ABB RELION REX640 Installation Manual
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ABB RELION REX640 Installation Manual

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RELION
PROTECTION AND CONTROL
REX640
Installation Manual

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Summary of Contents for ABB RELION REX640

  • Page 1 — ® RELION PROTECTION AND CONTROL REX640 Installation Manual...
  • Page 3 Document ID: 1MRS759115 Issued: 2023-02-10 Revision: E © Copyright 2023 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 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.
  • 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 8: Table Of Contents

    Contents Contents Introduction..................... 10 This manual.............................10 Intended audience..........................10 Product documentation........................11 1.3.1 Product documentation set....................11 1.3.2 Document revision history....................11 1.3.3 Related documentation......................11 Symbols and conventions........................12 1.4.1 Symbols........................... 12 1.4.2 Document conventions......................12 Environmental aspects................14 Sustainable development........................14 Disposal of a device..........................14 Unpacking, inspecting and storing............
  • Page 9 Contents Connecting....................67 Required tools............................67 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 Connecting protective earthing......................70 5.3.1 Connecting protective earthing to relay................70 5.3.2 Connecting protective earthing to local HMI..............

  • Page 10: Introduction

    Introduction 1MRS759115 E 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 11: Product Documentation

    1MRS759115 E Introduction Product documentation 1.3.1 Product documentation set Quick installation guide Brochure Product guide Operation manual Installation manual Engineering manual Technical manual Application manual Communication protocol manual IEC 61850 engineering guide Cyber security deployment guideline Hardware modification instructions Modification sales guideline Figure 1: The intended use of documents during the product life cycle 1.3.2 Document revision history...

  • Page 12: Related Documentation

    Introduction 1MRS759115 E 1.3.3 Related documentation www.abb.com/ Download the latest documents from the ABB Web site mediumvoltage 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.
  • Page 13 1MRS759115 E Introduction 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". •...

  • Page 14: Environmental Aspects

    Environmental aspects 1MRS759115 E 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 device. The choice of materials and suppliers has been made according to the EU RoHS directive (2011/65/EU).

  • Page 15: Unpacking, Inspecting And Storing

    1MRS759115 E Unpacking, inspecting and storing 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 cover (supplied with the relay) on the top side of the relay for the installation phase.

  • Page 16: Inspecting Product And Delivery Items

    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. 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.

  • Page 17: Mounting

    1MRS759115 E Mounting Mounting Required tools • TX25 and TX30 screwdrivers for installing the protection relay with mounting kits • TX25 and TX20 screwdrivers for mounting the LHMI 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.

  • Page 18: Mounting Options

    Mounting 1MRS759115 E Mounting options 4.3.1 Mounting local HMI 4.3.1.1 Flush mounting local HMI Make a cutout for the LHMI according to the dimensional drawing. 188 ±1 mm (7.4016 ±0.03937 in) 151 ±1 mm (5.9449 ±0.03937 in) Figure 3: Making a cutout REX640 Installation Manual...
  • Page 19 1MRS759115 E Mounting Mount the LHMI to the cutout with the installation brackets and screws. LHMI Screws Installation brackets Figure 4: Mounting the local HMI to the cutout Tighten the screws evenly to 3.5 Nm ±5% (2.5815 ft-lb ±5%). Screws Figure 5: Tightening the screws REX640 Installation Manual...
  • Page 20 Mounting 1MRS759115 E 212.5 mm (8.3661 in) 50.0 mm (1.9685 in) 177.5 mm (6.9882 in) 7.6 mm (0.2992 in) Figure 6: Flush mounted local HMI REX640 Installation Manual...
  • Page 21 1MRS759115 E Mounting 4.3.1.2 Surface mounting local HMI Make a cutout for the LHMI and drill holes for the raising frame according to the dimensional drawing. 197 ±1 mm (7.7559 ±0.03937 in) 179 ±0.4 mm (7.0472 ±0.01575 in) Ø 6.0 mm (0.2362 in) 213 ±0.4 mm (8.3858 ±0.01575 in) 209 ±1 mm (8.2283 ±0.03937 in) Figure 7: Making a cutout and drilling holes...
  • Page 22 Mounting 1MRS759115 E Mount the raising frame to the panel with the M5 screws. Raising frame M5 screws Figure 8: Mounting the raising frame Tighten the screws to4 Nm ±5% (2.9502 ft-lb ±5%). REX640 Installation Manual...
  • Page 23 1MRS759115 E Mounting Mount the LHMI with the installation brackets. Installation brackets Figure 9: Mounting the local HMI REX640 Installation Manual...
  • Page 24 Mounting 1MRS759115 E 230.0 mm (9.0551 in) 56.0 mm (2.2047 in) 235.0 mm (9.2520 in) 3.5 mm (0.1378 in) Figure 10: Surface mounted local HMI REX640 Installation Manual...
  • Page 25 1MRS759115 E Mounting 4.3.1.3 Tilt/inclined mounting local HMI Make a cutout for the LHMI and drill holes for the raising frame according to the dimensional drawing. 197 ±1 mm (7.7559 ±0.03937 in) 179 ±0.4 mm (7.0472 ±0.01575 in) Ø 6.0 mm (0.2362 in) 213 ±0.4 mm (8.3858 ±0.01575 in) 209 ±1 mm (8.2283 ±0.03937 in) Figure 11: Making a cutout and drilling holes...
  • Page 26 Mounting 1MRS759115 E Mount the tilt frame to the panel with M5 screws. Tilt frame M5 screws Figure 12: Mounting the raising frame Tighten the screws to 4 Nm ±5% (2.9502 ft-lb ±5%). Mount the LHMI with the installation brackets. Installation brackets Figure 13: Mounting the local HMI REX640...
  • Page 27 1MRS759115 E Mounting 230.0 mm (9.0551 in) 3.5 mm (0.1378 in) 25° 108.0 mm (4.2520 in) 236.0 mm (9.2913 in) Figure 14: Tilt mounted local HMI REX640 Installation Manual...

  • Page 28: Mounting Protection Relay

    Mounting 1MRS759115 E 4.3.2 Mounting protection relay 4.3.2.1 Wall mounting protection relay Drill four M5 screw holes according to the dimensional drawing. 322 ±0.4 mm (12.6772 ±0.01575 in) M5 hole 237 ±0.4 mm (9.3307 ±0.01575 in) Figure 15: Drilling screw holes REX640 Installation Manual...
  • Page 29 1MRS759115 E Mounting Mount the M5 screws in the upper holes, but do not tighten them. Leave them 3...4 mm (0.1181...0.1575 in) open. M5 screws Figure 16: Mounting M5 screws in the upper holes REX640 Installation Manual...
  • Page 30 Mounting 1MRS759115 E Attach the mounting bracket to the protection relay with M6 screws and tighten the screws to 9 Nm ±5% (6.6381 ft-lb ±5%). Mounting bracket M6 screws Figure 17: Mounting M6 screws Lift the protection relay to its place on the existing screws on the panel. Mount the M5 screws in the bottom holes.
  • Page 31 1MRS759115 E Mounting Tighten all the M5 screws. M5 screws Figure 18: Mounting and tightening the M5 screws Figure 19: Wall mounted protection relay REX640 Installation Manual...
  • Page 32 Mounting 1MRS759115 E   338.0 mm (13.3071 in) 265.0 mm (10.4331 in) 255.7 mm (10.0669 in) with compression type CT/VT connectors 276.6 mm (10.8898 in) with ring-lug type CT/VT connectors 287.5 mm (11.3189 in) with a grounding bar A minimum of 50 mm (1.9685 in) space is needed between two kits. Check the allowed minimum bending radius from the optical cable manufacturer.
  • Page 33 1MRS759115 E Mounting Mount the roof mounting bracket to the roof with M5 screws using either the through holes on top of the cabinet or the M5 holes in the roof inside the cabinet. Mount the M5 screws in the upper M5 holes of the roof mounting bracket, but do not tighten them.
  • Page 34 Mounting 1MRS759115 E Attach the mounting bracket to the protection relay with M6 screws and tighten the screws to 9 Nm ±5% (6.6381 ft-lb ±5%). Mounting bracket M6 screws Figure 22: Mounting M6 screws Lift the protection relay to its place on the existing screws on the roof mounting bracket.
  • Page 35 1MRS759115 E Mounting Tighten the four M5 screws on the roof mounting bracket to 4 Nm ± 5 % (2.9502 ft-lb ±5%). M5 screws Figure 23: Mounting and tightening the M5 screws REX640 Installation Manual...
  • Page 36 Mounting 1MRS759115 E 417.0 mm (16.4173 in) 357.0 mm (14.0551 in) 306.5 mm (12.0669 in) 273.5 mm (10.7677 in) with compression type CT/VT connectors 285.4 mm (11.2362 in) with ring-lug type CT/VT connectors 305.3 mm (12.0197 in) with a grounding bar Figure 24: Roof mounted protection relay REX640 Installation Manual...
  • Page 37 1MRS759115 E Mounting 4.3.2.3 Door mounting protection relay Drill holes according to the dimensional drawing. 249 ±0.4 mm (9.8032 ±0.01575 in) 245 ±0.4 mm (9.6457 ±0.01575 in) Ø 7.0 mm (0.2756 in) Figure 25: Drilling holes REX640 Installation Manual...
  • Page 38 Mounting 1MRS759115 E Mount the protection relay to the door or panel with the M6 screws. M6 screws Figure 26: Mounting the protection relay to the door REX640 Installation Manual...
  • Page 39 1MRS759115 E Mounting Tighten the four M6 screws to 9 Nm ±5% (6.6381 ft-lb ±5%). M6 screws Figure 27: Tightening the M6 screws REX640 Installation Manual...
  • Page 40 Mounting 1MRS759115 E 264.8 mm (10.4252 in) 242.2 mm (9.5354 in) with 304.0 mm (11.9685 in) compression type CT/VT connectors 254.1 mm (10.0039 in) with ring-lug type CT/VT connectors 274.0 mm (10.7874 in) with a grounding bar Figure 28: Door mounted protection relay 4.3.2.4 Rack mounting protection relay Attach the protection relay to a 7U rack plate with M6 screws.
  • Page 41 1MRS759115 E Mounting Tighten the M6 screws to 9 Nm ±5% (6.6381 ft-lb ±5%). 7U rack plate M6 screws Figure 29: Mounting the protection relay to the rack plate Mount the protection relay and rack plate to a 19" rack. The rack plate can also be mounted to the rack before the protection relay is attached to it.

  • Page 42: Mounting Protection Relay With Local Hmi

    Mounting 1MRS759115 E 482.60 mm (19 in) 242.20 mm (9.5354 in) 310.35 mm (12.2185 in), 7U with compression type CT/VT connectors 254.10 mm (0.0039 in) with ring-lug type CT/VT connectors 274.00 mm (10.7874 in) with a grounding bar Figure 30: Rack mounted protection relay Check the allowed minimum bending radius from the optical cable manufacturer.
  • Page 43 1MRS759115 E Mounting 4.3.3.1 Rack mounting protection relay with local HMI and RTXP 24 test switch REX640 has two rack mounting options for the relay, HMI and RTXP 24 test switch. Contents of the installation kits are identical apart from the 6U or 7U high rack plates.
  • Page 44 Mounting 1MRS759115 E Install the RTXP test switch to the assembly part using torx pan head tapping screw ST3.5x13. Door mounting bracket M3 screws M6 screws RTXP 24 mounting part 6U or 7U rack plate ST3.5 screws M5 screws RJ-45 coupler with a cable Figure 31: Installation kit contents REX640 Installation Manual...
  • Page 45 1MRS759115 E Mounting 4.3.3.2 Door mounting protection relay with local HMI Make a cutout for the LHMI and drill holes for the mounting bracket according to the dimensional drawing. 188 ±1 mm (7.4016 ±0.03937 in) 230 ±0.4 mm (9.0551 ±0.01575 in) Ø...
  • Page 46 Mounting 1MRS759115 E M5 screws Mounting bracket LHMI installation brackets Figure 33: Mounting the local HMI and mounting brackets Attach the mounting bracket to the protection relay with the M6 screws. Mounting bracket M6 screws Figure 34: Attaching the mounting bracket to the protection relay Tighten the M6 screws to 9 Nm ±5% (6.6381 ft-lb ±5%).
  • Page 47 1MRS759115 E Mounting Mount the M5 screws in the bottom holes. Tighten the four M5 screws to (2.9502 ft-lb ±5%). M5 screws Figure 35: Mounting and tightening the M5 screws REX640 Installation Manual...
  • Page 48 Mounting 1MRS759115 E 265.0 mm (10.4331 in) 7.6 mm (0.2992 in) 339.0 mm (13.3465 in) 212.5 mm (8.3661 in) 313.2 mm (12.3307 in) 177.5 mm (6.9882 in) with compression type CT/VT connectors 325.1 mm (12.7992 in) with ring-lug type CT/VT connectors 345.0 mm (13.5827 in) with a grounding bar Figure 36: Door mounted protection relay with local HMI...
  • Page 49 1MRS759115 E Mounting M5 screws LHMI installation brackets 7U rack plate Mounting bracket Figure 37: Mounting the local HMI and mounting bracket Install the RJ-45 coupler with a cable to the panel cutout and connect the cable to the LHMI service port X1.2. RJ-45 coupler Figure 38: Installing the RJ-45 coupler Attach the mounting bracket to the protection relay with M6 screws.
  • Page 50 Mounting 1MRS759115 E Tighten the M6 screws to 9 Nm ±5% (6.6381 ft-lb ±5%). Mounting bracket M6 screws Figure 39: Mounting M6 screws Lift the protection relay to its place on the existing screws on the mounting bracket. Mount the M5 screws in the bottom holes. Tighten the four M5 screws on the mounting bracket to 4 Nm ±5% (2.9502 ftlb ±5%).

  • Page 51: Mounting Grounding Bar Kit

    1MRS759115 E Mounting 482.6 mm (19 in) 19 mm (0.7480 in) 310.35 mm (12.2185 in), 7U 313.2 mm (12.3307 in) 265.0 mm (10.4331 in) with compression type CT/VT 7.6 mm (0.2992 in) connectors 325.1 mm (12.7992 in) with ring-lug type CT/VT connectors 345.0 mm (13.5827 in) with a grounding bar 339 mm (13.3465 in)
  • Page 52 Mounting 1MRS759115 E Place the grounding bar between the front plates' bendings and mount it to the front plate with M3 screws and washers. Module M3 screws and washers Grounding bar Edge with chamfer towards the module's collar screw Figure 42: Mounting grounding bar Tighten the M3 screws to 0.8 Nm ±5% (0.5900 ft-lb ±5%).
  • Page 53 1MRS759115 E Mounting Install the module back to the same slot in the protection relay. Figure 43: Installing the module REX640 Installation Manual...
  • Page 54 Mounting 1MRS759115 E Install connectors with cables to the module. Use peeled cables to get contact to the grounding bar. Figure 44: Installing connectors REX640 Installation Manual...
  • Page 55 1MRS759115 E Mounting Install shield clamps to connect the cable sheathing to the grounding bar. Shield clamp Figure 45: Installing shield clamps Chapter 5.4.2.1 Shielding RTD/mA instrument cables See also REX640 Installation Manual...

  • Page 56: Mounting Lens Sensors For An Arc Protection System

    Mounting 1MRS759115 E 4.3.5 Mounting lens sensors for an arc protection system Arc protection is used to detect arc situations in air-insulated metal-clad switchgear. Drill a Ø 10 mm (0.3937 in) hole in the wall of the supervised space. 3.5 mm (0.1378 in) Ø...
  • Page 57 1MRS759115 E Mounting Fit the lens sensor into the hole and fasten it with a self-tapping M3 screw. Alternatively, the lens sensor can be fastened with a cable tie. To do this, secure the cable tie to a suitable point of attachment on the cubicle wall and wrap the cable tie tightly around the sensor.

  • Page 58: Manufacturing Tailored Length Loop Sensor For An Arc Protection System

    ® 400 μm V-System Termination Kit DT03732-34 by OFS Fitel, LLC to be purchased from local distributor, not in ABB’s offering. Bulk glass core arc sensor fiber, offered in REA accessories as three alternative lengths: 1MSC 380018.100  ARC sensor fiber, delivery length 100 m 1MSC 380018.300 ARC sensor fiber, delivery length 300 m...
  • Page 59 1MRS759115 E Mounting Diamond Cleave Tool Cable Stripper Crimp Tool Scissors Fiber Stripper Brush Prong Tool Figure 49: Contents of the termination tool kit Cable Stripper tool is not needed as the naked fiber 1MSC 380018.x00 has no jacket to be stripped. Step by step procedure: Cut with scissors required length of the fiber, note that allowed maximum arc loop sensor length with REX640 is 60 meters.
  • Page 60 Mounting 1MRS759115 E Spacer sleeves are used to increase the unjacketed fiber diameter to fit the size of crimp ring. b) Feed fiber through spacer sleeve and crimp ring, large diameter first. Slide the spacer along the fiber until it is 63 mm (2½ inch) from the end of the fiber.
  • Page 61 1MRS759115 E Mounting Make sure to use the appropriate strip tool insert for the buffer removal process: ROYAL BLUE. Be careful while handling the FIBER STRIPPER. Handle as a precision device and do not strike on hard surfaces or drop. Be sure to clean blades frequently using small bristle brush supplied.
  • Page 62 Mounting 1MRS759115 E Release the buffer strip tool handles. d) Inspect HCS cladding for damage from improper buffer stripping (i.e. white dusty stripes). Figure 55: Correct HCS cladding If unable to insert buffered fiber through guide tube, trim tip of the fiber using scissors.
  • Page 63 1MRS759115 E Mounting Slide the ferrule onto the fiber, large diameter first, and push completely into the outer flange of the crimp ring. Figure 56: Sliding the ferrule onto the fiber Figure 57: Ferrule in place b) Insert the crimp ring completely into the rear die nest of the crimp tool. Be sure the ferrule flange is flush against the edge of the die nest.
  • Page 64 Mounting 1MRS759115 E Figure 58: Inserting the crimp ring into the crimp tool Squeeze crimp tool handles together until it clicks, then releases. Be careful not to touch the HCS fiber coating. Once the fiber has been stripped, the coating will retain finger oils, which can transfer to and damage gripper pads in the cleaver.
  • Page 65 1MRS759115 E Mounting Holding the cleave tool in a horizontal position, grip the handle while leaving your index finger free to actuate trigger. b) Place the ferrule into the hole of the positioner plate until it is fully inserted. Figure 59: Placing the ferrule into the cleave tool It is critical to fully insert the connector into the positioner plate.

  • Page 66: Mounting Rj-45 Coupler For An Hmi Service Port

    Mounting 1MRS759115 E Before releasing the trigger, remove the connector from the cleave tool and grasp the top of the scrap fiber while releasing the trigger. Gently remove the scrap fiber while keeping it away from the diamond blade. Dispose of scrap fiber safely in a hard-sided container. Repeat these procedure steps 2-5 to the other end of the arc sensor fiber and then the arc loop sensor is ready.

  • Page 67: Connecting

    1MRS759115 E Connecting Connecting Required tools Table 3: Tools for connector installation Connector type Tool for anchoring connector Tool for connecting wire Slotted head (DIN ISO 8764/2 Slotted head (DIN 5264) (mm) 5364) (mm) CT/VT connectors Compression 0.6x3.5 – 0.6x3.5 Ring lug 1.0x4 –...

  • Page 68: Connecting Wires To Screw-Compression Type Connectors

    Connecting 1MRS759115 E 5.2.1 Connecting wires to screw-compression type connectors Terminal blocks of screw-compression type are used for electrical connections. Open the screw terminal before inserting a wire into it for the first time. To open the screw terminal, turn the fixing screw anti-clockwise until the terminal hole is wide open (the inside of the terminal hole is surrounded by metal).

  • Page 69: Connecting Wires To Push-In Type Connectors

    1MRS759115 E Connecting Table 5: Wire specifications for ring-lug type connectors Connector Wire size Ring-lug Contact Connector type type screw fixing screw Stranded Crimp tightening tightening ferrule torque torque CT/VT 2.62…6.64 TE ring lug 1.2. 1.5 Nm 1.2 Nm TE-35787 (0.8851 ft-lb) connectors mm²...

  • Page 70: Connecting Protective Earthing

    Connecting 1MRS759115 E Connecting protective earthing 5.3.1 Connecting protective earthing to relay Connect the protection relay to earth using a 6 mm (AWG 10) flat braided copper cable. Use an earth lead of maximum 1.5 m (4.9 ft). Extra length is required for door mounting.

  • Page 71: Connecting Analog Signals

    1MRS759115 E Connecting 5.3.2 Connecting protective earthing to local HMI Connect the LHMI to earth using an earth lead of at least 6.0 mm (AWG 10). Loosen the protective earth screw T20 on the LHMI to connect a separate earth protection lead.

  • Page 72: Connecting Current And Voltage Inputs

    Connecting 1MRS759115 E Light gray pairs with short circuit Dark gray pairs without short facility (CT), RAL7035 circuit facility (VT), RAL7042 Figure 64: Identifying CT/VT color coding CT connector coding Empty connector VT connector coding Figure 65: Loose CT/VT connector coding CT connector coding Empty connector VT connector coding...
  • Page 73 1MRS759115 E Connecting • Connect the wires from the CTs/VTs to the correct device according to the phase order and the connection diagram. Sensors (non-conventional instrument transformers) Current measurement is based on Rogowski coil and voltage measurement is based on voltage divider. Both current and voltage measurements interface the relay via one RJ45 connector per phase.
  • Page 74 Connecting 1MRS759115 E L1 L2 L3 AIM1001 57-240V Positive VT1 (Vab) Load flow Direction 57-240V VT2 (Vbc) 57-240V VT3 (Vca) 57-240V 57-240V 1/5A 1/5A 1/5A 1/5A 0.2/1A CT5 (for residual current only) Figure 68: AIM1001 module (two phase-to-phase VTs) REX640 Installation Manual...
  • Page 75 1MRS759115 E Connecting L1 L2 L3 AIM1002 57-240V Positive Load flow Direction 57-240V 57-240V 57-240V 1/5A 1/5A 1/5A 1/5A 1/5A 1/5A Figure 69: AIM1002 module REX640 Installation Manual...
  • Page 76 Connecting 1MRS759115 E L1 L2 L3 AIM1002 57-240V Positive VT1 (Vab) Load flow Direction 57-240V VT2 (Vbc) 57-240V VT3 (Vca) 57-240V 1/5A 1/5A 1/5A 1/5A 1/5A 1/5A Figure 70: AIM1002 module (two phase-to-phase VTs) REX640 Installation Manual...
  • Page 77 1MRS759115 E Connecting L1 L2 L3 Positive Current Direction SIM1901 Sensor I Sensor U Sensor I Sensor U Sensor I Sensor U 57-240 0.2/1A (for residual current only) Figure 71: SIM1901 module (VT primary connection phase-to-earth) REX640 Installation Manual...
  • Page 78 Connecting 1MRS759115 E L1 L2 L3 Positive Current Direction SIM1901 Sensor I Sensor U Sensor I Sensor U Sensor I Sensor U 57-240 0.2/1A (for residual current only) Figure 72: SIM1901 module (VT primary connection phase-to-phase) REX640 Installation Manual...
  • Page 79 1MRS759115 E Connecting L1 L2 L3 Positive Current Direction SIM1902 Sensor I Sensor U Sensor I Sensor U Sensor I Sensor U 57-240 0.2/1A (for residual current only) Figure 73: SIM1902 module (VT primary connection phase-to-earth) REX640 Installation Manual...
  • Page 80 Connecting 1MRS759115 E L1 L2 L3 Positive Current Direction SIM1902 Sensor I Sensor U Sensor I Sensor U Sensor I Sensor U 57-240 0.2/1A (for residual current only) Figure 74: SIM1902 module (VT primary connection phase-to-phase) REX640 Installation Manual...

  • Page 81: Connecting Rtd And Ma Inputs

    1MRS759115 E Connecting 5.4.2 Connecting RTD and mA inputs • Connect the wires from the transducers to the correct device. Each terminal for RTDs and mA inputs is dimensioned for one 0.5...2.5 mm (AWG 20-14) wire or for two 0.5...1.0 mm (AWG 20-17) wires.
  • Page 82 Connecting 1MRS759115 E RTD1002 RTD1 RTD2 RTD3 BI10 BI11 BI12 Figure 76: RTD1002 REX640 Installation Manual...
  • Page 83 1MRS759115 E Connecting 5.4.2.1 Shielding RTD/mA instrument cables Install connectors with cables to the module. Strip the cables to ensure contact to the grounding bar. The cable position affects the stripping length and position. Connectors with cables Examples of stripping length and position Figure 77: Installing connectors REX640...
  • Page 84 Connecting 1MRS759115 E Install shield clamps to connect the cable sheathing to the grounding bar. Shield clamp Figure 78: Installing shield clamps REX640 Installation Manual...

  • Page 85: Connecting Binary Signals

    1MRS759115 E Connecting Connecting binary signals • Connect the wires for the binary signals to the correct device. Each terminal for binary input and output signal is dimensioned for one 0.5...2.5 mm (AWG 20-14) wire or for two 0.5...1.0 mm (AWG 20-17) wires.
  • Page 86 Connecting 1MRS759115 E BIO1002/ BIO1004 SPO1 SPO2 SPO3 SPO4 SPO5 SPO6_TCS SPO6 SPO7 SPO8_TCS SPO8 Figure 80: BIO1002/BIO1004 REX640 Installation Manual...

  • Page 87: Connecting Power Supply

    1MRS759115 E Connecting PSM100x Uaux Uaux SSO1 SSO2 POSP1 POSP2 PODP1 PO1_TCS PODP2 PO2_TCS PODP3 PO3_TCS Figure 81: PSM100x Connecting power supply The permitted auxiliary voltage range is found on the protection relay's sticker. • Connect the protection relay's auxiliary voltage to slot G terminal X1:1-2. •...

  • Page 88: Connecting Communication

    Connecting 1MRS759115 E Figure 82: Connecting auxiliary voltage Connecting communication • Before connecting communication, check that the HW module has the correct communication interfaces. The communication module is located in slot A2. See the technical manual for the communication interfaces. Check the allowed minimum bending radius from the optical cable manufacturer.

  • Page 89: Connecting External Display Module

    1MRS759115 E Connecting Plug the SFP transceiver into the socket and ensure that the transceiver is seated and latched properly, that is, the locking lever is on the upper position. Remove the dust cap of the SFP transceiver. Connect the fiber-optic cable to the SFP transceiver. Do not remove the dust cap from the SFP transceiver if the fiber- optic cable is not immediately connected to the SFP transceiver.
  • Page 90 Connecting 1MRS759115 E USB port RJ-45 ports Figure 83: Local HMI connectors REX640 Installation Manual...

  • Page 91: Checking Installation

    1MRS759115 E Checking installation Checking installation Identifying hardware and software version • Check the label on the case of the protection relay for the hardware and software version information. • Check the module labels to identify the modules inside the protection relay. Checking mounting •...
  • Page 92 Checking installation 1MRS759115 E Energize the power supply of the protection relay and the optional LHMI. This can be done in a number of ways, from energizing a whole cubicle to energizing a single protection relay. The following sequence is expected when the protection relay is energized: •...

  • Page 93: Removing, Repairing And Exchanging

    Check with your local ABB if the protection relay can be upgraded. Sending protection relay for repair • In case of product problems, contact the nearest ABB office or representative for consultation and instructions. REX640...

  • Page 94: Exchanging Protection Relay

    The exchangeable units can be found in the PartsOnLine system, see www.abb.com/partsonline . Use of PartsOnLine requires user registration. Check with your local ABB if the protection relay can be upgraded. REX640 Installation Manual...

  • Page 95: Technical Data

    1MRS759115 E Technical data Technical data Local HMI USB port RJ-45 ports Figure 85: Local HMI connectors REX640 Installation Manual...

  • Page 96: Connector Side

    Technical data 1MRS759115 E Connector side Slot markings in enclosure (top and Ready LED bottom) Figure 86: Connector side of the protection relay REX640 Installation Manual...

  • Page 97: Dimensions

    1MRS759115 E Technical data Dimensions 304.0 mm (11.9685 in) 242.2 mm (9.5354 in) with 264.8 mm (10.4252 in) compression type CT/VT connectors 254.1 mm (10.0039 in) with ring-lug type CT/VT connectors 274.0 mm (10.7874 in) with a grounding bar Figure 87: REX640 main dimensions Table 7: Dimensions of the local HMI Description Value...

  • Page 98: Enclosure Class

    Technical data 1MRS759115 E Description Value Width 212.5 mm (8.3661 in) Height 177.5 mm (6.9882 in) Depth 57.6 mm (2.2677 in) Weight 1.6 kg (3.5 lb) Enclosure class Table 8: Degree of protection of the protection relay Description Value Front/connector side IP 20 (with ring-lug signal connectors IP 00 or IP 10 depending on wiring) Top and bottom...
  • Page 99 1MRS759115 E Technical data Side Front/connector side Bottom Rear Figure 88: REX640 sides REX640 Installation Manual...

  • Page 100: Accessories And Ordering Data

    Accessories and ordering data 1MRS759115 E Accessories and ordering data Table 10: HMI Item Order number LHMI (including mounting bracket kit) 2RCA033008A0001 LHMI, conformal coated (including mounting 2RCA033008A0901 bracket kit) SHMI (including mounting bracket kit) 2RCA033008A0002 SHMI, conformal coated (including mounting 2RCA033008A0902 bracket kit) 0.5 m (1.6 ft) connection cable for HMI...
  • Page 101 1MRS759115 E Accessories and ordering data Item Order number Door mounting with LHMI 2RCA040882A0001 19" relay rack mounting with LHMI 2RCA041125A0001 19" relay rack mounting without LHMI 2RCA041127A0001 19" relay rack mounting for relay and LHMI, 2RCA051498A0001 including a provision for RTXP 24 test switch, 19"...
  • Page 102 Accessories and ordering data 1MRS759115 E Item Order number ARC loop sensor cable 40.0 m (131.2 ft), glass 2RCA041050A0040 fiber ARC loop sensor cable 50.0 m (164.0 ft), glass 2RCA041050A0050 fiber ARC loop sensor cable 60.0 m (196.9 ft), glass 2RCA041050A0060 fiber Blind extension cable for ARC loop sensors,...
  • Page 103 1MRS759115 E Accessories and ordering data Table 14: Connectors Item Order number Compression-type signal connectors SYJ-ZRK 2Z18P1 Ring-lug type signal connectors SYJ-ZRK 33X18 Push-in type signal connectors SYJ-ZRK 53P18PM 1 CT-1 VT compression-type connector 2RCA040474A0004 5 CT compression-type connector 2RCA040474A0001 5 VT compression-type connector 2RCA040474A0002 1 CT-4 VT compression-type connector...

  • Page 104: Glossary

    Glossary 1MRS759115 E Glossary American wire gauge Current transformer EIA-485 Serial communication standard according to Electronics Industries Asso- ciation Electromagnetic compatibility Human-machine interface Hardware International Electrotechnical Commission IRIG-B Inter-Range Instrumentation Group's time code format B Connector type for glass fiber cable, IEC 61754-20 Liquid crystal polymer LHMI Local human-machine interface...
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