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615 Series: Installation Manual
615 Series: Installation Manual
615 series
Installation Manual
Document ID: 1MRS756375
Issued: 2013-12-20
Revision: L
Product version: 5.0
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.
http://www.abb.com/substationautomation
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 anti virus 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.
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 2004/108/EC) and concerning
electrical equipment for use within specified voltage limits (Low-voltage directive
2006/95/EC). This conformity is the result of tests conducted by ABB in
accordance with the product standards EN 50263 and 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.
Safety information
Dangerous voltages can occur on the connectors, even though the
auxiliary voltage has been disconnected.
When the plug-in unit has been detached from the case, do not
touch the inside of the case. The IED case internals may contain
high voltage potential and touching these may cause personal injury.
Table of contents
Section 1 Introduction.......................................................................5
This manual........................................................................................5
Intended audience..............................................................................5
Product documentation.......................................................................6
Product documentation set............................................................6
Document revision history.............................................................6
Related documentation..................................................................7
Symbols and conventions...................................................................7
Symbols.........................................................................................7
Document conventions..................................................................8
Section 4 Mounting.........................................................................13
Checking environmental conditions and mounting space................13
Detaching and installing the plug-in unit...........................................13
Detaching the plug-in unit............................................................13
Installing the plug-in unit..............................................................14
Sealing the plug-in unit................................................................17
Securing the handle.....................................................................18
Mounting the IED..............................................................................19
Required tools.............................................................................19
Flush mounting the IED...............................................................19
Semi-flush mounting the IED.......................................................23
Semi-flush mounting the IED inclined..........................................26
Rack mounting the IED................................................................28
Wall mounting the IED.................................................................30
Rack mounting the IED and test switch RTXP to a 19”
equipment frame..........................................................................33
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Table of contents
Section 5 Connecting.....................................................................53
Required tools..................................................................................53
Connecting wires..............................................................................53
Connecting ring-lug type wires....................................................54
Connecting protective earthing.........................................................54
Connecting analog signals...............................................................55
Connecting current and voltage inputs .......................................55
Connecting RTD and mA inputs..................................................61
Connecting IED with a test switch...............................................62
Connecting binary signals................................................................62
Connecting power supply.................................................................65
Connecting communication..............................................................66
Energizing the IED............................................................................67
2 615 series
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Table of contents
Section 9 Glossary.........................................................................79
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4
1MRS756375 L Section 1
Introduction
Section 1 Introduction
The installation manual contains instructions on how to install the IED. The
manual provides procedures for mechanical and electrical installation. The chapters
are organized in chronological order in which the IED should be installed.
This manual addresses the personnel responsible for installing the product hardware.
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Installation Manual
Section 1 1MRS756375 L
Introduction
Maintenance
Engineering
Planning &
Installation
Operation
Quick start guide purchase
Quick installation guide
Brochure
Product guide
Operation manual
Installation manual
Connection diagram
Engineering manual
Technical manual
Application manual c
Communication protocol manual c
IEC 61850 Engineering guide
Point list manual
GUID-12DC16B2-2DC1-48DF-8734-0C8B7116124C V1 EN
Figure 1: The intended use of documents during the product life cycle
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1MRS756375 L Section 1
Introduction
1.4.1 Symbols
The tip icon indicates advice on, for example, how to design your
project or how to use a certain function.
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Installation Manual
Section 1 1MRS756375 L
Introduction
• Abbreviations and acronyms in this manual are spelled out in the glossary. The
glossary also contains definitions of important terms.
• Push-button navigation in the LHMI menu structure is presented by using the
push-button icons.
To navigate between the options, use and .
• HMI menu paths are presented in bold.
Select Main menu/Settings.
• LHMI messages are shown in Courier font.
To save the changes in non-volatile memory, select Yes and press .
• 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".
• IED input/output messages and monitored data names are shown in Courier font.
When the function starts, the START output is set to TRUE.
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1MRS756375 L Section 2
Environmental aspects
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 IED.
The choice of materials and the suppliers have been made according to the EU
RoHS directive (2002/95/EC). This directive limits the use of hazardous substances
which are the following:
Operational reliability and long life time have been assured 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.
All parts used in this product are recyclable. When disposing of an IED or its parts
contact a local waste handler who is authorized and specialized in disposing
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Installation Manual
Section 2 1MRS756375 L
Environmental aspects
electronic waste. These handlers can sort the material by using dedicated sorting
processes and dispose of the product according to the local requirements.
1) Polycarbonate
2) Liquid crystal polymer
3) Polybutylene terephthalate
4) Polyamide
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Unpacking, inspecting and storing
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. Attach the protective film (supplied with the IED) on the top side of the unit
for the installation phase.
1. Locate the IED's order number from the label on top of the plug-in unit.
2. Compare the IED's order number with the ordering information to verify that
the received product is correct.
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Installation Manual
Section 3 1MRS756375 L
Unpacking, inspecting and storing
If the IED has damaged during transportation, make a claim against the transport
contractor, and notify the local ABB representative.
3.3 Storing
If the IED is stored before installation, 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.
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Mounting
Section 4 Mounting
The mechanical and electrical environmental conditions at the installation site must
be within the limits described in the technical manual.
Before detaching the plug-in unit from the case, the auxiliary
voltage must be disconnected.
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Section 4 1MRS756375 L
Mounting
A070577 V4 EN
Do not touch terminals inside the case after removing the plug-in
unit. Live terminals can be inside the case.
The signal connectors are left open when the plug-in unit is detached.
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Mounting
Before fitting the plug-in unit into the case, check that the unit and
the case have the same serial number.
1
GUID-BCE48661-E92A-460E-8E72-4F0EA261FB9E V1 EN
Forcing a non-suitable plug-in unit into the case can break both the
plug-in unit and the case and may cause danger.
1. Lift the handle 90 degrees and push the plug-in unit into the case.
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Mounting
GUID-45469A2C-56EF-4467-9F1C-9AD5D74536D8 V1 EN
2. Let the handle swing down about 45 degrees. At the same time, push the plug-
in unit into the case as far as it goes.
Plug-in unit stops at about 7 mm distance from the case.
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Mounting
A
GUID-C1D10939-1A1B-4FE3-A3E2-72193FD7780F V1 EN
A 7 mm
3. Turn down the handle to push the plug-in unit into its final position in the case.
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Mounting
1 2
GUID-10D2039E-4C58-4372-B0B2-EDFF0C2A451C V2 EN
1 Sealing screw
2 Sealing wire and seal
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Mounting
1 2
GUID-8158C704-BD99-42EB-A495-6BD015C240CD V2 EN
1 Spacer
2 Sealing screw
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Section 4 1MRS756375 L
Mounting
1. Loosen the four M5 fixing screws in the case to fit the case into the panel cut-
out.
2. Mount the case to the panel cut-out.
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1
A070581 V4 EN
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Mounting
A070582 V4 EN
22 615 series
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Mounting
D
A E F
B G
A070584 V4 EN
A 177 mm
B 177 mm
C 164 mm
D 201 mm
E 153 mm
F 48 mm
G 160 mm
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Mounting
• Raising frame
• Gasket
• Screws
1. Mount the raising frame into the panel cut-out with four M4 screws.
A
B E
C
D
1 2 3
A070589 V4 EN
2. Loosen the four M5 fixing screws in the case to fit the case to the raising frame.
3. Mount the case to the raising frame.
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Mounting
A070590 V4 EN
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Mounting
C
D E
A
F
B
A070591 V4 EN
A 186 mm
B 177 mm
C 201 mm
D 103 mm
E 98 mm
F 160 mm
Check the allowed minimum bending radius from the optical cable
manufacturer.
• Angle frame
• Gasket
• Screws
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Mounting
1. Mount the angle frame into the panel cut-out with four M4 screws.
A
B H
G
D
C
E
A070586 V4 EN
A 177 ±0.3 mm
B 167 ±1 mm
C 203 ±1 mm
D 40.5 mm
E 122 mm
F 40.5 mm
G ∅ 5.5 mm
H 190 mm
2. Loosen the four M5 fixing screws in the case to fit the case into the angle frame.
3. Mount the case to the angle frame.
With the angled frame, the IED can be mounted inclined downward to a 25°
angle.
4. Tighten the screws.
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Mounting
A
G
B F
C
D E
1 2 3 4 5
A071314 V4 EN
A 25 ° 1 M4 screws
B 221 mm 2 Gasket
C 9 mm 4 Case
D 107 mm 3 Angled frame
E 133 mm 5 Plug-in unit
F 230 mm
G 190 mm
• Mounting panel; the type of the mounting panel depends on the number of
mounted relays
• Screws
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Mounting
A070580 V3 EN
A 482.6 mm (19")
B 177 mm (4U)
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Section 4 1MRS756375 L
Mounting
A070579 V4 EN
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Mounting
A070593 V4 EN
A 430 mm
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Mounting
A070592 V4 EN
A 214 mm
B 177 mm
C 270 mm
When connecting the wires, a wall-mounted IED can be pulled out and turned 45°
(or 90°) degrees downwards or upwards.
• To release the IED for pulling it out, push the locks beside the mounting frame.
• To rotate the IED, loosen the knurled-head screws in the rails.
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Mounting
A070594 V4 EN
A 455 mm
4.3.7 Rack mounting the IED and test switch RTXP to a 19”
equipment frame
A mounting kit is needed for rack mounting the IED in a 19" equipment frame. In
addition to the detailed mounting instructions, the mounting kit includes:
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Section 4 1MRS756375 L
Mounting
• Mounting panel
• Metallic frame for mounting the RTXP 18 or 24 test switch to the panel
A071312 V3 EN
Figure 21: Mounting of the metallic frame for an RTXP 18 test switch
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Mounting
A070588 V4 EN
Figure 22: IED and the test switch RTXP 18 mounted into a 19" equipment panel
• Mounting bracket for the case and optionally with RTXP test switch
1. Install the mounting bracket into the combiflex equipment frame by using
tapping screws ST3.5x13 from rear side.
2. Loosen the four M5 fixing screws in the case to fit the case into the mounting
bracket.
3. Mount the case to the mounting bracket.
4. Tighten the M5 screws.
The allowed range for the fixing screws’ tightening torque is 0.7...1 Nm.
5. Install the plug-in unit into the case.
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Mounting
2 3
1
A070576 V4 EN
Figure 23: Mounting the IED into a 19" combiflex equipment frame
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Mounting
2 3
A070575 V4 EN
The arc protection system determines where in the switchgear cubicle the optional
lens sensors are installed.
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Mounting
C
A D
A040183 V2 EN
A 3.5 mm
B 10 mm
C ∅ 9.5 mm
D 19 mm
2. 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.
A040182 V1 EN
3. Make sure that the cable tie lies in the groove of the sensor to prevent it from
blocking the light.
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Mounting
1. Drill new screw holes (∅4.5 mm) to the panel according to the dimensional
drawing.
B E
C D C
GUID-C7CA77AA-74EA-40D2-B98E-84735BCADDA2 V1 EN
Figure 27: Screw hole and existing panel cut-out dimensions for
replacing a SP_J40 series IED
A 442 mm
B 183 mm
C 150 mm
D 152 mm
E 194 mm
2. Mount the installation plate to the existing panel cut-out with M5 thread
forming screws.
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Section 4 1MRS756375 L
Mounting
2
GUID-B5A98F9F-E10D-4F92-A1ED-73D9B7719916 V1 EN
1 Installation plate
2 Torx head screw M5x10
1. Make a new panel cut-out to the existing mounting panel according to the
dimensional drawing.
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Mounting
A A
B
C E
D 1
GUID-7D44F5DE-6452-455A-8076-2A67FD463CC7 V1 EN
Figure 29: New panel cut-out and screw hole dimensions for replacing
two SP_J3 series relays
2. Drill new screw holes (∅4.5 mm) to the panel according to the dimensional
drawing.
3. Mount the installation plate to the panel cut-out with M5 thread forming screws.
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Mounting
GUID-24CF4D5D-1EAE-487A-A1DE-557DF59658B0 V1 EN
1 Installation plate
2 Torx head screw M5x10
1. Mount the installation plate to the existing panel cut-out with M6 screws and
nuts.
Use the existing screw holes.
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B D
GUID-F1B5DA9A-05ED-419F-A795-6FD6E2A4CF95 V1 EN
Figure 31: Screw hole and existing panel cut-out dimensions for
replacing a SP_J3/J6 series relay
A 446 mm
B 196 mm
C 460 mm
D 114,5 mm
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Mounting
2
GUID-90BDC1BA-F671-4178-8136-8E8D9E56A7A3 V1 EN
Figure 32: Installation plates for replacing SP_J3/J6 relay in 19" rack
1 Installation plate
2 Torx head screw M6x20
3 Hexagon nut M6
1. Drill new screw holes (∅4.5 mm) to the panel according to the dimensional
drawing.
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Mounting
B D
C
GUID-57FA3F1B-C6EB-43A4-80E8-5D13CD08D9FF V1 EN
Figure 33: Screw hole and existing panel cut-out dimensions for a
SP_J6 series relay
A 186 ± 1 mm
B 186 ± 1 mm
C 196 mm
D 196 mm
2. Mount the installation plate to the existing panel cut-out with M5 thread
forming screws.
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Mounting
GUID-2B059F45-1287-4D8D-92A6-E6583B0ADAEB V1 EN
1 Installation plate
2 Torx head screw M5x10
1. Make a new panel cut-out to the existing mounting panel according to the
dimensional drawing.
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B D
C C
GUID-A309A8C4-5AB1-4859-91D2-CD8C4556BA7F V1 EN
Figure 35: Existing panel cut-out and screw hole dimensions for three
BBC S_ series relays
A 92 mm
B 234 mm
C 100 mm
D 250 mm
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Mounting
GUID-FEC7A3B8-7A65-4ACF-BDEB-DD8BB2BF5F57 V1 EN
Figure 36: New panel cut-out for replacing BBC S_ series relays
2. Mount the installation plate to the panel cut-out with M5 screws, nuts and
washers.
Use the existing screw holes.
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Mounting
4
GUID-71136C37-E662-426D-B378-9BF21ADFC51A V1 EN
1 Installation plate
2 Torx head screw M5x16
3 Hexagon nut M5
4 Spring washer
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Section 4 1MRS756375 L
Mounting
1. Make a new panel cut-out to the existing mounting panel according to the
dimensional drawing.
B D
C E
GUID-F20D587E-5E99-4593-B9EE-A1B125A95524 V1 EN
Figure 38: New panel cut-out and screw hole dimensions for replacing a
SPA 300 series relay
A Min. 186 mm
B 161.5 ± 1 mm
C 224 mm
D 176 mm
E 7 mm
2. Drill new screw holes (∅4.5 mm) to the panel according to the dimensional
drawing.
3. Mount the installation plate to the panel cut-out with M5 thread forming screws.
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Mounting
GUID-A8741360-1066-494D-9340-3DA0AF81E778 V1 EN
1 Installation plate
2 Torx head screw M5x10
For replacement kit ordering numbers, see the ordering number table.
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1MRS756375 L Section 5
Connecting
Section 5 Connecting
Only use a screwdriver and insert bits for Phillips (PH 1) cross-recessed head
screws (M3.5) when handling CT/VT terminals (X120) of screw-compression type.
A
B
A071178 V2 EN
A MAX ∅5.5 mm
B MAX ∅5 mm
A
A071180 V2 EN
A MIN 15 mm
All connections are made on the rear of the case. No soldering is needed.
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Section 5 1MRS756375 L
Connecting
The earth lead must be at least 6.0 mm2. If the earth lead is long,
the cross section of the wire must be increased.
1. Loosen the protective earth screw (T20) to connect a separate earth protection
lead.
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
A070772 V1 EN
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Connecting
Each IED must have its own earth lead connected to the earth
circuit connector.
1. Open the lid that covers the ring-lug fixing screw with the tip of a
screwdriver. Every fixing screw has its own lid.
2. Remove the fixing screw.
3. Slide the screw through the terminal lug and screw it back on.
4. Close the lid.
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Connecting
AIM0003
X130
1 + mA
mA 1
2 _
3 +
_ RTD1
4
5
6 + RTD2
7 _
8
60 -
9 210V
UoB (U12B)
10 N
60 -
11 210V
U1
12 N
60 -
13 210V
U2
14 N
60 -
15 210V
U3
16 N
60 -
17 210V
Uo
18 N
GUID-CBD8B42A-9715-4A67-92F1-0F47F8DF8F12 V1 EN
GUID-CC5FAADB-60C3-43EF-A172-7572FF85FC44 V2 EN
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Connecting
AIM0005
GUID-CAB8DAAA-8A15-4AF6-AFC7-CA232D253F3D V4 EN
AIM0006
GUID-7FC759CB-AFC5-4029-972A-BFC8677763F9 V4 EN
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Connecting
GUID-7473CEBA-AA9C-4F58-8091-F9717AEE7F3A V1 EN
AIM0016
A071228 V5 EN
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AIM0017
A071232 V5 EN
A071230 V4 EN
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Connecting
A071234 V4 EN
SIM0002
GUID-D69CC201-88FD-4A54-AB43-8B1C19C21049 V1 EN
Figure 52: Example of SIM0002 card variant (4I+3U with 0.2/1 A Io channel)
60 615 series
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Connecting
GUID-965E94AF-4E0F-48D3-A46D-72228BD3A7E6 V1 EN
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Connecting
• Connect the wires for the binary signals to the correct device according to the
connection diagram. Each terminal for binary input and output signal is
dimensioned for one 0.5...2.5 mm2 wire or for two 0.5...1.0 mm2 wires.
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GUID-1BE0210A-D182-4354-916E-EBEAF8F2BD48 V1 EN
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Connecting
GUID-ED2EA005-C136-4DB1-B71F-B828997A6EDB V1 EN
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Connecting
BIO0007
X110
1
BI 1
2
BI 2
3
BI 3
4
BI 4
5
6
BI 5
7
BI 6
8
BI 7
9
BI 8
10
11 N.C.
12 N.C.
13 N.C.
14 N.C.
15
HSO1
16
17 N.C.
18 N.C.
19
HSO2
20
21 N.C.
22 N.C.
23
HSO3
24
GUID-498E3D67-EE9D-4FEB-9554-30ADCDA4E0CC V1 EN
The permitted auxiliary voltage range of the IED is marked on top of the IED's
LHMI.
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Connecting
1
2
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
A070770 V1 EN
• Before connecting communication, check that the HW module has the correct
communication interfaces.
The communication module is located on the left side of the IED when
viewing the case from the rear.
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Connecting
• Before connecting the auxiliary power, check that the terminal strip is wired
and placed correctly.
• Remove the protective film from the top side of the unit. Check that there is no
debris visible in the ventilation holes.
GUID-97A2D4BA-29FC-4E2F-8C4D-81EE5E77CF79 V2 EN
During the startup, all the LEDs are lit for a short period.
If the IED detects a diagnostic error during startup, the green Ready LED flashes
and the internal fault code is displayed on the LCD.
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1MRS756375 L Section 6
Removing, repairing and exchanging
At some point of the product lifecycle, the IED is upgraded to a next generation
unit. When selecting the original product, already consider the upgrading and
extension possibilities that the specific product offers for its whole lifecycle.
IED-specific options can be found from Retrofit Solutions Database on the Internet
www.abb.com by following the links within ABB Service Guide or via ABB
Product Guide from the product specific Service & Support sheet.
The IED information includes detailed information about the device, such as
version and serial number. The IED information is shown on the display for a few
seconds when the device starts up. The same information is found also in the IED
menu.
The Site identifiers submenu contains information about the site where the IED
has been installed.
The System identifiers submenu contains the unique Technical key which cannot
be changed.
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Removing, repairing and exchanging
A070582 V4 EN
• To exchange the IED with another identical unit, remove the IED and install
the new one.
The exchangeable units can be found from the PartsOnLine system, see
www.abb.com/partsonline. Use of PartsOnLine requires user registration.
• To exchange an IED to a different unit, change the case and connect the wires.
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Technical data
IECA070904 V3 EN
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Technical data
IECA070901 V3 EN
72 615 series
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Technical data
A070596 V1 EN
Figure 61: Rear view of an 615 series IED with communication module
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Technical data
7.2 Dimensions
D
A E F
G
B
GUID-6BA24DB4-935E-4B81-AEE6-FD8B7FC4140F V3 EN
A 177 mm
B 177 mm (4U)
C 164 mm
D 201 mm
E 153 mm
F 48 mm
G 160 mm
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Technical data
Table 5: Dimensions
Description Value
Width frame 177 mm
case 164 mm
Height frame 177 mm (4U)
case 160 mm
Depth 201 mm (153 + 48 mm)
Weight complete IED 4.1 kg
plug-in unit only 2.1 kg
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1MRS756375 L Section 8
Accessories and ordering data
Table 7: Cables
Item Order number
Cable for optical sensors for arc protection 1.5 m 1MRS120534-1.5
Cable for optical sensors for arc protection 3.0 m 1MRS120534-3.0
Cable for optical sensors for arc protection 5.0 m 1MRS120534-5.0
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1MRS756375 L Section 9
Glossary
Section 9 Glossary
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Contact us
www.abb.com/substationautomation