ABB SPACOM replaces REX615

6.2 CT/VT Wiring Special Handling

For the secondary wires of current transformers (CT) and voltage transformers (VT), independent push in terminals are provided in the modified connector kit due to the precision and polarity involved. During the bracket auxiliary wiring stage, the CT/VT wire is first connected to the push in terminal. When the connector is finally installed back into REX615, it is necessary to remove these CT/VT wires from the push in terminals and connect them to the corresponding positions of REX615's X120 terminals. This step is the only part that requires reference to the relay manual, but the amount of operation is very small.

6.3 Protection Grounding

The kit includes a 2-meter-long, 6mm ² yellow green grounding wire with M4 ring terminals at both ends. One end is fixed on the grounding stud of REX615, and the other end is connected to the grounding bar of the switchgear. Ensure reliable grounding of the relay to prevent electromagnetic interference and electric shock risks.

Engineering configuration: Mapping from SPACOM functionality to REX615

The renovation plan provides configuration support services. Users can request assistance from ABB engineers to complete the configuration when placing an order. The configuration work is based on ABB's PCM600 software and REX615's dedicated connectivity package.

7.1 Pre configuration plan

If a pre configured order (suffix C) is selected, ABB will configure REX615 according to the standard functionality of the original SPACOM relay. This includes:

The activation of protection functions (overcurrent, ground fault, phase to phase short circuit, etc.) corresponds to the set value range.

The mapping of binary input/output is consistent with the original SPACOM, ensuring that external circuits (such as trip coils, signal lights, pressure plates) do not need to be modified.

The logic of the alarm LED indicator is the same as that of the original relay.

After the pre configuration is completed, users only need to input specific setting values (such as overcurrent setting value, time constant) on site to put it into operation.

7.2 Custom Configuration Extension

Due to the fact that REX615 has more functions than SPACOM, users can use this renovation to add additional protection (such as negative sequence overcurrent, thermal overload, circuit breaker failure), measurement functions (harmonic analysis, power factor), or control logic (interlocking, automatic switching). These functions can be graphically configured through the Application Configuration tool of PCM600 and saved as templates for batch renovation projects.

7.3 Fixed value setting method

Fixed value parameters can be modified in the following two ways:

The local HMI: REX615 front panel comes with an LCD screen and buttons, suitable for small-scale on-site adjustments.

PCM600: Connect relays through Ethernet or serial port, upload setting value groups in batches, suitable for overall project debugging.

Implementation steps for on-site renovation (recommended process)

Based on the above technical preparations, it is recommended that the on-site team follow the following steps to carry out the renovation:

Power off isolation: Confirm that the switchgear has been powered off, the CT secondary side short circuit or open circuit protection is in place, and hang the grounding wire.

Record the original wiring: Take photos or mark each terminal wiring of the original SPACOM. Although the modified connectors have corresponding numbers, it is recommended to backup them.

Dismantling the old relay: Remove the panel fixing screws of SPACOM, unplug the back connector (if any), and take out the relay.

Installation bracket: Fix the installation bracket in the original relay position.

Wiring: Remove the secondary wire from the SPACOM terminal and reconnect it to the modified connector on the bracket according to the number on the connector. Connect the CT/VT wire to the push in terminal first.

Cutting hole: Use the cutting tool kit to enlarge the panel hole to the required size of REX615. If a cover plate is used, locate the hole according to the cover plate.

Remove bracket: After all wiring is completed, remove the pre connected modified connector from the bracket.

Install REX615: Insert the relay into the panel opening and secure it with screws. Then insert the modified connector into the back of REX615 (X100, X110, X130, etc.). Finally, connect the CT/VT wire from the push in terminal to the X120 terminal of REX615.

Grounding and inspection: Connect the grounding wire, check that all wiring is securely fastened and there are no omissions.

Power on and configuration: Close the DC power supply and perform relay self-test. If you choose pre configuration, enter the fixed value directly; If it is an empty configuration, download the configuration file through PCM600.

Functional testing: Use a relay protection tester to verify the protection action logic, trip outlet, and signal indication. Optional Relion BIO Tester for automated testing.

Resume operation: After confirming that there are no errors, remove the temporary grounding, restore the CT circuit, and put the switchgear into operation.