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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.
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ABB is not liable for any such damages and/or losses.
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(Low-voltage directive 2014/35/EU). 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.
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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.
Section 1 1MAC051065-MB K 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. Intended audience This manual addresses the personnel responsible for installing the product hardware.
Cyber security deployment guideline GUID-12DC16B2-2DC1-48DF-8734-0C8B7116124C V2 EN Figure 1: The intended use of documents during the product life cycle Product series- and product-specific manuals can be downloaded from the ABB Web site http://www.abb.com/relion. 1.3.2 Document revision history Document revision/date Product series version...
Content updated Download the latest documents from the ABB Web site http://www.abb.com/substationautomation. 1.3.3 Related documentation Product series- and product-specific manuals can be downloaded from the ABB Web site http://www.abb.com/substationautomation. Symbols and conventions 1.4.1 Symbols The electrical warning icon indicates the presence of a hazard which could result in electrical shock.
Section 1 1MAC051065-MB K Introduction The information icon alerts the reader of important facts and conditions. The tip icon indicates advice on, for example, how to design your project or how to use a certain function. Although warning hazards are related to personal injury, it is necessary to understand that under certain operational conditions, operation of damaged equipment may result in degraded process performance leading to personal injury or death.
Section 2 1MAC051065-MB K 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 the suppliers have been made according to the EU RoHS directive (2002/95/EC).
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Section 2 1MAC051065-MB K 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.
Section 3 1MAC051065-MB K 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.
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.
Section 4 1MAC051065-MB K 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.
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Section 4 1MAC051065-MB K Mounting Turn off the power. Open the seal on the front panel by removing the sealing wire and screw the sealing screw all the way in. Lift the handle to 90 degrees to release the latching mechanism. The unit is pushed about 0.28 inches (7 mm) out of the case and the connectors are separated.
Section 4 1MAC051065-MB K Mounting The signal connectors are left open when the plug-in unit is detached. 4.2.2 Installing plug-in unit The protection relay is constructed in a way that a plug-in unit with voltage- or current- measuring inputs can only be plugged into a corresponding case. This prevents fitting an unsuitable plug-in unit into a wrong case.
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Section 4 1MAC051065-MB K Mounting GUID-BCE48661-E92A-460E-8E72-4F0EA261FB9E V1 EN Figure 3: Serial number in the case 1 Rating label with serial number Forcing an unsuitable plug-in unit into the case can break both the plug-in unit and the case and may cause danger. Lift the handle 90 degrees and push the plug-in unit into the case.
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Section 4 1MAC051065-MB K Mounting GUID-45469A2C-56EF-4467-9F1C-9AD5D74536D8 V1 EN Figure 4: Installing a plug-in unit into the case 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 0.28 inches (7 mm) distance from the case.
Section 4 1MAC051065-MB K Mounting GUID-C1D10939-1A1B-4FE3-A3E2-72193FD7780F V1 EN Figure 5: Pushing the plug-in unit into the case A 7 mm Turn down the handle to push the plug-in unit into its final position in the case. The handle must be locked or sealed to secure the mechanical performance under any conditions caused by vibration, pressure, shock or bump, seismic activity or other equivalent circumstances.
Section 4 1MAC051065-MB K Mounting Open the sealing screw about nine turns. Thread a sealing wire through the holes in the sealing screw and the handle. GUID-10D2039E-4C58-4372-B0B2-EDFF0C2A451C V2 EN Figure 6: Sealing screw 1 Sealing screw 2 Sealing wire and seal 4.2.4 Securing handle The front panel of the protection relay has an integrated sealing screw.
Section 4 1MAC051065-MB K Mounting The protection relay packaging includes a plastic bag containing loose parts such as the spacer. GUID-8158C704-BD99-42EB-A495-6BD015C240CD V2 EN Figure 7: Sealing screw with spacer 1 Spacer 2 Sealing screw Mounting protection relay 4.3.1 Required tools •...
Section 4 1MAC051065-MB K Mounting 4.3.2 Flush mounting protection relay All the mounting elements are integrated in the protection relay. Requirements for installation: • Panel cut-out of 6.52 × 6.36 inches (165.5 × 161.5 mm) • Depth behind the panel 6.02 inches (153 mm) A protection relay equipped with optic connections requires a minimum depth of 7.09 inches (180 mm).
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Section 4 1MAC051065-MB K Mounting A070581 V4 EN Figure 8: Flush mounting a case into a panel cut-out A 6.52 inches (165.5 ±1 mm) 1 M5 fixing screws B 6.36 inches (161.5 ±1 mm) Tighten the M5 (T25) screws. The allowed range for the fixing screws’ tightening torque is 0.52...0.74 foot-pounds (0.7...1 Nm).
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Section 4 1MAC051065-MB K Mounting A070582 V4 EN Figure 9: Flush mounted case, tightening the M5 fixing 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.
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Section 4 1MAC051065-MB K Mounting A070584 V4 EN Figure 10: Flush mounted case and plug-in unit 6.97 inches (177 mm) 6.97 inches (177 mm) C 6.46 inches (164 mm) D 7.91 inches (201 mm) 6.02 inches (153 mm) 1.89 inches (48 mm) G 6.30 inches (160 mm) 615 series ANSI Installation Manual...
Section 4 1MAC051065-MB K Mounting 4.3.3 Semi-flush mounting protection relay A mounting kit is needed for semi-flush mounting the protection relay. In addition to the detailed mounting instructions, the mounting kit includes: • Raising frame • Gasket • Screws Requirements for installation: •...
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Section 4 1MAC051065-MB K Mounting A070589 V4 EN Figure 11: Mounting the raising frame A 6.83 inches (173.5 ±0.3 mm) 1 Panel B 6.52 inches (165.5 ±1 mm) 2 Raising frame C 6.36 inches (161.5 ±1 mm) 3 M4 screw D 5.24 inches (133 ±0.3 mm) E ∅...
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Section 4 1MAC051065-MB K Mounting Tighten the M5 screws. The allowed range for the fixing screws’ tightening torque is 0.52...0.74 foot-pounds (0.7...1 Nm). Attach the protective film back on the top side of the case. Install the plug-in unit into the case. The purpose of the protective film is to prevent debris falling inside the unit while installing electrical wiring.
Section 4 1MAC051065-MB K Mounting 4.3.4 Semi-flush mounting protection relay inclined A mounting kit is needed for semi-flush mounting the protection relay inclined. In addition to the detailed mounting instructions, the mounting kit includes: • Angle frame • Gasket • Screws Requirements for installation •...
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Section 4 1MAC051065-MB K Mounting A070586 V4 EN Figure 14: Mounting the angled frame 6.97 inches (177 ±0.3 mm) 6.57 inches (167 ±1 mm) C 7.99 inches (203 ±1 mm) D 1.59 inches (40.5 mm) 4.80 inches (122 mm) 1.59 inches (40.5 mm) G 0.22 inches (5.5 mm) H 7.48 inches (190 mm) Loosen the four M5 fixing screws in the case to fit the case into the angle frame.
Section 4 1MAC051065-MB K Mounting B 7 inches (177 mm), 4U Tighten the screws. The allowed range for the fixing screws’ tightening torque is 0.52...0.74 foot-pounds (0.7...1 Nm). 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.
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Section 4 1MAC051065-MB K Mounting • Wall mounting frame and rail parts • Back plate • Screws • Dimensions for screw holes Drill screw holes according to the dimensional drawing. Mount the wall mounting frame and the rails. Install the back plate. Loosen the four M5 fixing screws in the case to fit the case into the mounting frame.
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Section 4 1MAC051065-MB K Mounting The allowed range for the fixing screws’ tightening torque is 0.52...0.74 foot-pounds (0.7...1 Nm). 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.
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Section 4 1MAC051065-MB K Mounting When connecting the wires, a wall-mounted protection relay can be pulled out and turned 45° (or 90°) degrees downwards or upwards. • To release the protection relay for pulling it out, push the locks beside the mounting frame.
Section 4 1MAC051065-MB K Mounting Minimum of 1.97 inches (50 mm) space is needed above and below the frame for rotating. 4.3.7 Flush mounting protection relay with a protection cover A mounting kit is needed for flush mounting the protection relay with a protection cover. The mounting kit includes detailed mounting instructions and the protection cover.
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Section 4 1MAC051065-MB K Mounting GUID-D6A8507C-E074-4FA9-8CC9-6A4AF5E94892 V1 EN Figure 21: Mounting the protection cover 1 Protection cover Tighten the M5 (T25) screws. The allowed fixing screws’ tightening torque is 0.52...0.74 foot- pounds (0.7...1 Nm). Install the plug-in unit into the case. There is a protective film on the top side of the protection relay.
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Section 4 1MAC051065-MB K Mounting GUID-FA930762-64DE-4597-B0C8-5C5BEE78E6AA V1 EN Figure 22: Flush mounted case and a plug-in unit with the protection cover 6.97 inches (177 mm) 6.97 inches (177 mm) C 7.91 inches (201 mm) D 8.70 inches (221 mm) 6.69 inches (170 mm) 1.89 inches (48 mm) G 7.48 inches (190 mm) 615 series ANSI...
Section 4 1MAC051065-MB K Mounting 4.3.8 Mounting lens sensors for an arc flash detector system Arc flash detector is used to detect arc situations in air insulated metal-clad switchgear. The arc flash detector system determines where in the switchgear cubicle the optional lens sensors are installed.
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Section 4 1MAC051065-MB K Mounting A040182 V1 EN Figure 24: Mounting the lens sensor Make sure that the cable tie lies in the groove of the sensor to prevent it from blocking the light. 615 series ANSI Installation Manual...
Section 5 1MAC051065-MB K Connecting Section 5 Connecting Required tools Only use a screwdriver and insert bits for Phillips (PH 2) cross-recessed head screws when handling CT/VT terminals (X120) of screw-compression type. A071178 V2 EN Figure 25: Screwdriver for CT/VT terminals of screw-compression type A Max.
Section 5 1MAC051065-MB K Connecting • Open the screw-compression type terminals before inserting any wires. By default the terminals are closed at the time of delivery. • Connect each signal connector (X100 and X110) terminal with one 14 or 16 Gauge wire.
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Section 5 1MAC051065-MB K Connecting A070772-ANSI V1 EN Figure 27: The protective ground screw is located between connectors X100 and X110 The ground lead should be as short as possible but extra length is required for door mounting. Each protection relay must have its own ground lead connected to the ground circuit connector.
Section 5 1MAC051065-MB K Connecting Connecting analog signals A connection diagram is needed to connect the analog signals. When using the ring-lug type for CT/VT terminals, follow these steps. Open the lid that covers the ring-lug fixing screw with the tip of a screwdriver. Every fixing screw has its own lid.
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Section 5 1MAC051065-MB K Connecting AIM0003 X130 mA 1 RTD1 RTD2 60 - 210V V0B (V12B) 60 - 210V 60 - 210V 60 - 210V 60 - 210V GUID-2A958C72-4ACB-47E5-AAE8-D9AC7F37E61F V1 EN Figure 28: Example of AIM0003 card variant (5 V, 2 RTD + 1 mA channel) 615 series ANSI Installation Manual...
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Section 5 1MAC051065-MB K Connecting GUID-CC5FAADB-60C3-43EF-A172-7572FF85FC44-ANSI V1 EN Figure 29: Example of AIM0004 card variant (4 I + 3 V with 1/5 A IG channel) GUID-CAB8DAAA-8A15-4AF6-AFC7-CA232D253F3D-ANSI V1 EN Figure 30: Example of AIM0005 card variant (7 I with 1/5 A IG channel) 615 series ANSI Installation Manual...
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Section 5 1MAC051065-MB K Connecting GUID-7FC759CB-AFC5-4029-972A-BFC8677763F9-ANSI V1 EN Figure 31: Example of AIM0006 card variant (5 V) 615 series ANSI Installation Manual...
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Section 5 1MAC051065-MB K Connecting VA(2) VB(2) VC(2) VA(1) VB(1) VC(1) GUID-6E69AF2C-727D-460E-ACCD-8A6B456B61A7 V2 EN Figure 32: Example of AIM0007 card variant (3 BI+ 6 V) 615 series ANSI Installation Manual...
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Section 5 1MAC051065-MB K Connecting GUID-7473CEBA-AA9C-4F58-8091-F9717AEE7F3A-ANSI V1 EN Figure 33: Example of AIM0013 card variant (4 I + 3 V with 0.2/1 A IG channel) AIM0015 X120 1/5A IA(2) 1/5A IB(2) 1/5A IC(2) 1/5A IA(1) 1/5A IB(1) 1/5A IC(1) 0.2/1A GUID-51B26066-CD83-4B90-9F01-3C8279F89C8B V1 EN Figure 34: Example of AIM0015 card variant, (7 I with 0.2/1 A IG channel)
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Section 5 1MAC051065-MB K Connecting A071228-ANSI V1 EN Figure 35: Example of AIM0016 card variant (4 I with 1/5 A IG channel) 615 series ANSI Installation Manual...
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Section 5 1MAC051065-MB K Connecting GUID-A88841ED-8810-408E-B63D-55B49A39D814 V1 EN Figure 36: Example of AIM0017 card variant (4 I with 0.2/1 A IG channel) 615 series ANSI Installation Manual...
Section 5 1MAC051065-MB K Connecting SIM0002 X130 0.2/1A X131 X132 X133 GUID-8DBD0C9E-650D-4A19-A4B0-BABB03F643B8 V2 EN Figure 37: Example of SIM0002 card variant (4I+3V with 0.2/1 A IG channel) 5.4.2 Connecting RTD and mA inputs • Connect the wires from the transducers to the correct device according to the connection diagram.
Section 5 1MAC051065-MB K Connecting GUID-965E94AF-4E0F-48D3-A46D-72228BD3A7E6 V1 EN Figure 38: Example of RTD0001 card variant (6 RTD + 2 mA channel) 5.4.3 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.
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Section 5 1MAC051065-MB K Connecting The wire combination green/yellow should not be used as the drain wire has no protective function. 1.2. Install the drain wire. The wire can be installed, for example, with a Shield-Kon one-piece connector (Thomas & Betts). For detailed instructions, see the manufacturer's manual. 1.3.
Section 5 1MAC051065-MB K Connecting GUID-C323C8A4-E434-4DCA-8DA8-C0ED44BC693D V1 EN Figure 40: Connection of drain wires 1 Drain wires Connecting binary signals • 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 14 or 16 Gauge wire.
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Section 5 1MAC051065-MB K Connecting GUID-1BE0210A-D182-4354-916E-EBEAF8F2BD48 V1 EN Figure 41: Example of BIO0005 card variant (8 BI + 4 BO) 615 series ANSI Installation Manual...
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Section 5 1MAC051065-MB K Connecting GUID-ED2EA005-C136-4DB1-B71F-B828997A6EDB V1 EN Figure 42: Example of BIO0006 card variant (6 BI + 3 BO) 615 series ANSI Installation Manual...
Section 5 1MAC051065-MB K Connecting BIO0007 GUID-E2019CAF-ED78-46F4-830E-82EA7BF357D5 V3 EN Figure 43: Example of BIO0007 card variant (8 BI + 3 BO) Connecting power supply The permitted auxiliary voltage range of the protection relay is marked on top of the protection relay's LHMI. 615 series ANSI Installation Manual...
Section 5 1MAC051065-MB K Connecting • Connect the protection relay's auxiliary voltage to terminals X100-1 and X100-2. • Connect the positive lead to terminal X100-1. A070770-ANSI V1 EN Figure 44: Connecting auxiliary voltage Connecting communication • Before connecting communication, check that the HW module has the correct communication interfaces.
Section 5 1MAC051065-MB K Connecting Energizing protection relay Before connecting the auxiliary power, check that the protective film is removed from top of the protection relay. • Before connecting the auxiliary power, check that the terminal strip is wired and placed correctly.
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Connecting Green Normal LED starts to flash. LCD lights up and ABB logo is displayed. LCD test patterns are displayed and all the LEDs are lit for a short period. The measurements view is displayed. A steady green Ready LED indicates a successful start-up.
Protection relay 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. Checking protection relay information The protection relay information includes detailed information about the device, such as version and serial number.
Figure 46: Loosening the M5 screws Detach the case from the panel cut-out. Sending protection relay for repair • In case of product problems, contact the nearest ABB office or representative for consultation and instructions. 615 series ANSI Installation Manual...
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.
Section 7 1MAC051065-MB K Technical data Section 7 Technical data Case and HMI display variants 7.1.1 Front side of the protection relay A070704-ANSI V3 EN Figure 47: Large display 615 series ANSI Installation Manual...
Section 7 1MAC051065-MB K Technical data Table 4: Large display Rows in the view Characters per row Character size Small, mono-spaced (6 × 12 pixels) 1) Depending on the selected language 7.1.2 Rear side of the protection relay A070596-ANSI V1 EN Figure 48: Rear view of a protection relay with communication module 615 series ANSI...
Section 7 1MAC051065-MB K Technical data Dimensions GUID-6BA24DB4-935E-4B81-AEE6-FD8B7FC4140F V3 EN Figure 49: 615 series main dimensions A 6.97 inches (177 mm) B 6.97 inches (177 mm), 4U C 6.46 inches (164 mm) D 6.02 inches (153 mm) E 1.89 inches (48 mm) 6.30 inches (160 mm) 615 series ANSI Installation Manual...
Section 8 1MAC051065-MB K Accessories and ordering data Section 8 Accessories and ordering data Table 7: Mounting accessories Item Order number Semi-flush mounting kit 1MRS050696 Wall mounting kit 1MRS050697 Inclined semi-flush mounting kit 1MRS050831 19” rack mounting kit with cut out for one relay 1MRS050694 19”...