ABB RELION REX610 Installation Manual
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ABB RELION REX610 Installation Manual

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RELION® PROTECTION AND CONTROL
REX610
Installation Manual

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Summary of Contents for ABB RELION REX610

  • Page 1 — RELION® PROTECTION AND CONTROL REX610 Installation Manual...
  • Page 3 Document ID: 2NGA000821 Issued: 2022-04-21 Revision: A Product version: 1.0 © Copyright 2022 ABB. All rights reserved...
  • Page 4 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.
  • Page 5 ABB is not liable for any such damages and/or losses.
  • Page 6 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).
  • Page 7 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.

  • Page 9: Table Of Contents

    Table of contents Table of contents Section 1 Introduction...............3 This manual..................3 Intended audience................3 Product documentation...............4 Product documentation set............4 Document revision history............. 4 Related documentation..............4 Symbols and conventions..............4 Symbols..................4 Document conventions..............5 Section 2 Environmental aspects............. 7 Sustainable development..............7 Disposal of a protection relay ............
  • Page 10 Table of contents Section 5 Connecting..............33 Required tools.................. 33 Connecting wires ................33 Connecting functional earthing............34 Connecting analog signals............... 36 Connecting current and voltage inputs ........36 Connecting protection relay with a test switch ......38 Connecting binary signals..............38 Connecting power supply..............

  • Page 11: Section 1 Introduction

    Section 1 2NGA000821 A Introduction Section 1 Introduction 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.

  • Page 12: Product Documentation

    Product version History A/2022-04-21 First release 1.3.3 Related documentation Download the latest documents from the ABB Web site abb.com/mediumvoltage. Symbols and conventions 1.4.1 Symbols The electrical warning icon indicates the presence of a hazard which could result in electrical shock.

  • Page 13: Document Conventions

    Section 1 2NGA000821 A Introduction 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.
  • Page 14 Section 1 2NGA000821 A Introduction • This document assumes that the parameter setting visibility is "Advanced". • A functional earth terminal is indicated in figures with the symbol • Equipment protected throughout by double insulation or reinforced insulation (equivalent to class II of IEC 61140) is indicated in figures with the symbol REX610 Installation Manual...

  • Page 15: Section 2 Environmental Aspects

    Section 2 2NGA000821 A Environmental aspects Section 2 Environmental aspects 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 protection relay. The choice of materials and suppliers has been made according to the EU RoHS directive 2011/65/EU and the amended EU directive 2015/863/EU.
  • Page 16 Section 2 2NGA000821 A Environmental aspects All parts used in this product are recyclable. When disposing of a protection relay 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.

  • Page 17: Section 3 Unpacking, Inspecting And Storing

    Section 3 2NGA000821 A Unpacking, inspecting and storing Section 3 Unpacking, inspecting and storing Removing transport packaging Protection relays require careful handling. Examine the delivered products to ensure that they have not been damaged during the transport. Remove the transport packaging carefully without force. Attach the protective film (supplied with the protection relay) on the top side of the unit for the installation phase.

  • Page 18: Returning A Product Damaged In Transit

    Returning a product damaged in transit If damage has occurred during transport, appropriate actions must be taken against the latest carrier. Please inform the nearest ABB office or representative. Notify ABB immediately if there are any discrepancies in relation to the delivery documents.

  • Page 19: Section 4 Mounting

    Section 4 2NGA000821 A Mounting Section 4 Mounting 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.
  • Page 20 Section 4 2NGA000821 A Mounting GUID-1491675A-1072-46FD-940B-0DD7CFC78424 V1 EN-US Figure 2: Detaching a plug-in unit from the case The analog cards are part of the case. Therefore, detaching the plug-in unit does not open the secondary circuit of the CT which could cause dangerously high voltages.

  • Page 21: Installing Plug-In Unit

    Section 4 2NGA000821 A Mounting 4.2.2 Installing plug-in unit The protection relay is constructed in a way that a plug-in unit can be plugged into any REX610 case. Analog cards are not part of the plug-in unit. They are separate modules that can be inserted or removed independently.

  • Page 22: Sealing Plug-In Unit

    Section 4 2NGA000821 A Mounting GUID-0F2047A7-41D7-4180-8F04-3510B1EAD55D V1 EN-US Figure 4: Pushing the plug-in unit into the case Rotate the handle to the right until it latches to the case and a clicking sound is heard. The handle is in the latched position. 4.2.3 Sealing plug-in unit The front panel of the protection relay has a locking mechanism for sealing the...

  • Page 23: Securing Handle

    Section 4 2NGA000821 A Mounting GUID-78C7E468-BE91-4415-B0A8-5FB66E01721B V1 EN-US Figure 5: Sealing wire 1 Sealing wire and seal 4.2.4 Securing handle The front panel of the protection relay has an additional locking mechanism to secure the handle in place. A padlock can be fitted to the locking mechanism to prevent the handle from opening.

  • Page 24: Inserting Or Removing Sd Card

    Section 4 2NGA000821 A Mounting GUID-2A7F396F-1382-4CF2-9447-9650EA7B6E41 V1 EN-US Figure 6: Locking mechanism for securing the handle 4.2.5 Inserting or removing SD card Detach the plug-in unit from the case. Locate the SD card slot on the rear of the plug-in unit. REX610 Installation Manual...
  • Page 25 Section 4 2NGA000821 A Mounting GUID-09362795-7B9C-4CF5-81CD-ED4FABE35B32 V1 EN-US Figure 7: Locating the SD card 1 SD card Unlock and lift the slot lid. Insert the SD card, close the lid and lock it to hold the SD card in place. The protection relay supports SD and MMC cards.

  • Page 26: Installing Module Cassettes

    Section 4 2NGA000821 A Mounting Installing module cassettes The analog cards in REX610 are part of cassettes. The cassettes can be attached and removed from the case. There are two types of analog CT modules, AIC2001 and AIC2002, which have compression type and ring-lug type terminals. Detach the plug-in unit from the case as shown in Detaching plug-in unit.
  • Page 27 Section 4 2NGA000821 A Mounting GUID-F3EFA8B2-8483-43F1-8B02-A09B6E8F1CF3 V1 EN-US Figure 9: Installing AIU2001 GUID-2B68BF02-5240-4A7C-BC8E-24FB9C83407D V1 EN-US Figure 10: Installing AIC2001 and AIC2002 REX610 Installation Manual...

  • Page 28: Detaching Module Cassettes

    Section 4 2NGA000821 A Mounting Detaching module cassettes The analog cards in REX610 are part of cassettes. The cassettes can be attached and removed from the case. There are two types of analog CT modules, AIC2001 and AIC2002, which have compression type and ring-lug type terminals. Detach the plug-in unit from the case as shown in Detaching plug-in unit.
  • Page 29 Section 4 2NGA000821 A Mounting GUID-968FA228-FF6D-44A8-A30D-BA1DC5AF6D22 V1 EN-US Figure 12: Removing CT module cover Release the module cassettes by pressing the clip finger at the top or bottom of the module cassette using a flat-tip screwdriver. REX610 Installation Manual...
  • Page 30 Section 4 2NGA000821 A Mounting GUID-92E0EBBF-9DAB-4C0E-A0D4-DD8B4E2B4D76 V1 EN-US GUID-132667CC-A8A5-495A-8520-4A3D0FF75B36 V1 EN-US Figure 13: Releasing a module cassette Pull the cassette out carefully. REX610 Installation Manual...

  • Page 31: Mounting Protection Relay

    Section 4 2NGA000821 A Mounting Mounting protection relay 4.5.1 Required tools • T10 Torx screwdriver for mounting the case and for connecting the protective earthing Only use adjustable torque screwdrivers. 4.5.2 Flush mounting protection relay All the mounting elements are integrated in the protection relay. Requirements for installation: •...
  • Page 32 Section 4 2NGA000821 A Mounting GUID-EBB21A7E-998A-4F37-B29C-3A2B1BA87F3F V1 EN-US Figure 14: Detaching the fixing clamp assembly A 129.0 ± 1 mm (5.0787 ± 0.03937 in) B 139.0 mm (5.4724 in) Mount the case to the panel cutout. Mount the fixing clamp assembly back to the case. REX610 Installation Manual...
  • Page 33 Section 4 2NGA000821 A Mounting GUID-F7BD5AD5-A39A-4160-B07C-360581FDF78B V1 EN-US Figure 15: Mounting the fixing clamp assembly Tighten the M3 (1.5 mm Allen key) screws to secure the case. The allowed range for the fixing screws’ tightening torque is 0.7 ± 10% Nm (0.5162 ± 10% ft lb). REX610 Installation Manual...
  • Page 34 Section 4 2NGA000821 A Mounting GUID-C85A92A1-4B9B-4991-AB68-7917495DAC35 V1 EN-US Figure 16: Tightening the M3 screws Install the plug-in unit into the case. There is a protective film on the top side of the protection relay. Its purpose is to prevent debris falling inside the unit while installing electrical wiring. Remove the protective film before energizing the protection relay.
  • Page 35 Section 4 2NGA000821 A Mounting GUID-946396D4-6A23-4EDB-BD0D-3C18A84E48D1 V1 EN-US Figure 17: Flush mounted case and plug-in unit 149.5 mm (5.8858 in) 159.5 mm (6.2795 in) C 127.5 mm (5.0196 in) D 202.8 mm (7.9842 in) 163.6 mm (6.4409 in) 39.2 mm (1.5433 in) G 155.5 mm (6.1220 in) H 137.5 mm (5.4133 in) REX610...

  • Page 36: Rack Mounting Protection Relay

    Section 4 2NGA000821 A Mounting 4.5.3 Rack mounting protection relay A mounting kit is needed for rack mounting the protection relay. In addition to the detailed mounting instructions, the 19" rack mounting kit includes: • Mounting panel • Screws Flush mounting protection relay for illustrations of the steps to mount the relay on a rack.
  • Page 37 Section 4 2NGA000821 A Mounting GUID-98214A59-0718-41F7-BFCB-DDC1BAE4C647 V1 EN-US Figure 18: Wall mounting the protection relay A 365 mm (14.3700 in) 1 Side panels B ∅ 7.5 mm (0.2952 in) 2 Hexagon socket head cap screw M5x8 (4 pieces) C 66.5 mm (2.6181 in) 3 Front panel D 133 mm (5.2362 in) 4 Torx screw M5x10 (4 pieces)
  • Page 38 Section 4 2NGA000821 A Mounting GUID-DB10D030-9F9E-4940-AE80-4762B565565F V1 EN-US Figure 19: Wall mounted protection relay A 390 mm (15.3543 in) B 181.80 mm (7.1574 in) C 214.12 mm (8.4299 in) Connect the wires. A wall-mounted protection relay can be released by loosening the fixing clamp.
  • Page 39 Section 4 2NGA000821 A Mounting GUID-5EA78DE0-96C9-49F8-9223-65B30732DB94 V1 EN-US Figure 20: Swinging out the protection relay A 54 mm (2.1259 in) 1 Remove the screws before swinging out the frame B 574 mm (22.5984 in) Swing the frame back to the wall and insert the removed screws. REX610 Installation Manual...

  • Page 41: Section 5 Connecting

    Section 5 2NGA000821 A Connecting Section 5 Connecting Required tools When handling CT/VT terminals in slots C1 and D2 respectively, use a flat-blade screwdriver. Table 3: Required tools Terminal Slotted screw (part of Screwdriver blade the connector) Width Thickness CT (C1) ∅3.5 mm (0.1377 in) Max.

  • Page 42: Connecting Functional Earthing

    Section 5 2NGA000821 A Connecting Table 4: Wire specifications for connections on the rear of the relay Terminal Wire size Stripping length Solid and flexible Wire-end ferrule Plastic collar ferrule A1 (PSU2001) 7 ± 1 mm 0.5...2.5 mm 0.5...2.5 mm 0.5...1.5 mm B (DIO2001) (0.2755 ±...
  • Page 43 Section 5 2NGA000821 A Connecting GUID-4B6444A0-27E7-43BA-ABCB-D52BE6B94719 V1 EN-US Figure 21: Locating the functional earth screw 1 Upper functional earth screw 2 Lower functional earth screw The earth lead should be as short as possible but extra length is required for door mounting. Each protection relay must have its own earth lead connected to the earth circuit connector.

  • Page 44: Connecting Analog Signals

    Section 5 2NGA000821 A Connecting Select a suitable ring lug to fit under the M3 screw. Tighten the functional earth screw. The allowed tightening torque is 0.75 Nm ± 10% (0.55 ft lb ± 10%). Use the lower functional screw to earth the RS-485 shield wire in the RS-485 cable when hard earth shielding is required.
  • Page 45 Section 5 2NGA000821 A Connecting ft lb). The allowed tightening torque for the ring-lug wire clamp is 0.8 Nm ± 10% (0.5900 ft lb ± 10%). AIC2001/AIC2002 1/5 A 1/5 A 1/5 A 1/5 A GUID-A14D08B9-E96F-41BA-A8BB-2F0AA0F09D5F V1 EN-US Figure 22: AIC2001/AIC2002 card REX610 Installation Manual...

  • Page 46: Connecting Protection Relay With A Test Switch

    Section 5 2NGA000821 A Connecting AIU2001 250 Vac 250 Vac 250 Vac 250 Vac GUID-1ECB58F0-5DA1-4BB8-86A9-711DA91DB3DC V1 EN-US Figure 23: AIU2001 card 5.4.2 Connecting protection relay with a test switch • When the protection relay is used with a test switch, connect the current and voltage transformers directly to the switch.

  • Page 47: Connecting Power Supply

    Section 5 2NGA000821 A Connecting DIO2001 (Signal) (signal) (non-configurable) CSO1 (Signal) CSO2 (Signal) GUID-5915733A-F036-44F1-803B-63096B5664AD V1 EN-US Figure 24: DIO2001 card Connecting power supply The permitted auxiliary voltage range of the protection relay is marked on top of the protection relay's LHMI. •...
  • Page 48 Section 5 2NGA000821 A Connecting PSU2001 + / ~ - / ~ Func�onal earth (Trip) TCS1 (Trip) TCS2 GUID-DD1E7547-C3D4-4F48-BD89-7DED17395353 V1 EN-US Figure 25: PSU2001 card GUID-8E3BB97D-85A5-46EB-A0C5-90F58C8FA580 V1 EN-US Figure 26: Connecting auxiliary voltage REX610 Installation Manual...

  • Page 49: Connecting Communication

    Section 5 2NGA000821 A Connecting Connecting communication The isolated RS-485 interface is available with four pins. It features an isolated, bidirectional, balanced communication bus (A and B) and a connection for isolated ground. The fourth pin is an AC coupled shield terminal. Typical connection is through a shielded twisted-pair (STP) cable.

  • Page 50: Connecting Relay Via Usb

    Section 5 2NGA000821 A Connecting GUID-70CC22A6-3938-469D-AC08-C174A4ED458C V1 EN-US Figure 28: Locating the Modbus termination jumper 1 Modbus termination jumper Connecting relay via USB The protection relay can be connected from the front USB using a micro USB (type B) connector. The relay supports USB based power-up.

  • Page 51: Energizing Protection Relay

    Section 5 2NGA000821 A Connecting See the technical, engineering and operation manuals for details on features supported by the USB based connectivity and the USB based power-up. Energizing protection relay Before connecting the auxiliary power, check that the protective film is removed from top of the protection relay. •...
  • Page 52 Section 5 2NGA000821 A Connecting If the protection relay detects a diagnostic error during start-up, the green Normal LED flashes and the internal fault code is displayed on the LCD. REX610 Installation Manual...

  • Page 53: Section 6 Removing, Repairing And Exchanging

    Internet www.abb.com by following the links within ABB Service Guide or via ABB Product Guide from the product specific Service & Support sheet. Checking protection relay information The protection relay information includes detailed information about the device, such as version and serial number. The protection relay information is shown on the display for a few seconds when the device starts up.

  • Page 54: Removing Protection Relay

    Detach the panel fixing clamp from the case. Remove the case from the panel cutout. Sending protection relay for repair • In case of product problems, contact the nearest ABB office or representative for consultation and instructions. REX610 Installation Manual...

  • Page 55: Exchanging Protection Relay

    The exchangeable units can be found from the PartsOnLine system, see www.abb.com/partsonline. Use of PartsOnLine requires user registration. • To exchange a protection relay to a different unit, change the case and connect the wires.

  • Page 57: Section 7 Technical Data

    Section 7 2NGA000821 A Technical data Section 7 Technical data Case and HMI display variants 7.1.1 Front side of the protection relay GUID-8E4EB9A8-0A01-4DD3-A8F3-0E116433B5E4 V1 EN-US Figure 31: Display Table 6: Display Rows in the view Characters per row Character size Small, mono-spaced (6 ×...

  • Page 58: Rear Side Of The Protection Relay

    Section 7 2NGA000821 A Technical data 7.1.2 Rear side of the protection relay GUID-24D5F963-9C71-45E6-A4E5-3574A1466AF7 V1 EN-US Figure 32: Rear view of the protection relay REX610 Installation Manual...

  • Page 59: Dimensions

    Section 7 2NGA000821 A Technical data Dimensions GUID-3990F9AC-7261-422D-B924-1069CABAE21B V1 EN-US Figure 33: REX610 main dimensions 149.5 mm (5.8858 in) 159.5 mm (6.2795 in) C 127.5 mm (5.0196 in) D 202.8 mm (7.9842 in) 163.6 mm (6.4409 in) 39.2 mm (1.5433 in) G 155.5 mm (6.1220 in) H 137.5 mm (5.4133 in) REX610...

  • Page 60: Enclosure Class

    Section 7 2NGA000821 A Technical data Table 7: Dimensions Description Value Width Frame 149.5 mm (5.8858 in) Case 127.5 mm (5.0196 in) Height Frame 159.5 mm (6.2795 in) Case 155.5 mm (6.1220 in) Depth 202.8 mm (163.6 mm + 39.2 mm) (7.9842 in) Weight Protection relay with the four...

  • Page 61: Section 8 Accessories And Ordering Data

    Section 8 2NGA000821 A Accessories and ordering data Section 8 Accessories and ordering data Table 9: Mounting accessories Item Order number Wall mounting kit 2RCA055188A0001 19” rack mounting kit with cutout for one relay 2REA060349A0001 19” rack mounting kit with cutout for two relays 2REA060349A0002 REX610 Installation Manual...

  • Page 63: Section 9 Glossary

    Section 9 2NGA000821 A Glossary Section 9 Glossary American wire gauge Current transformer Electromagnetic compatibility Ethernet A standard for connecting a family of frame-based computer networking technologies into a LAN Human-machine interface Hardware International Electrotechnical Commission Liquid crystal display Light-emitting diode LHMI Local human-machine interface RoHS...
  • Page 64 — ABB Distribution Solutions P.O. Box 699 FI-65101 VAASA, Finland Phone +358 10 22 11 abb.com/mediumvoltage © Copyright 2022 ABB. All rights reserved.

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