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RRP Retrofit

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Relay Retrofit Program Product Guide
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Page 1: RRP Retrofit

Relay Retrofit ProgramProduct Guide

Page 2: RRP Retrofit

Contents

1. Description.....................................................................3

2. Existing relays and replacement IEDs.............................3

3. Engineering and testing tools for replacementIEDs...............................................................................4

4. Retrofit installation accessories.......................................6

5. Retrofit mounting accessories........................................6

6. Selection and ordering data............................................7

7. Accessories and ordering data.......................................8

8. Tools..............................................................................8

9. Documentation...............................................................9

10. Training.........................................................................9

11. References....................................................................9

12. Document revision history...........................................10

Disclaimer

The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any

errors that may appear in this document.

© Copyright 2014 ABB.

All rights reserved.

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.

1MRS757396 ARelay Retrofit Program

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1. DescriptionABB’s life cycle extension initiative is aimed at supporting thelife cycle management (LCM) of utility and industrial powerdistribution systems. One strategic consideration of the LCMof a power system is to extend the life cycle of a switchgearpanel through retrofit programs targeted at selectedswitchgear equipment. A timely executed retrofit program forselected devices will also allow the life cycle of the remainingswitchgear components to be fully utilized.

The Relay Retrofit program is based on using IntelligentElectronic Devices (IEDs) belonging to the Relion® productfamily as replacement devices, pre-designed installationaccessories and the dedicated IED Migration Support Tool.The carefully engineered program provides a controlled andrepeatable procedure for replacing existing protection relayswith modern IEDs. The various retrofit phases can beaccurately scheduled and timely executed to minimizedowntime of production or power distribution processes.

A number of ABB experts in power system protection havebeen involved in developing the program. The aim is to enablecontrolled and repeatable execution of relay retrofit projects.The dedicated tools and accessories simplify the workprocedures.

The Relay Retrofit program for replacing selected SPACOMrelays with Relion 615 IEDs consists of a set of tools andaccessories, documentation and training.

• IED Migration Support Tool• Relion Test Box RTB615 with masking plates• Test templates for replacement IEDs• Wire markings and wiring harnesses• Cutting tool• Documentation• Training

Table 1. Supported retrofit project phases

Retrofit project phases Dedicated tools and accessories

Engineering IED Migration Support ToolDocumentation

Installation Wire markings and wiring harnessCutting toolDocumentation

Testing Relion Test Box RTB615Test templates for replacement IEDsDocumentation

2. Existing relays and replacement IEDsThe selection of replacement IEDs for existing relays has beencarefully considered based on expert knowledge of previousproduct generations and recent developments in protectionand control technology. The selected replacement IEDs allbelong to the 615 series and their functionality correspondsto that of the existing relays. In addition, the 615 series offersthe possibility to expand the functionality of the powerprotection system further, for example by adding an optionalarc flash protection. The compact size of the IEDs minimizesthe need for additional space in a retrofit installation.

The globally recognized product series features nativesupport for the IEC 61850 standard for communication insubstations, Parallel Redundancy Protocol (PRP) and theHigh-availability Seamless Redundancy (HSR) protocolincluded. Also legacy protocols are widely supported.

The order code for a replacement IED includes a fixed (incapital letters) and a non-fixed (in hashes (#)) part. The non-fixed part can be freely selected as when ordering any 615series IED.

1MRS757396 ARelay Retrofit Program

Issued: 2014-04-15Revision: A

ABB 3

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Table 2. Existing relay types and replacement IEDs

Relay type to be retrofitted Replacement IED Order code1)

SPAJ 140 C REF615 standard configuration “C” #BFCAC##########1E

SPAJ 141 C REF615 standard configuration “C” #BFCAD##########1E

SPAJ 142 C REF615 standard configuration “C” #BFCAD##########1E

SPAM 150 C REM615 standard configuration “A” #BMAAC##########1E

#BMAAG##########1E2)

SPAU 130 C REU615 standard configuration “A” #BUAEA##########1E

1) The order code for a replacement IED includes a fixed (in capital letters) and a non-fixed (in hashes (#)) part. The non-fixed part can be freely selected as when ordering any 615 seriesIED.

2) With RTD inputs

3. Engineering and testing tools for replacement IEDs

IED Migration Support ToolIED Migration Support Tool (MST) processes the parametersof the existing relay and maps them to the selectedreplacement IED. It also defines the configuration of the IED.The result of the migration is therefore a fully parameterizedand configured replacement IED, with the exception ofcommunication configuration.

MST uses the information provided by the retrofit migrationpackages, which contain the existing relay-specific migrationrules. MST runs on PCM600 and is included in the retrofitconnectivity package together with the retrofit migrationpackages.

The parameters of the existing relay can be read from a file ormanually entered in the template. The method depends onthe capabilities of the existing relay.

PCM600

Retrofitconnectivity

package

PCM600MST

Relayparameters

file withSPAJ 140 C

Mapping of the existing

relay parameters

Migrationwith

necessary Q&A

Migrationsummary

report

Retrofitmigrationpackages

Retrofit IED New IEDREF615

Switchgear x

REF615, bay 1

REF615, bay 2

REF615, bay 3

REF615, bay 4

REF615, bay 5

Switchgear x

Bay 1

Bay 2

Bay 3

Bay 4

Bay 5

GUID-7B3190A7-F0A8-4B07-9BA4-9A0F40778AD9 V1 EN

Figure 1. Migration process from SPAJ 140 C to REF615 using PCM600 and MST

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GUID-D8882A54-6217-48EC-93B7-2123D7C0E6F8 V1 EN

Figure 2. Existing relay migration with MST

Relion Test Box RTB615RTB615 is a test box for the 615 series’ plug-in units.RTB615 provides auxiliary power for the plug-in unit and aninterface for a secondary test device, such as Omicron.RTB615 is equipped with an IED type-specific masking plateleaving only those terminals accessible which are needed for

testing the selected IED. [1]

The basic functionality of the replacement IED can be easilyverified in the project laboratory before entering the site. The

same functionality can be tested at the site using the RTB615test box, thus reducing the amount of tests to be carried outwhen the 615 series plug-in unit is inserted to its original case

and installed. [2]Using the XRIO-based test templates forreplacement IEDs together with RTB615 and the secondarytest device Omicron will considerably simplify and speed upthe testing.

IECA070901 V3 EN

S1

S2

X1

X2

X3

F1,F2

X100

X110

X120

X130

PE

+48 VDC OUT

+48 VDC IN

0 1

PCM600 &Omicron Test Universe

Omicron test device

Relion® test boxVoltage

Current

GUID-9D8D7515-95A9-457E-8072-2C47EB180D65 V1 EN

Figure 3. Test set-up for replacement IEDs

[1] 615 product variants where X130 card slot is in use are not currently supported.

[2] RTB615 can also be used for periodical testing, commissioning, demonstrations and training.

1MRS757396 ARelay Retrofit Program

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Test templates for replacement IEDsThe IED-specific replacement test templates include test rulesused by the Omicron Test Universe for testing replacementIEDs once the IED has been configured and parametersmigrated. The test templates specify the content and formatof the test report.

The test templates for replacement IEDs correspond to thefunctionality of the existing relays. Together with Omicron, thetemplates create a semi-automated testing procedure toensure that the replacement IEDs have the same functionalityas the existing relays. The templates receive the IED settingsfrom PCM600 in XRIO-based format.

PCM600

ParameterSetting tool

Exportparameters toXRIO format

Omicron TestUniverse

Testsequence

Testreport

Replacement IEDtest template“SPAJ 140 C to REF615”

GUID-933B1408-F94E-4B3C-8EC4-9AD801113208 V1 EN

Figure 4. Test workflow for replacement IEDs

4. Retrofit installation accessories

Wire markings and wiring harnessesWire markings are provided as complete sets. The setscorrespond to the terminal set-up of the existing relay and thereplacement IED. The press-on type markers are in whitecolor with a printed black text. Wire markings sets areavailable for all of the relays supported in the Relay Retrofitprogram.

A wiring harness is a type-specific wire set of an existing relayincluding marked wires for each terminal of the replacementIED. The wire set is delivered inside a grey protective plasticbraided sleeve. The length of the wire set is four meters andthe color of the wires is black. The wires have white printedwire markings at 15-cm intervals.

5. Retrofit mounting accessories

Cutting toolThe cutting tool is a dedicated handheld device for machiningthe existing panel cutout to the required size. The toolconsists of a battery-operated power unit and a cutting head.The cutting head consists of two parts, a punch and a die.The cutting tool can cut a panel metal sheet with a thicknessof a maximum of 2.5 mm.

The cutting tool enables a precise quality cut. Neither time-consuming measurements or additional panel surfaceprotection is needed. The enlargement of the existing panelcutout can be done in the most convenient direction. The toolis silent, fast and safe to use.

1MRS757396 ARelay Retrofit Program

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The cutting tool is delivered in a cutting tool kit. The tool kit isa plastic case containing the power unit, the SPACOM cuttinghead, two batteries and a battery charger.

GUID-4CD835EA-FD45-4BB9-AA2E-F3E98869DB1B V1 EN

Figure 5. Cutting tool

6. Selection and ordering dataWhen ordering replacement IEDs and accessories, pleasespecify the order code and quantity. The order code identifies

the IED type and consists of a string of letters and digitsgenerated from the IED's hardware and software modules.

Table 3. Order codes for replacement IEDs

Item Existing relay type Order code

REF615 standard configuration “C” SPAJ 140 C #BFCAC##########1E

REF615 standard configuration “C” SPAJ 141 C #BFCAD##########1E

REF615 standard configuration “C” SPAJ 142 C #BFCAD##########1E

REM615 standard configuration “A” SPAM 150 C #BMAAC##########1E

#BMAAG##########1E1)

REU615 standard configuration “A” SPAU 130 C #BUAEA##########1E

1) With RTD inputs

1MRS757396 ARelay Retrofit Program

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7. Accessories and ordering data

Table 4. Order code for retrofit installation accessories

Item Item description Order Code

SW Support for retrofit REF615 SW support for retrofit 2RCA031973

REM615 SW support for retrofit 2RCA031974

REU615 SW support for retrofit 2RCA031975

Wiring harnesses and wire marking sets

Wiring harnesses SPAJ 140 C, 141 C and 142 C 2RCA031581A0001

SPAM 150 C 2RCA031644A0001

SPAU 130 C 2RCA031792A0001

Wire markings SPAJ 140 C, 141 C and 142 C 2RCA031628P0001

SPAM 150 C 2RCA031762P0001

SPAU 130 C 2RCA031796P0001

Cutting tool kit1) SPACOM100 and 300 series 2RCA031784

Cutting tool accessories

Cutting tool power unit 2RCA032139

Cutting head for SPACOM 100 and 300 series 2RCA031786

Additional battery for the power unit 2RCA031785

Battery charger for a cutting tool 2RCA032140

SPACOM accessories CAP 505 communication cable for SPACOM100 and 300 series

SPA-ZP 5A3

1) The cutting tool kit includes a power unit, one cutting head, two batteries, a battery charger and a plastic case.

Table 5. RTB615 and accessories

Item Description Order Code

Relion Test Box RTB615 (includingmasking plates)

2RCA031791

RTB615 masking plate REF615 #BFCACAB#######1E and#BFCADAB#######1E

2RCA032077

RTB615 masking plate REM615 #BMAACAD#######1E 2RCA032078

8. Tools

Table 6. Tools

Configuration and setting tools Version

PCM600 2.6 or later

615 series IED connectivity package 4.1.1 or later

Retrofit connectivity package 1.0 or later

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9. Documentation

Table 7. Customer documentation

Material Content ID number

Relay Retrofit Program Application Manual Presents a technical approach toapplying the Relay Retrofit Programdeliverables to a retrofit project

1MRS757638 A

Relay Retrofit Program Migration Support ToolTutorial

Explains the role of MST and how touse it

1MRS757634 A

Relay Retrofit Program Testing Tutorial Presents how to use RTB615 andthe XRIO-based test templates forreplacement IEDs

1MRS757639 A

RTB615 Technical Manual Presents the features of RTB615 1MRS758004 A

Relay Retrofit Program Cutting Tool AssemblyGuide

Demonstrates step by step how toassembly the cutting tool

1MRS757994 A

Relay Retrofit Program Cutting Tool AssemblyGuide (video)

Demonstrates step by step how toassembly the cutting tool

1MRS757993 A

Relay Retrofit Program Cutting Tool SafetyGuide

Introduces how to safely use thecutting tool

1MRS757995 A

Relay Retrofit Program Cutting Tool OperatingGuide SPACOM 100

Demonstrates step by step how tooperate the SPACOM 100 series

1MRS757998 A

Relay Retrofit Program Cutting Tool OperatingGuide SPACOM 100 (video)

Demonstrates step by step how tooperate the SPACOM 100 series

1MRS758001 A

Table 8. Marketing documentation

Material Content ID number

Relay Retrofit Program General Presentation Presents a brief overview of programdeliverables

1MRS757635 A

10. TrainingThe Relay Retrofit program includes a one-day trainingcourse. The aim of the course is to introduce the tools andequipment used in the program. The course also providespractical information on how to effectively carry out relayretrofit projects.

The course code is P271. For additional information pleasevisit the training page and the program page.

11. ReferencesThe www.abb.com/substationautomation portal providesinformation on the entire range of distribution automationproducts and services.

On the program page, you will find the latest on the RelayRetrofit program.

The download area to the right contains the latest programdocumentation, such as the application manual and userguide videos.

The Retrofit Program tab contains additional program-relatedinformation.

1MRS757396 ARelay Retrofit Program

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12. Document revision history

Document revision/date Program version History

A/2014-04-15 1.0 First release

1MRS757396 ARelay Retrofit Program

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Contact us

ABB OyMedium Voltage ProductsP.O. Box 699FI-65101 VAASA, Finland

www.abb.com/service

www.abb.com/substationautomation

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