ABB RELION REX640 User manual

—
RELION® PROTECTION AND CONTROL
REX640
Installation Manual

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

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.
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 .
Warranty
Please inquire about the terms of warranty from your nearest ABB representative.
www.abb.com/mediumvoltage

Disclaimer
The data, examples and diagrams in this manual are included solely for the concept or product
description and are not to be deemed as a statement of guaranteed properties. All persons responsible
for applying the equipment addressed in this manual must satisfy themselves that each intended
application is suitable and acceptable, including that any applicable safety or other operational
requirements are complied with. In particular, any risks in applications where a system failure and/or
product failure would create a risk for harm to property or persons (including but not limited to
personal injuries or death) shall be the sole responsibility of the person or entity applying the
equipment, and those so responsible are hereby requested to ensure that all measures are taken to
exclude or mitigate such risks.
This product has been designed to be connected and communicate data and information via a network
interface 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 the network, its system and interface included, against any kind of security breaches,
unauthorized access, interference, intrusion, leakage and/or theft of data or information. ABB is not
liable for any such damages and/or losses.
This document has been carefully checked by ABB 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 ABB be responsible or liable for any loss or
damage resulting from the use of this manual or the application of the equipment.
In case of discrepancies between the English and any other language version, the wording of the
English version shall prevail.

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. The product
is designed in accordance with the international standards of the IEC 60255 series.

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.
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 should be taken to avoid
inadvertent tripping.

Contents
1 Introduction............................................................................................. 10
1.1 This manual.............................................................................................................................................10
1.2 Intended audience.................................................................................................................................10
1.3 Product documentation........................................................................................................................11
1.3.1 Product documentation set.................................................................................................11
1.3.2 Document revision history...................................................................................................11
1.3.3 Related documentation........................................................................................................ 11
1.4 Symbols and conventions.................................................................................................................... 12
1.4.1 Symbols................................................................................................................................... 12
1.4.2 Document conventions.........................................................................................................12
2 Environmental aspects........................................................................... 14
2.1 Sustainable development.................................................................................................................... 14
2.2 Disposal of a device.............................................................................................................................. 14
3 Unpacking, inspecting and storing....................................................... 15
3.1 Removing transport packaging..........................................................................................................15
3.2 Inspecting product and delivery items............................................................................................. 16
3.2.1 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 Mounting grounding bar kit................................................................................................ 51
4.3.5 Mounting lens sensors for an arc protection system.................................................... 55
4.3.6 Manufacturing tailored length loop sensor for an arc protection system................ 57
4.3.7 Mounting RJ-45 coupler for an HMI service port............................................................66
4.3.8 Arranging ventilation............................................................................................................66
Contents
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5 Connecting............................................................................................... 67
5.1 Required tools........................................................................................................................................67
5.2 Connecting wires...................................................................................................................................67
5.2.1 Connecting wires to screw-compression type connectors.......................................... 68
5.2.2 Connecting wires to ring-lug type connectors............................................................... 68
5.2.3 Connecting wires to push-in type connectors................................................................69
5.3 Connecting protective earthing......................................................................................................... 70
5.3.1 Connecting protective earthing to relay.......................................................................... 70
5.3.2 Connecting protective earthing to local HMI.................................................................. 70
5.4 Connecting analog signals...................................................................................................................71
5.4.1 Connecting current and voltage inputs............................................................................ 72
5.4.2 Connecting RTD and mA inputs..........................................................................................81
5.5 Connecting binary 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 information.......................................................................................... 93
7.3 Removing protection relay.................................................................................................................. 93
7.4 Sending protection relay for repair ...................................................................................................93
7.5 Exchanging protection relay .............................................................................................................. 94
8 Technical data..........................................................................................95
8.1 Local HMI.................................................................................................................................................95
8.2 Connector side.......................................................................................................................................95
8.3 Dimensions.............................................................................................................................................96
8.4 Enclosure class...................................................................................................................................... 98
9 Accessories and ordering data............................................................100
10 Glossary..................................................................................................104
Contents
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1 Introduction
1.1 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.
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.
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1.3 Product documentation
1.3.1 Product documentation set
Planning & purchase Engineering Installation Commissioning Operation Maintenance Decommissioning, deinstallation &
disposal
Quick installation guid
e
B
rochure
P
roduct guide
Operation
manual
Installation
manual
Engineering
manual
Technical
manual
Application
manual
Communica
tion protocol manual
IEC
61850 engineering guide
Cybe
r security deployment guideline
Hardware modificat
ion 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 Content updated to correspond to the prod-
uct connectivity level
E/2023-02-10 PCL4 Content updated to correspond to the prod-
uct connectivity level
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REX640
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1.3.3 Related documentation
Download the latest documents from the ABB Web site www.abb.com/
mediumvoltage .
1.4 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. 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 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 this manual.
• Abbreviations and acronyms are spelled out in the glossary. The glossary also
contains definitions of important terms.
• Menu paths are presented in bold.
Select Main menu> Settings.
• Parameter names are shown in italics.
The function can be enabled and disabled with the
Operation setting
• Parameter values are indicated with quotation marks.
The corresponding parameter values are "On" and "Off".
• Input/output messages and monitored data names are shown in Courier font.
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When the function starts, the START output is set to TRUE.
• Values of quantities are expressed 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 .
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2 Environmental aspects
2.1 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 device.
The choice of materials and suppliers has been made according to the EU RoHS
directive (2011/65/EU). This directive limits the use of hazardous substances.
Operational reliability and long life time have been ensured with extensive testing
during the design and manufacturing processes. Moreover, long life time is
supported by maintenance and repair services as well as by the availability of spare
parts.
Design and manufacturing have been done under a certified 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.
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. When disposing of a device or its parts,
contact a local waste handler who is authorized and specialized in disposing of
electronic waste. These handlers can sort the material by using dedicated sorting
processes and dispose of the product according to the local requirements.
Table 1: Materials of the protection relay parts
Protection relay Parts Material
Case Casted enclosure Aluminium
Metallic plates Aluminium
Screws, bushes Steel
Plastic parts PC 1, LCP 2
LHMI Various
Package Box Cardboard
Attached material Manuals Paper
1Polycarbonate
2Liquid crystal polymer
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3 Unpacking, inspecting and storing
3.1 Removing transport packaging
Protection relays require careful handling.
1. Examine the delivered products to ensure that they have not been damaged
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.
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3.2 Inspecting product and delivery items
3.2.1 Identifying product
1. Locate the protection relay's order number on the label attached to the
protection relay's case.
2. Compare the protection relay's order number with the ordering information to
verify that the received product is correct.
3.2.2 Checking delivery items
• Check that all items are included in the delivery in accordance with the delivery
documents.
3.2.3 Inspecting product
Protection relays require careful handling before installation on site.
• Check the protection relay to see if any damage occurred during 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 immediately if there are any discrepancies in relation to the
delivery documents.
3.3 Storing
If the protection relay is stored before installation, it must be done in the original
transport packaging in a dry and dust-free place.
• Observe the environmental requirements stated in the technical manual.
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4 Mounting
4.1 Required tools
• TX25 and TX30 screwdrivers for installing the protection relay with mounting kits
• TX25 and TX20 screwdrivers for mounting the LHMI
4.2 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.
• Avoid installation in dusty, damp places.
Avoid places susceptible to rapid temperature variations, powerful vibrations
and shocks, surge voltages of high amplitude and fast rise time, strong induced
magnetic fields or similar extreme conditions.
• Check that sufficient space is 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 unit
must be installed behind an observation window. Only the HMI flush-
mounting option is supported.
UL listed observation windows:
- FTTA/7, Model AMHMI120CCHTP, manufactured by Allied Moulded Products
Inc, measuring overall 302.91 mm × 257.70 mm × 57.68 mm (11.9256 in ×
10.1457 in × 2.2709 in), rated for 1, 2, 3, 3R, 4, 4X, 12 and 13.
- Alternatively, any FTTA/7 or NITW rated for 1, 2, 3, 3R, 4, 4X, 12 and 13.
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4.3 Mounting options
4.3.1 Mounting local 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
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2. Mount the LHMI to the cutout with the installation brackets 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
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REX640
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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
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