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ABB Relion REX640 User Manual
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ABB Relion REX640 User Manual

ABB Relion REX640 User Manual

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BIO-Tester Relion® REX640
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  • Page 1 — BIO-Tester Relion® REX640 User Manual...
  • Page 3 Document ID: 2NGA000105 Issued: 2019-12-03 Revision: B Product version: 1.0 © Copyright 2019 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. In case of discrepancies between the English and any other language version, the wording of the English version shall prevail.
  • 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 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.
  • Page 7 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.

  • Page 9: Table Of Contents

    Table of contents 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........
  • Page 10 Table of contents Section 5 Life cycle services............33 Ordering data..................33 Section 6 Technical data..............35 Section 7 Glossary................. 39 BIO-Tester Relion® REX640 User Manual...

  • Page 11: Section 1 Introduction

    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. BIO-Tester Relion® REX640 User Manual...

  • Page 12: Symbols And Conventions

    Section 1 2NGA000105 B Introduction 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.

  • Page 13: Section 2 Environmental Aspects

    Section 2 2NGA000105 B 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 device. The choice of materials and suppliers has been made according to the EU RoHS directive (2011/65/EU).
  • Page 14 Section 2 2NGA000105 B Environmental aspects Device Parts Material Package Cardboard Filling Attached material Manuals Paper 1) Polypropylene copolymer resin 2) Polycarbonate 3) Liquid crystal polymer 4) Polyethylene BIO-Tester Relion® REX640 User Manual...

  • Page 15: Section 3 Unpacking, Inspecting And Storing

    Section 3 2NGA000105 B Unpacking, inspecting and storing Section 3 Unpacking, inspecting and storing Removing transport packaging The deliverables 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. Inspecting product and delivery items 3.2.1 Identifying product...
  • Page 16 Unpacking, inspecting and storing 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 Notify ABB immediately if there are any discrepancies in relation to the delivery documents. BIO-Tester Relion® REX640 User Manual...

  • Page 17: Inspecting Product

    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.

  • Page 19: Section 4 Bio-Tester Relion® Rex640

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 Section 4 BIO-Tester Relion® REX640 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.

  • Page 20: Connector Cables And Interfaces

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 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.
  • Page 21 Section 4 2NGA000105 B BIO-Tester Relion® REX640 GUID-7D9AC410-D1FA-47A1-A20B-5F38CF472B78 V1 EN Figure 3: ® Front view of BIO-Tester Relion REX640 PSM1001/PSM1002/PSM1003 connector BIO1001/BIO1003 connector BIO1002/BIO1004 connector LHMI 48 V DC connector PSM1001/PSM1002/PSM1003 test switches and indication LEDs BIO1001/BIO1003 test switches and indication LEDs BIO1002/BIO1004 test switches and indication LEDs Main power switch and main’s wall plug connector Protection relay's auxiliary power supply selection: 48 V DC or 110 V DC...

  • Page 22: Terminal Layouts And Connection Diagrams

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 Follow the connectors' color coding when connecting the cables to BIO-Tester. Use the separate connector cable for the LHMI. Terminal layouts and connection diagrams BIO-Tester follows the same terminal description as in REX640 protection relays. It is equipped with test switches and indication LEDs for power supply and BIO modules.
  • Page 23 Section 4 2NGA000105 B BIO-Tester Relion® REX640 GUID-5D4C7B10-17CA-4F59-B9E0-8024CB82CDE8 V1 EN Figure 4: Connector side of the protection relay 1 Slot markings in enclosure (top and bottom) 2 Ready LED The relay has mandatory and optional slots. A mandatory slot always contains a module, while an optional slot may be empty, depending on the composition variant ordered.
  • Page 24 Section 4 2NGA000105 B BIO-Tester Relion® REX640 Table 3: Module slots Module Slot A1 Slot A2 Slot B Slot C Slot D Slot E Slot F Slot G BIO1001 ● BIO1002 ● BIO1003 BIO1004 ● = Mandatory to have one of the allocated modules in the slot o = Optional to have one of the allocated modules in the slot.
  • Page 25 Section 4 2NGA000105 B BIO-Tester Relion® REX640 Table 4: REX640 modules and the corresponding BIO-Tester connectors, test switches and LEDs REX640 module ® BIO-Tester Relion REX640 Connector Test switches and indication LEDs Power supply module, PSM1001/1002/1003 PSM1001/1002/1003 PSM100x Uaux Uaux PODP1 PODP2 SSO1...
  • Page 26 Section 4 2NGA000105 B BIO-Tester Relion® REX640 REX640 module ® BIO-Tester Relion REX640 Connector Test switches and indication LEDs Binary input/output module, BIO1001/1003 BIO1001/1003 BIO1001/ BIO1003 BI10 BI11 BI12 BI13 BI14 Table continues on next page BIO-Tester Relion® REX640 User Manual...
  • Page 27 Section 4 2NGA000105 B BIO-Tester Relion® REX640 REX640 module ® BIO-Tester Relion REX640 Connector Test switches and indication LEDs Binary input/output module, BIO1002/1004 BIO1002/1004 BIO1002/ BIO1004 SPO1 SPO1 SPO2 SPO2 SPO3 SPO3 SPO4 SPO4 SPO5 SPO5 SPO6 SPO6_TCS SPO6 SPO7 SPO7 SPO8 SPO8_TCS...
  • Page 28 Section 4 2NGA000105 B BIO-Tester Relion® REX640 Follow the connector label when connecting the cables between BIO- Tester and the protection relay. GUID-0D4D6DFA-0ED5-4301-99C7-9E46305A094A V1 EN Figure 5: Earth lead connected to the earth screw 1 Connector labels 2 Earth lead BIO-Tester Relion®...

  • Page 29: Binary Inputs And Outputs

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 GUID-6E81BACE-4BEF-4C1E-B616-596C6CB1509F V1 EN Figure 6: Connecting protective earth lead to LHMI Binary inputs and outputs 4.4.1 Binary inputs The rated voltage of binary inputs is 24...250 V DC and the operating range is ±20% of the rated voltage.

  • Page 30: Binary Outputs

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 Binary input threshold voltage GUID-C685F10B-6B79-433C-B292-8AFB71CFE4B9 V1 EN Figure 7: Setting the binary input threshold voltage The parameter Input threshold voltage in REX640 is used to set the threshold level of the binary inputs. Input threshold voltage determines the voltage level for the activation of the inputs.

  • Page 31: Energizing Bio-Tester And Testing Binary Input And Output Operation

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 The contacts used for external signalling, recording and indicating, the signal outputs, need to adjust to smaller currents, but they can require a minimum current (burden) to ensure a guaranteed operation. The protection relay provides both power output and signal output contacts. To guarantee proper operation, the type of the contacts used are chosen based on the operating and reset time, continuous current rating, make and carry for short time, breaking rate and minimum connected burden.
  • Page 32 Section 4 2NGA000105 B BIO-Tester Relion® REX640 GUID-DFAA2EB2-19DF-4832-8C3B-C99C9C402001 V1 EN Figure 9: Main power switch and main’s wall plug connector Select the protection relay's operating voltage depending on the power supply module used in the relay. • If PSM1001 module is used, select 48 V DC. •...

  • Page 33: Selecting Ied Test Mode

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 Supply to the LHMI is always 48 V DC. 4.5.2 Selecting IED test mode The test mode can be activated using the LHMI. The Home button is flashing green at low frequency to indicate that the test mode is activated. By default, the test mode can only be changed from the LHMI.

  • Page 34: Testing Binary Inputs

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 paths within the menu structure, is provided in a collectively grouped and visualized format on the Testing and Commissioning pages found on the top bar menu. Some of the Testing and Commissioning pages require the relay to be set in test mode.
  • Page 35 Section 4 2NGA000105 B BIO-Tester Relion® REX640 The Error LED can be deactivated with the Reset button. It resets the detected BI fault situation and red colour Error LED turns off. It is important to take the needed corrective action on the detected faulty BIO modules of the relay under testing. Select the correct rated voltage by adjusting the potentiometer.
  • Page 36 Section 4 2NGA000105 B BIO-Tester Relion® REX640 BIO1001/1003 BIO1002/1004 SPO1 SPO2 SPO3 SPO4 SPO5 SPO6 SPO7 SPO8 GUID-CCD0C8F8-D81F-4D7C-9C54-4F8453903AA3 V1 EN Figure 14: Test switches and indication LEDs of BIO modules On the View I/O page, monitor the status of digital inputs and outputs. Tap the module on the page to open the module-specific page.

  • Page 37: Testing Binary Outputs

    Section 4 2NGA000105 B BIO-Tester Relion® REX640 GUID-D6A397FC-EF84-4C5D-BA21-AA7B909FCBED V1 EN Figure 15: View I/O page 4.5.5 Testing binary outputs BIO-Tester provides LED indication next to each binary output. When a binary output is activated from the LHMI, its LED lights up. This way, the status of activated binary outputs can be monitored on BIO-Tester.
  • Page 38 Section 4 2NGA000105 B BIO-Tester Relion® REX640 Table 8: IRF LED status Color Decsription Green Normal mode Activated The trip circuit supervision hardware includes constant current generator to provide trip circuit supervision (TCS) current and TCS input that can be connected to the TCS function with Application Configuration in PCM600.

  • Page 39: Online Testing With Pcm600

    After testing ensure that the Test mode is deactivated and the relay is set back to Normal mode. Online testing with PCM600 ® PCM600 is ABB’s common tool for configuring all Relion products. The REX640 relay's application configuration can be tested in the Work Online mode. BIO-Tester Relion® REX640...
  • Page 40 Section 4 2NGA000105 B BIO-Tester Relion® REX640 GUID-6F525407-6FDB-4518-9F41-E5651CAB69A8 V1 EN Figure 18: PCM600 Activate the Work Online mode while testing the configuration. GUID-57B245EA-D85D-456A-8AFC-551BFF43405D V1 EN Figure 19: Activating the Work Online mode Use BIO-Tester to simulate the binary signals. BIO-Tester Relion® REX640 User Manual...

  • Page 41: Section 5 Life Cycle Services

    Section 5 Life cycle services ABB provides product support for the users throughout the products’ entire life cycle by offering high-quality, global services. Products that have gone through systematic life cycle service operations are today efficient and long-lived products that have become smarter and more environmentally friendly in the last decades.

  • Page 43: Section 6 Technical Data

    Section 6 2NGA000105 B Technical data Section 6 Technical data GUID-BCEC83A6-A90B-4177-BE69-659F18E73C26 V1 EN Figure 20: Main dimensions A 1524 mm B 3810 mm C 2667 mm D 1722 mm E 3287 mm 4125 mm Table 11: Dimensions Description Value Width Interior 2667 mm Exterior...
  • Page 44 Section 6 2NGA000105 B Technical data Table 12: ® Degree of protection of BIO-Tester Relion REX640 Description Value Closed lid IP 67 Open lid IP 20 Table 13: Environmental conditions Description Value Application field Indoor use Operating temperature range +5...50°C (+41...122°F) Transport and storage temperature range -25...+70°C (-13...+158°F) Humidity range...
  • Page 45 Section 6 2NGA000105 B Technical data Table 16: Power cord Description Value Type Schuko to C13 Connector 1 Type F (CEE7/7) Connector 2 Type C13 (IEC 60320-1) Current rating Max. 10 A Voltage rating Max. 250 V Number of conductors Wire gauge 0.75 mm Length...

  • Page 47: Section 7 Glossary

    Section 7 2NGA000105 B Glossary Section 7 Glossary Binary input Binary input and output Human-machine interface Intelligent electronic device 1. Internal fault 2. Internal relay fault Liquid crystal polymer Light-emitting diode LHMI Local human-machine interface Normally closed Normally open 1. Personal computer 2.
  • Page 48 — ABB Distribution Solutions Electrification Service P.O. Box 503 FI-65101 VAASA, Finland Phone +358 10 22 11 www.abb.com/service www.abb.com/mediumvoltage © Copyright 2019 ABB. All rights reserved.

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