ABB RELION REX640 User manual

—
RELION® PROTECTION AND CONTROL
REX640
Operation Manual

Document ID: 1MRS759118
Issued: 2023-02-10
Revision: D
© 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.

Contents
1 Introduction..............................................................................................11
1.1 This manual............................................................................................................................................. 11
1.2 Intended audience................................................................................................................................. 11
1.3 Product documentation....................................................................................................................... 12
1.3.1 Product documentation set................................................................................................ 12
1.3.2 Document revision history...................................................................................................12
1.3.3 Related documentation........................................................................................................12
1.4 Symbols and conventions.................................................................................................................... 13
1.4.1 Symbols................................................................................................................................... 13
1.4.2 Document conventions.........................................................................................................13
2 Environmental aspects........................................................................... 14
2.1 Sustainable development.................................................................................................................... 14
2.2 Disposal of a device.............................................................................................................................. 14
3 REX640 overview..................................................................................... 15
3.1 Overview..................................................................................................................................................15
3.2 Relay hardware....................................................................................................................................... 15
3.3 Local HMI.................................................................................................................................................16
3.4 Switchgear HMI..................................................................................................................................... 20
3.4.1 Bay overview area..................................................................................................................22
3.4.2 Physical and virtual Home buttons....................................................................................23
3.4.3 Navigation...............................................................................................................................23
3.5 HMI communication ports...................................................................................................................24
3.6 Web HMI.................................................................................................................................................. 24
3.6.1 Command buttons................................................................................................................26
3.7 User authorization.................................................................................................................................27
Local user account management.......................................................................................................28
3.8 Station communication....................................................................................................................... 29
3.9 PCM600................................................................................................................................................... 29
3.9.1 Connectivity packages.........................................................................................................29
3.9.2 PCM600 and relay connectivity package version........................................................... 30
3.10 Modification Sales................................................................................................................................ 30
4 Using HMI..................................................................................................31
4.1 Logging in............................................................................................................................................... 31
4.1.1 Managing forgotten password...........................................................................................33
4.2 Logging out............................................................................................................................................ 33
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Operation Manual
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4.3 Selecting local or remote use............................................................................................................. 34
4.4 Identifying device..................................................................................................................................35
4.5 Changing backlight brightness and timeout...................................................................................36
4.6 Changing setting visibility...................................................................................................................37
4.7 Monitoring relay status........................................................................................................................38
4.7.1 Switchgear HMI status indications....................................................................................39
4.8 Changing language............................................................................................................................... 41
4.9 Alarms...................................................................................................................................................... 41
4.9.1 Viewing alarm list.................................................................................................................. 41
4.9.2 Acknowledging alarms......................................................................................................... 41
4.10 Measurements and phasor diagrams............................................................................................... 43
4.10.1 Viewing measurements....................................................................................................... 43
4.10.2 Viewing phasor diagrams....................................................................................................43
4.11 Showing parameters............................................................................................................................44
4.11.1 Viewing Protection Characteristics...................................................................................45
4.12 Editing values.........................................................................................................................................46
4.13 Committing settings............................................................................................................................ 47
4.14 Clearing and acknowledging.............................................................................................................. 48
4.15 Accessing disturbance records.......................................................................................................... 49
4.16 Viewing fault records........................................................................................................................... 50
4.17 Selecting USB actions...........................................................................................................................51
4.18 Using local HMI help..............................................................................................................................52
4.19 Changing setting group.......................................................................................................................53
4.20 Controlling..............................................................................................................................................54
4.21 Bookmarking pages..............................................................................................................................57
5 Using Web HMI.........................................................................................59
5.1 Connecting to Web HMI....................................................................................................................... 59
5.1.1 Logging in...............................................................................................................................59
5.1.2 Logging out............................................................................................................................ 62
5.2 Navigating in menus.............................................................................................................................62
5.3 Identifying device..................................................................................................................................62
5.4 Viewing dashboard............................................................................................................................... 63
5.5 Viewing self-supervision......................................................................................................................63
5.6 Changing language...............................................................................................................................64
5.7 Alarms......................................................................................................................................................64
5.7.1 Viewing alarm list..................................................................................................................64
5.7.2 Acknowledging alarms.........................................................................................................65
5.8 Measurements and phasor diagrams............................................................................................... 67
5.8.1 Viewing measurements........................................................................................................67
5.8.2 Viewing phasor diagrams....................................................................................................67
5.9 Viewing monitoring.............................................................................................................................. 69
5.10 Viewing single-line diagram................................................................................................................70
5.11 Showing parameters.............................................................................................................................71
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Operation Manual

5.12 Editing values......................................................................................................................................... 72
5.13 Committing settings............................................................................................................................ 74
5.14 Clearing and acknowledging...............................................................................................................76
5.15 Accessing event view............................................................................................................................ 77
5.16 Accessing disturbance record view................................................................................................... 78
5.16.1 Saving disturbance records.................................................................................................79
5.16.2 Triggering disturbance recorder manually...................................................................... 79
5.16.3 Deleting disturbance records.............................................................................................80
5.17 Viewing fault records............................................................................................................................81
5.18 Exporting load profile records............................................................................................................ 81
5.19 Importing and exporting of settings................................................................................................ 82
5.19.1 Exporting settings................................................................................................................ 82
5.19.2 Importing settings................................................................................................................82
5.20 Exporting report summary................................................................................................................. 84
5.21 Using Web HMI help..............................................................................................................................85
6 Troubleshooting......................................................................................86
6.1 Fault tracing...........................................................................................................................................86
6.1.1 Identifying hardware errors................................................................................................86
6.1.2 Identifying runtime errors...................................................................................................86
6.1.3 Identifying communication errors.....................................................................................86
6.1.4 Reading of internal log files................................................................................................ 87
6.1.5 Checking local HMI connectivity........................................................................................ 88
6.2 Self-supervision.....................................................................................................................................88
6.2.1 Internal faults.........................................................................................................................90
6.2.2 Warnings................................................................................................................................. 99
6.2.3 Power supply module Ready LED and HMI Home button LED....................................101
6.3 Correction procedures........................................................................................................................103
6.3.1 Creating relay backup in HMI............................................................................................ 103
6.3.2 Rebooting the software.....................................................................................................104
6.3.3 Restoring factory settings................................................................................................ 104
6.3.4 Restoring relay backup from local HMI........................................................................... 104
6.3.5 Restoring relay backup from switchgear HMI............................................................... 108
6.3.6 Setting passwords.............................................................................................................. 108
6.3.7 Identifying relay application problems .......................................................................... 109
7 Commissioning.......................................................................................111
7.1 Commissioning checklist....................................................................................................................111
7.2 Checking installation........................................................................................................................... 111
7.2.1 Checking power supply.......................................................................................................111
7.2.2 Checking CT circuits............................................................................................................112
7.2.3 Checking VT circuits............................................................................................................112
7.2.4 Checking binary input and output circuits..................................................................... 113
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7.3 Authorizations...................................................................................................................................... 113
7.3.1 User authorization ..............................................................................................................113
7.4 Setting protection relay and communication................................................................................ 114
7.4.1 Setting the communication between protection relays and PCM600......................115
7.4.2 Communication settings....................................................................................................116
7.4.3 Connecting and setting HMI............................................................................................. 125
7.5 Testing of protection relay operation............................................................................................. 138
7.5.1 Selecting IED test mode ....................................................................................................138
7.5.2 Testing and commissioning support on local HMI....................................................... 138
7.5.3 Using HMI Client..................................................................................................................149
7.5.4 Selecting the internal fault test........................................................................................150
7.5.5 Selecting IED blocked or IED test and blocked mode..................................................150
7.6 ABB Product Data Registration.........................................................................................................151
8 Maintenance and Periodical Testing................................................... 153
8.1 Maintenance and Periodical Testing................................................................................................153
8.1.1 Maintenance......................................................................................................................... 153
8.1.2 Periodical Testing................................................................................................................ 153
9 Glossary.................................................................................................. 158
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1 Introduction
1.1 This manual
The operation manual contains instructions on how to operate the protection relay
once it has been commissioned. The manual provides instructions for monitoring,
controlling and setting the relay. 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.
1.2 Intended audience
This manual addresses the operator who operates the protection relay frequently.
The operator must be trained in and have a basic knowledge of how to operate
protection equipment. The manual contains terms and expressions commonly used
to describe this kind of equipment.
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REX640
Operation Manual
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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/2019-05-24 PCL1 First release
B/2020-02-13 PCL2 Content updated to correspond to the
product connectivity level
C/2020-12-10 PCL3 Content updated to correspond to the
product connectivity level
D/2023-02-10 PCL4 Content updated to correspond to the
product connectivity level
1.3.3 Related documentation
Download the latest documents from the ABB Web site www.abb.com/
mediumvoltage .
Introduction 1MRS759118 D
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Operation Manual

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 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.
• WHMI menu names are presented in bold.
Click Information in the WHMI menu structure.
• 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.
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".
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REX640
Operation Manual
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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
Device 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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Operation Manual

3 REX640 overview
3.1 Overview
REX640 is a powerful all-in-one protection and control relay for use in advanced
power distribution and generation applications with unmatched flexibility available
during the complete life cycle of the device – from ordering of the device, through
testing and commissioning to upgrading the functionality of the modular software
and hardware as application requirements change.
The modular design of both hardware and software elements facilitates the
coverage of any comprehensive protection application requirement that may arise
during the complete life cycle of the relay and substation.
REX640 makes modification and upgrading easy and pushes the limits of what can
be achieved with a single device.
3.2 Relay hardware
The relay includes a Ready LED on the power supply module that indicates the
relay's status. In normal situations, the Ready LED has a steady green light. Any
other situation that requires the operator’s attention is indicated with a flashing
light.
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1
2
Figure 2: Hardware module slot overview of the REX640 relay
1Slot markings in enclosure (top and bottom)
2Ready LED
The relay has a nonvolatile memory which does not need any periodical
maintenance. The nonvolatile memory stores all events, recordings and logs to a
memory which retains data if the relay loses its auxiliary supply.
3.3 Local HMI
The LHMI is used for setting, monitoring and controlling the protection relay and
the related process. It comprises a 7-inch color screen with capacitive touch sensing
and a Home button at the bottom of the LHMI.
The LHMI is an accessory for the relay which is fully operational even
without the LHMI.
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Operation Manual

Figure 3: Example of a local HMI page
The LHMI presents pages in two categories.
• Operator pages are typically required as a part of an operator’s normal activities,
such as a single-line diagram, controls, measurements, events or alarms
• Engineer pages are specifically designed pages supporting relay
parametrization, troubleshooting, testing and commissioning activities
The Operator pages can be scrolled either by pressing the Home button or by
swiping the actual pages. The Engineer pages are accessible by tapping the menu
button in the menu bar on the top of the LHMI display.
The Home button indicates the relay’s status at a glance. In normal situations, the
Home button shows a steady green light. Any other situation that requires the
operator’s attention is indicated with a flashing light, a red light or a combination of
these.
Table 2: Power supply module Ready LED and local HMI Home button LED
State Power supply
module Ready
LED
LHMI Home
button
Alarm
acknowledged
Relay under normal operation and
LHMI connected
Steady green Steady green N/A
Relay’s IRF activated, but communi-
cates with LHMI
High frequency
blinking green 1
High frequency
blinking red 1
N/A
Communication lost between Relay
and LHMI, but no IRF
Steady green High frequency
blinking green 1
N/A
Table continues on the next page
1High frequency = 3 Hz
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State Power supply
module Ready
LED
LHMI Home
button
Alarm
acknowledged
LHMI not running normally or in
start-up initialization phase
Steady green High frequency
blinking green 1
N/A
Process related alarm active Steady green Low frequency
blinking red 2
No
Process related alarm active Steady green Steady red Yes
Process related alarm has been ac-
tive earlier, but is not any more ac-
tive.
Steady green Low frequency
blinking red 2
No
Process related alarm has been ac-
tive earlier, but is not any more ac-
tive.
Steady green Steady green Yes
Relay set to Test Mode Low frequency
blinking green 2
Low frequency
blinking green 2
No
The Operator pages can be used as such or customized according to the project’s
requirements using Graphical Display Editor in PCM600. The Engineer pages are
fixed and cannot be customized.
2
1 2 3 4 5 6 7 8 9 10
11 8
Figure 4: Menu bar elements
1Bay name for the relay
2Page name
3Edit mode active (parameter editing)
4Date, time and time synchronization status
5Page help (visible if help is available for the page)
6Login button/logged in user and role indication
7Local/remote indication
8USB memory not connected/connected (visible only if USB port is enabled)
9Number of active alarms
10 Menu button for Engineer pages
11 Store or reject changed parameters indication
2Low frequency = 1 Hz
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Operation Manual

Table 3: Local HMI default pages
Page category Pages Subpages
Operator pages Overview Alarms
Events
Fault Records
Timeline
Measurements Phasors
Load Profile Records
Engineer pages Parameters
Testing and Commissioning Force Functions
Force Outputs
Simulate Inputs
View I/O
Send Events
Secondary Injection Monitoring
Protection Measurement Direction
Coil Controller Commissioning 3
View GOOSE sending
View GOOSE receiving
View SMV sending
View SMV receiving
Relay Status Monitoring
Clear
Disturbance Records
Alarms
Device Information
USB Actions
Network Settings
3Available with the Petersen coil control application package
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REX640
Operation Manual
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Figure 5: Engineer pages menu
3.4 Switchgear HMI
The SHMI is used for setting, monitoring and controlling up to 20 REX640
protection relays and the related processes. It comprises a 7-inch color screen with
capacitive touch sensing and a Home button at the bottom of the SHMI. All features
of standard HMI are also available in the SHMI.
The SHMI is an accessory for the relay which is fully operational even
without the SHMI.
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Operation Manual