ABB RELION REX640 User manual

—
BIO-Tester Relion® REX640
User Manual

Document ID: 2NGA000105
Issued: 2019-12-03
Revision: B
Product version: 1.0
© Copyright 2019 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.
Warranty
Please inquire about the terms of warranty from your nearest ABB representative.
The equipment can be opened by authorized personnel only. If this practice is not
followed, the warranty expires.
www.abb.com/service
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 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 concerning electrical
equipment for use within specified voltage limits (Low-voltage directive 2014/35/
EU).
This conformity is the result of partial Safety Approval tests conducted by the third
party testing laboratory SGS Fimko Oy in accordance with essential safety
requirements as defined in the safety standards IEC/EN 61010-1:2010 and IEC/EN
61010-2-030:2010.

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 trained and qualified persons are allowed to connect and operate
BIO-Tester Relion REX640.
National and local electrical safety regulations must always be
followed.
The necessary and required earthing connections must be made
according to the product guidelines and regulations.
When the withdrawable module has been detached from the case, do
not touch the inside of the case. The relay case internals may contain
high voltage potential and touching these may cause personal injury.
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.

Table of contents
Section 1 Introduction.......................................................................3
This manual........................................................................................ 3
Intended audience.............................................................................. 3
Product documentation.......................................................................3
Document revision history............................................................. 3
Related documentation..................................................................3
Symbols and conventions...................................................................4
Symbols.........................................................................................4
Document conventions.................................................................. 4
Section 2 Environmental aspects.....................................................5
Sustainable development................................................................... 5
Disposal of a device........................................................................... 5
Section 3 Unpacking, inspecting and storing................................... 7
Removing transport packaging...........................................................7
Inspecting product and delivery items................................................ 7
Identifying product......................................................................... 7
Checking delivery items.................................................................7
Inspecting product......................................................................... 9
Returning a product damaged during transport.............................9
Storing........................................................................................... 9
Cleaning........................................................................................ 9
Section 4 BIO-Tester Relion® REX640......................................... 11
Application examples........................................................................11
Connector cables and interfaces...................................................... 12
Terminal layouts and connection diagrams...................................... 14
Binary inputs and outputs................................................................. 21
Binary inputs................................................................................21
Binary outputs..............................................................................22
Energizing BIO-Tester and testing binary input and output
operation...........................................................................................23
Starting BIO-Tester......................................................................23
Selecting IED test mode ............................................................. 25
Testing and commissioning support on local HMI ...................... 25
Testing binary inputs................................................................... 26
Testing binary outputs................................................................. 29
Online testing with PCM600............................................................. 31
Table of contents
BIO-Tester Relion® REX640 1
User Manual

Section 5 Life cycle services.......................................................... 33
Ordering data....................................................................................33
Section 6 Technical data................................................................35
Section 7 Glossary......................................................................... 39
Table of contents
2BIO-Tester Relion® REX640
User Manual

Section 1 Introduction
1.1 This manual
The user manual contains general information about the features of BIO-Tester
Relion® REX640. The manual presents the different parts of the device, operating
guidelines and examples of using the tester in different applications.
1.2 Intended audience
This manual addresses system engineers and installation and commissioning
personnel, who use technical data during engineering, installation and
commissioning, and in normal service.
The system engineer must have a thorough knowledge of protection systems,
protection equipment, protection functions and the configured functional logic in the
protection relays. The installation and commissioning personnel must have a basic
knowledge of handling electronic equipment.
1.3 Product documentation
1.3.1 Document revision history
Document revision/date Program version History
A/2019-11-13 1.0 First release
B/2019-12-03 1.0 Content updated
Download the latest documents from the ABB Web site
http://www.abb.com/mediumvoltage.
1.3.2 Related documentation
See the REX640 documentation for detailed technical information on
the protection relay. Download the latest documents from the ABB
Web site www.abb.com/relion.
2NGA000105 B Section 1
Introduction
BIO-Tester Relion® REX640 3
User 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.
• 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.
Section 1 2NGA000105 B
Introduction
4BIO-Tester Relion® REX640
User Manual

Section 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 device parts
Device Parts Material
Case Case PPC resin1)
Metallic parts and screws Steel
Plastic parts PC2), LCP3)
Front panel Aluminium
Electronic plug-in module Various
Table continues on next page
2NGA000105 B Section 2
Environmental aspects
BIO-Tester Relion® REX640 5
User Manual

Device Parts Material
Package Box Cardboard
Filling PE4)
Attached material Manuals Paper
1) Polypropylene copolymer resin
2) Polycarbonate
3) Liquid crystal polymer
4) Polyethylene
Section 2 2NGA000105 B
Environmental aspects
6BIO-Tester Relion® REX640
User Manual

Section 3 Unpacking, inspecting and storing
3.1 Removing transport packaging
The deliverables 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.
3.2 Inspecting product and delivery items
3.2.1 Identifying product
1. Locate the device's technical details on the label on top of the unit.
2. Compare the device's label with the ordering information to verify that the
received product is correct.
3. Position the closed tester unit's case so that the information label is on the top and
the handle is facing towards the user.
3.2.2 Checking delivery items
1. Check all delivered items.
•BIO-Tester Relion® REX640 in a waterproof case includes six items.
•BIO-Tester Relion®REX640
• Power supply cable
• C-60A200 RE_640 tester BIO1001 cable
• C-61A200 RE_640 tester BIO1002 cable
• C-62A200 RE_640 tester PSM100x cable
• C-63A200 RE_640 tester HMI cable
Use only original cables delivered together with the BIO-Tester.
Cables are placed in the pocket inside the case. If the equipment
is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.
2NGA000105 B Section 3
Unpacking, inspecting and storing
BIO-Tester Relion® REX640 7
User Manual

GUID-2C62C3E0-EE06-4172-B72C-9CF2EFBA6459 V1 EN
Figure 1: BIO-Tester Relion® REX640 in a waterproof case
GUID-0950C34D-6094-4387-BA17-DE591556901D V1 EN
Figure 2: Required cables
2. Notify ABB immediately if there are any discrepancies in relation to the delivery
documents.
Section 3 2NGA000105 B
Unpacking, inspecting and storing
8BIO-Tester Relion® REX640
User Manual

3.2.3 Inspecting product
• Inspect the device for any visible damage.
Operation of damaged equipment may result in degraded process
performance leading to personal injury or death.
If the device has been found damaged on receipt of delivery from ABB, make a claim
against the transport company at the time of receipt of the device. Notify the local
ABB representative immediately about the damage.
3.2.4 Returning a product damaged during transport
• Contact the local ABB representative and check the device return process for
returning a damaged product.
3.2.5 Storing
If the device is stored before its use, 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.
3.2.6 Cleaning
1. Unplug the power cord from the power supply and unplug all connectors so that
all hazardous live parts are disconnected and the device is switched off.
2. Use a dry cloth to clean the surface of BIO-Tester Relion® REX640.
2NGA000105 B Section 3
Unpacking, inspecting and storing
BIO-Tester Relion® REX640 9
User Manual

10

Section 4 BIO-Tester Relion® REX640
4.1 Application examples
The health of the protection system depends on the quality of work done in all project
phases, such as engineering, installation and commissioning, as well as the care taken
during routine periodical testing. It is also important to check different engineering,
testing and commissioning aspects, such as the application configuration, including
relay settings, and protection and control schemes. Applying good engineering
practices improves the effectiveness of the protection system, which can prevent
equipment damage, and most importantly, ensures personnel safety.
Protection relays are not intended only for protection, but they should also fulfill
requirements regarding control, measurement and communication, for instance.
Binary inputs and outputs (BIOs) play an important role in the overall operation of
protection relays, for example, in various control and interlocking schemes and by
generating alarm and trip signals to the circuit breaker. In addition to secondary
injection testing of protection functions, it is advisable to check the health of important
hardware such as BIOs. Incorrect operation of the control scheme may result in
process or revenue loss, including safety threats to the personnel or damage to the
equipment. BIOs can be checked already at the primary design stage to ensure the
correctness of the logic as well as during routine maintenance and testing.
BIO testers have been developed to facilitate the testing of BIOs and provide several
benefits.
• Save time in configuration testing
• Reduce the risk of configuration errors
• Safe to operate
• Easy to use
• Easy to bring on site due to small size
• Create new relay testing and repair service opportunities
BIO-Tester Relion® REX640 is intended for testing the BIOs of multifunction
REX640 relays. This easy-to-use and compact tester enables simulation of the
protection and control scheme operation.
The testers can be used for troubleshooting during the application configuration
design and for routine maintenance and testing. They help wiring the signals from the
test equipment when testing the application configuration during the engineering
period. Test switches and indication LEDs simulate process signals when testing the
logic IED configuration. PCM600 Application Configuration in online mode and
Testing and Commissioning pages of the REX640 LHMI together with BIO-Tester
offer many possibilities to test and verify the logic.
2NGA000105 B Section 4
BIO-Tester Relion® REX640
BIO-Tester Relion® REX640 11
User Manual

When planning periodical testing, it is assumed that the system is properly and
comprehensively commissioned. The scope of the periodical testing usually includes
injecting known current and voltage signals to verify measuring accuracy, protection
functionality and correct operation of input and output contacts. BIO-Tester enables
testing without separate test switches or disconnecting terminals inside the
installation. This approach speeds up the periodical testing.
The final trip test (operating the circuit breaker) should always be
done as a part of final commissioning checks while the relay is
installed on the switchgear panel.
4.2 Connector cables and interfaces
All the protection relay’s binary input and output interfaces are available on the BIO-
Tester’s front plate to be connected to the secondary terminals of REX640. The
marking of the interfaces corresponds to the markings of the protection relay's case
rear connections and the related relay connection terminal drawings.
Section 4 2NGA000105 B
BIO-Tester Relion® REX640
12 BIO-Tester Relion® REX640
User Manual