technical data..............................................................14
8. Mounting methods.......................................................19
9. Ordering data...............................................................19
10. Accessories and ordering data....................................22
11. Tools...........................................................................22
12. Terminal diagrams.......................................................23
13. References..................................................................25
14. Document revision history...........................................25
Disclaimer
The information in this document is subject to change without notice and should not be construed as a commitment by ABB Oy. ABB Oy assumes no responsibility
for any errors that may appear in this document.
© Copyright 2011 ABB Oy.
All rights reserved.
Trademarks
ABB is a registered trademark of ABB Group. All other brand or product names mentioned in this document may be trademarks or registered trademarks of their
respective holders.
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
2 ABB

1. Description
The Wireless Controllers REC601/603 are
compact, solution based devices for the remote
control and monitoring of secondary substations
such as network disconnectors, load break
switches and Ring Main Units (RMU’s) in
distribution networks.
The Wireless Controllers REC601/603 enable the
SCADA system to wirelessly monitor and control
the field devices over the public communication
infrastructure (GPRS).
The Wireless Controllers REC601/603 utilize the
built-in GPRS features for reliable and secure end-
to-end communication providing remote
monitoring and control of a single object with
Wireless Controller REC601, or up to three (3)
objects with Wireless Controller REC603.
The use of Wireless Controllers REC601/603 in
distribution networks improves the quality of
power distribution and dramatically reduces the
outage time in affected areas. The areas directly
adjacent to these affected areas would also show
reduced outages and overall effects. It also
reduces the capital expenditures in the
distribution network by limiting the replacement of
legacy devices and contributes to more direct
cost savings by facilitating preventative
maintenance. Wireless Controllers REC601/603
are also ideally suited to be retrofitted to existing
disconnectors and thus enabling remote control
of these devices and further extending the life
cycle of the disconnector itself.
SCADA (ABB MicroSCADA)
IEC-104 M2M Gateway
• Static IP addresses
• Firewall and VPN
TCP/IP
IEC-104 IEC-104
TCP/IP
Wireless Controller REC601/603 Wireless Gateway RER601/603
SPA
IEC-101
ABB IED
ABB load break switches
GPRS
Secure end-to-end VPN tunneling in public network
GUID-5BB3E76A-52DD-4A42-A1EE-122D795C95E6 V1 EN
Figure 1. Typical communication system example
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0 Issued: 2011-09-02
Revision: A
ABB 3

2. Applications
The Wireless Controllers REC601/603 are
important and powerful components in an
automated distribution network. Connected to the
central control system (SCADA/DMS) – that
manages the utility network - they serve as the
core of the secondary substation automation
system. These devices are recommended devices
for multiple disconnector or distribution
transformer applications in distribution networks
that require specifications and/or features like
listed below.
• Highly reliable control and monitoring of up to
three (3) objects (per REC603):
– Disconnector position indications with front
LEDs
– Separate LED indicators for earthing status
– Supports both local and remote disconnector
control
– More than one Wireless Controller
REC601/603 can be connected in a single
location to facilitate the Ethernet enabled
control and monitoring of more than three (3)
disconnectors
• Overload protection of actuator motors
– Load current measured in the motor circuit
– Measurement of object transition time
– Energy limit based motor overload protection
(“software fuse”)
• Always on two-way communication based on
GPRS via an M2M gateway
– Redundant IEC 60870-5-104 connections
provide extra availability
– Communication monitoring and automatic
connection re-establishment
– High level data security through internal VPN
and Firewall
– Possibility to act as an IEC 60870-5-101
master (router) for another communicating
sub-device (for example metering unit or fault
passage indicator)
• Built-in battery charger with advanced battery
control:
– Temperature compensated charging
– Battery monitoring/testing (condition
monitoring)
– Deep discharge protection
• Heater control to limit effects of ambient
temperature variations, such as condensation,
etc.
• Real-time clock for accurate event time-tagging
• Robust aluminium casing design for easy DIN
rail mounting
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
4 ABB

GUID-B0E0CD80-91B5-4437-B5B0-0BB47638EBFD V1 EN
Figure 2. Distribution automation system overview
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
ABB 5

Application examples
REC601
M
O
I
aux
MV
O
I
UEMC 50
Hall
sensor
mA
+
-
AC
+24V DC
Battery charging
Battery test
Heater control
Remote
on
off
GUID-2EA84B83-9D8A-4B3F-AC97-D99930FCB53B V1 EN
Figure 3. Within the UEMC 50 the REC601 unit is used for the remote control of a disconnector. The motor
operating device is placed in the same UEMC 50 enclosure as the other equipment.
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
6 ABB

LV
REC603
O
I
aux
O
I
O
I
O
I
80-265V ac/dc
or 18-80V dc
kWh
kVArh LV compartment in RMU
MV
Remote
on
o
Hall
SF6Alarm
Serial port
+24V DC
mA
+
-
sensor
MM
Battery charging
Battery test
Heater control
GUID-FA91F00E-70D2-404C-8F7A-AEA72FB7F30B V1 EN
Figure 4. A REC603 unit used for remote control of a Ring Main Unit
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
ABB 7

REC601
M
O
I
aux
MV
O
I
UEMC Control Cabinet
Remote
on
off
Hall
mA
+
-
AC
+24V DC
Battery charging
Battery test
Heater control
sensor
GUID-D6E454C7-00B1-4D98-8EFE-62048B5E37D4 V1 EN
Figure 5. Within the UEMC control cabinet the REC601 unit is used for remote control of a disconnector. The
motor operating device is fitted to the disconnector.
3. Battery condition monitoring
The Wireless Controllers REC601/603 are
equipped with condition based functionality that
make the conditioning monitoring of the built-in
battery of the device possible and optimize the
lifetime and maintenance intervals of the back-up
batteries in the control assembly.
The back-up battery could periodically (scheduled
by operator) be tested by switching off the
charger and switching on the dummy load.
Current and voltage measurements are taken for
a defined period of time (discharging time period).
Based on these measurements of the battery’s
current and voltage levels, an assessment is
made regarding the battery’s condition and
remaining operational capacity (in Ah). If the
assessment shows that the battery has a
significant depletion in capacity an IEC
60870-5-104 alarm event would then be
generated in the system.
Also the Wireless Controllers REC601/603 feature
the ability to protect the battery against complete
discharge. This is achieved by the fact that the
battery voltage is always measured in network
fault conditions (primary power source is
disconnected). If the measured battery voltage
level is below a defined limit (assumed as a
“battery failure”) an IEC 60870-5-104 alarm event
would then be generated in the system and the
load is disconnected from the battery.
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
8 ABB

4. Motor overload protection
The Wireless Controllers REC601/603 are
equipped with condition based functionality that
assists in the monitoring and management of the
disconnector motor by using over current
detection and shut down of the motor that is
connected to the device.
The over current detection is initialized as soon as
a switch-on command is received by the motor.
This overload detection process is based on
measurements done by a Hall-Effect Current
Transducer (optional accessory) for load current
and control duration measurements. As soon as a
predefined energy limit is exceeded, as shown by
the mentioned measurements, the motor is shut
down by disconnecting it via the relay output on
the Wireless Controllers REC601/603.
5. Inputs and outputs / Physical interfaces
The Wireless Controllers REC601/603 are
equipped with numerous input and output
connections to manage control operations that
are communicated via the wireless (GPRS)
capabilities of the devices.
Wireless Controller REC603 has 16 binary inputs
(REC601 has 6) for monitoring and alarms, and 7
binary outputs for disconnector control (REC601
has 3). Both REC601 and REC603 devices each
have 2 binary outputs and 2 analog inputs for
battery control within the ranges of 0-30 V, 0-10
A. Further both the devices each have a binary
output for over current motor control as well as
an analog input for motor control within the range
0-15 A.
Additionally the devices are equipped with a
transducer input and heater control output.
The Wireless Controllers REC601/603 also has
two serial ports (with DIP switches for serial port
2 hardware configuration) and an Ethernet
connector for communication and data transfer.
Also there is a SIM card insertion slot with SIM
card tray and antenna connector.
The status of the operational system is shown by
various groupings of LED light indicators. More
detailed information can be sourced via the
supported WebHMI.
Front panel LEDs
The Wireless Controllers REC601/603 are
equipped with 8 (eight) groups of LEDs indicating
the complete operational status of the device.
They are located on the device’s front panel and
are identified by accompanying labels.
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
ABB 9

Table 1. Description of available LEDs on the front panel
LED LED status Description
VPN On VPN connection is up
Blink VPN connection is starting
Off VPN connection is disabled
Power/Error On Operating power is turned on
Off Operating power is turned off
Function On Device is starting
Blink Device is operating normally
Eth On Ethernet link is up
Blink Ethernet link is transferring data
Off Ethernet link is down
GPRS Blink GPRS is starting or transferring data
Off GPRS is inactive
AC and LINK LEDs AC Connected to AC power
LINK IEC 60870-5-104 control link to
SCADA is active
Disconnector1) OPEN Open position indication
CLOSE Close position indication
LOCAL/REMOTE Local / remote control indication
Grounding disconnector2) OPEN Open position indication
CLOSE Close position indication
1) Applicable for disconnectors 1, 2 or 3 (for REC603 – REC601 only has 1 disconnector)
2) Applicable for grounding disconnectors 1, 2 or 3 (for REC603 – REC601 only has 1 grounding disconnector)
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
10 ABB

Front panel description
1 3 4 52
6 7 8
GUID-38343AB8-2790-4E25-BD31-DBB0C237712F V1 EN
Figure 6. Front panel
1. System status LEDs
2. X2.1 connector
3. X2.3 connector
4. X4 connector
5. AC and LINK LEDs
6. X3 connector
7. Disconnector status LEDs
8. Grounding disconnector status LEDs
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
ABB 11

Serial panel description
1
2
3
4
5
6
GUID-E93D22FF-C310-4B4E-929D-8AB8800F0241 V1 EN
Figure 7. Serial panel
1. Console serial port (DIP switch selectable application or console port RS1)
2. Power switch
3. Serial console switch (RS1)
4. Serial port 2 hardware configuration DIP switches
5. Serial port 2
6. Ethernet connector
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
12 ABB

Antenna panel description
1
2
3
GUID-35D4C58E-AD09-401B-91D1-09917E75F5C2 V1 EN
Figure 8. Antenna panel
Both Wireless Controllers REC 601/603 have a SIM card insertion slot with SIM card tray and antenna
connector on the antenna panel.
1. SIM card tray connector
2. SIM card tray release button
3. Antenna connector (FME male)
6. Communication
The Wireless Controllers REC601/603 have
wireless functionality that allows the use of
wireless applications within the customer defined
operator’s network. When a high-speed wireless
data transfer speed is needed it can be
supported, however the practical data transfer
rates depend on the subscription details and
wireless network capacity and bandwidth.
Operating within these wireless networks (GPRS/
GSM) the Wireless Controllers REC601/603 may
utilize the supported communication protocols.
This offers flexibility in system design, allowing
users to develop solutions for their own
applications with high data availability and
reliability. The devices are designed to withstand
the operational requirements of most secondary
substation environments and offer industrial
quality connectivity devices for the IEC 60870
protocol family. The IEC 60870 protocol family is
a vendor-independent communication standard
for the power distribution industry.
Additionally, with the Wireless Controllers
REC601/603 conventional IEC 60870-5-101
devices can be attached to a modern TCP/IP
based IEC 60870-5-104 control system. Ethernet
and GPRS/GSM data network interfaces provide
a seamless communication solution for most of
the applications.
IEC 60870-5-104 is used to communicate
towards a SCADA via an approved M2M Gateway
(available from ABB) over the available customer
chosen GPRS/GSM data network. In the opposite
direction IEC 60870-5-101 can be used to
communicate with the devices in the field via the
serial ports. This communication can also be
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
ABB 13

done using the Ethernet port and a RJ-45 cable
between the controlled device and the Wireless
Controllers REC601/603.
The Wireless Controllers REC601/603 have two
application serial ports. Serial port 1 is
configurable to either console or data mode and
supports only RS-232, while serial port 2 is
configurable to multiple serial modes
(RS-232/422/485). Serial port connectors are 9-
pin D-sub (male) connectors.
More information is available in the Technical Data
section of this product guide or technical manual
available at www.abb.com/substationautomation.
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
14 ABB

7. Technical data
Table 2. Dimensions
Description Value
Width x Height x Depth 150 x 177 x 135 mm (without antenna)
Table 3. Power supply
Description Value
Auxiliary voltage supply / battery charger 85...200 VDC/ 90...264 VAC
Power consumption 10 W (when not charging the battery)
Temperature compensated battery charger For 24 V sealed lead acid batteries
Monitoring and protection Voltage, load testing and deep discharge protection
Table 4. Hardware
Description Value
Processor Environment Processor 32 bit RISC
Memory 8 MB FLASH
32 MB SDRAM
Other Sensor Temperature
Internal clock Real time
Approvals CE
Environmental conditions Temperature ranges -40...+70 °C
(operation)
-40...+85 °C
(transport and storage)
Relative Humidity 5 to 85 % RH
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
ABB 15

Table 5. Software
Description Value
Communication protocols Via GPRS to and from
SCADA
IEC 60870-5-104
Via serial ports downward IEC 60870-5-101 or transparent mode
Downward Ethernet port
Network protocols PPP, IP, ICMP, UDP, TCP, ARP, DNS, DHCP, FTP,
TFTP, HTTP, POP3, SMTP
Tunneling (VPN) SSH-VPN client (requires M2M Gateway)
L2TP-VPN client (requires M2M Gateway)
SSH client
Management WWW, SSH, Telnet and console FTP, TFTP and HTTP
software update
Routing and firewall Static routing, proxy ARP, port forwarding, IP
masquerading/NAT, firewall
Serial device connectivity Device server application (IEC 60870-5-104 GW)
Simultaneous GPRS, CSD and SMS
SMS configuration and status reporting
IEC 60870-5-104 and IEC 60870-5-101 IEC 60870-5-104 over TCP or UDP
IEC 60870-5-101 FT 1.2 framing
Local IEC 60870-5-101 polling
ASDU replacer
Packet compressor
Table 6. Physical interfaces
Description REC601 REC603
Binary Analog Binary Analog
Inputs/Outputs I O I O I O I O
Disconnector control 6 3 - - 16 7 - -
Battery control - 2 21) - - 2 21) -
Motor control - 12) 13) - - 12) 13) -
Transducer input - - 14) - - - 14) -
Heater control output - 1 - - - 1 - -
1) ranges 0...30 V, 0...10 A
2) Overcurrent
3) 0...15 A
4) 0...5 A
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
16 ABB

Table 7. Network interfaces
Description Value
Ethernet 10/100 Base-T. Shielded RJ-45
1.5 kV isolation transformer
Ethernet IEEE 802-3, 802-2
CSD (GSM data) Up to 14.4 kbps
V.110
Non-transparent mode
USSD support
FME external antenna connector (50Ω) (Stub antenna included)
GPRS Bandwidth Quad band (850/900/1800/1900
MHz)
Module Internal module and SIM card
socket
Class Multi-slot class 20
Mobile station class B
Downlink speed Max. 85.6 kbps
Uplink speed Max. 85.6 kbps
Coding schemes CS1...4
Antenna connector FME (50 Ω)
Security Via encrypted VPN
Serial Ports Serial 1 / Console RS-232
IEC 60870-5-101 protocol support
Serial 2 RS-232/422/485 (selectable)
IEC 60870-5-101 protocol support
Table 8. Communication protocols
Description Value
Protocols Via GPRS to and from SCADA IEC 60870-5-104
Via serial ports IEC 60870-5-101
Via IP network Ethernet port
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
ABB 17

Table 9. Electromagnetic compatibility tests
Description Type test value Reference
Electrostatic discharge test: EN 61000-4-2
• Contact discharge: 4 kV
• Indirect contact discharge: 4 kV
Conducted RF Immunity test: EN 61000-4-6
• 150 kHz...80 MHz 3 V (rms)
Radiated RF Immunity test: EN 61000-4-3
• 80...2700 MHz 3 V/m (rms)
Fast transient disturbance tests: EN 61000-4-4
• All ports 1 kV
Surge immunity test: EN 61000-4-5
• AC power input ports 2 kV, line-to-earth
1 kV, line-to-line
Voltage dips and short interruptions 0 % / 1 cycle EN 61000-4-11
40 % / 10 cycles
70 % / 25 cycles
Emission tests: CISPR 22 (EN 55022), Class B
• Conducted
0.15...0.50 MHz < 66 dB(µV) quasi peak
< 56 dB(µV) average
0.5...5 MHz < 56 dB(µV) quasi peak
< 46 dB(µV) average
5...30 MHz < 60 dB(µV) quasi peak
< 50 dB(µV) average
• Radiated
30...230 Mhz < 35 dB(µV/m) quasi peak,
measured at 3 m distance
230...1000 MHz < 42 dB(µV/m) quasi peak,
measured at 3 m distance
1000...3000 MHz < 70 dB(µV/m) quasi peak,
< 50 dB(µV/m) average,
measured at 3 m distance
3000...6000 MHz < 74 dB(µV/m) quasi peak,
< 54 dB(µV/m) average,
measured at 3 m distance
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
18 ABB

Table 10. EMC compliance
Description Reference
Standard ETSI EN 301489-1 (V1.8.1 2008-04)
IEC 61000-6-1 (Second edition 2005–01)
IEC 61000-6-3 (2006–07)
Table 11. RoHS and REACH compliance
Description
Complies with RoHS directive 2002/95/EC
Complies with REACH directive 2006/1907/EC
8. Mounting methods
The devices have been equipped with mounting
arrangements that are specially designed to
enable wall or rack DIN rail mounting inside the
control cabinets. A set of DIN rail mounting clips
is included with the devices. The specific
mounting position is dependent on the intended
application of the device, preferably inside a
robust, weatherproof control cabinet.
As the device uses GPRS radio waves for data
transmission, the surrounding environment can
negatively affect the efficacy of these radio
signals. Therefore, if you are using a device with
the antenna mounted directly attached to the
antenna connector (device with standard antenna
without optional extension cable), try to avoid
placing the unit in a location where the radio
signal might be shadowed, and therefore
deteriorated by nearby obstacles or enclosures.
Note also that large metallic surfaces, racks or
walls with metallic structures (cabling, concrete
iron, etc.) may degrade the antenna performance
to a very high extent. In this case it is highly
recommended to use the optional external
antenna with appropriate cable. This allows for
better positioning of the devices, antennas and
thus optimal performance.
Another restriction to the positioning of the
device, when installing it, is that it should be
mounted in such a way that the required
environmental conditions that are set in the
Technical Data section of this Product Guide
would also be met.
9. Ordering data
Product label is found on the top of the device
and it contains the basic information about the
product (for example product name) as well as
unique data regarding the unit such as serial
number and Ethernet MAC address.
The order number consists of a string of codes
generated from the device's hardware and
software modules. Use the ordering key
information to generate the order number when
ordering complete devices.
As an example of how the ordering code is
generated the following schematics are shown.
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
ABB 19

R E C 6 0 1 A 1 AAA G 1 A
# DESCRIPTION
1-6
Wireless Controller REC601 REC601
7Version
1.0 A
8Power Supply
85-200 VDC, 90-264 VAC with battery charger
(24 VDC)
1
9Inputs and Outputs
5 BI + 6 BO, 3CT (0-10 A/0-15 A/4-20mA) + 1 VT
(0-30 VAC)
A
10 Communication Interface
Ethernet 10/100BaseT (RJ45) + RS232 + selectable
RS232/422/485
A
11 Communication Protocols
IEC 60870-5-101 + IEC 60870-5-104 A
12 Wireless Communication Standards
GPRS (+ CSD (GSM Data)) G
13
English 1
14 Additional components
Stub antenna + NTC sensor cable + DIN rail mounting
kit
A
Example code: R E C 6 0 1 A 1 A A A G 1 A
Your ordering code:
Digit (#) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Code              
GUID-137E2DD5-4762-4A92-ABB7-705F552C1088 V1 EN
Figure 9. REC601 ordering code example
Wireless Controller 1MRS757423 A
REC601/603
Product version: 1.0
20 ABB