ABB REX640 Protection and Control Relay

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1. Overview

The ABB REX640 is a powerful all-in-one multi-application protection and control relay, part of ABB’s Relion® family. It is designed for advanced medium-voltage power generation and distribution scenarios, offering modularity, flexibility, and a long lifecycle.

2. Technical Specifications

• Communication & Protocols

  • Supports IEC 61850 (Edition 1 and Edition 2.1) ABB Group+2ABB Group+2

  • Redundancy support with HSR and PRP. ABB Group

  • Supports IEC 60870-5-104 protocol for SCADA integration. ABB Group

  • Secure communication for IEC 60870-5-104 and DNP3, compliant with IEC 62351 cybersecurity standard. ABB Group

  • Flexible Product Naming (FPN) to map relay data model to customer SCADA naming. ABB Group

  • Can receive simulated GOOSE messages for digital scheme testing. ABB Group

• Measurement / Sampling

  • Accepts up to four streams of sampled measured values (SMVs). ABB Group

  • Transmits via IEC 61850-9-2 LE.

• Hardware Modularity

  • Modular design with slot-based architecture: standard model has 7 slots, new narrow version has 5 slots. ABB Group

  • Detachable connectors for easier wiring in tight switchgear spaces. ABB Group

• Functional Features

  • High-Speed Transfer (HST): monitors main feeder and, upon failure, disconnects and swiftly transfers busbar load to alternate feeder. ABB Group

  • Synchronizer: supports synchronization for both generator and non-generator breakers. ABB Group

  • Arc Fault Detection: supports 4 supervised arc sensor inputs (loop or lens type). ABB Group

  • Trip Circuit Supervision: continuous monitoring of the trip circuit, open-circuit, and breaker control voltage. abb-drive.com

  • Self-supervision: internal self-check of hardware and software; any fault triggers alarm or blocks protection. abb-drive.com

  • Load Profile Recorder: can record up to 12 load quantities (current, voltage, power, PF, etc.) to non-volatile memory. abb-drive.com

• Certifications / Approvals

  • DNV type approval for marine / offshore installations. ABB Group

  • Cyber-security compliance (IEC 62351).

• Physical / Installation

  • Narrow hardware variant for space-constrained switchgear. ABB Group

  • Supports LHMI (local HMI) and SHMI (switchgear-level HMI) with application-driven HMI pages, including a 64-channel alarm annunciator (SACO). ABB Group

  • Using SHMI (instead of LHMI) can reduce relay cost by up to ~15%. ABB Group

• Upgradability

  • Firmware and hardware upgrades are supported to adapt to evolving protection needs. ABB Group

  • Supports BIO-Tester (binary I/O tester) for field testing and commissioning. ABB Group

3. Advantages & Features

• High Flexibility & Customization: Modular software and hardware let you tailor the relay exactly to your application. ABB Group

• Lifecycle Adaptability: From ordering, through commissioning, to long-term operation, REX640 can evolve as your protection needs change. ABB Group+2ABB Group+2

• Cost Efficiency: A single device supports multiple protection and control functions, reducing the need for multiple relays. ABB Group

• Digital Integration: Advanced communication support (IEC 61850, IEC 60870-5-104, DNP3) and secure protocols make it ideal for modern digital substations. ABB Group

• High Reliability: Features like high-speed transfer, trip circuit supervision, and self-supervision enhance system reliability. abb-drive.com

• User-Friendly HMI: LHMI/SHMI with pre-built application pages simplifies operation and reduces engineering effort. ABB Group

• Space Saving: Narrow 5-slot variant is ideal for switchgear with limited space. ABB Group

• Security & Compliance: Meets cybersecurity standards (IEC 62351) and has type approval for challenging environments.

4. Application Areas

• Utilities

  • Medium-voltage distribution substations

  • Feeder (line) protection

  • Busbar protection

• Power Generation

  • Conventional power plants (gas, coal)

  • Renewables (wind, solar)

  • Synchronization of generators

• Transformer Stations

  • Transformer differential & backup protection

  • On-Load Tap Changer (OLTC) automatic voltage regulation

• Industry

  • Petrochemical plants, mining, metals, pulp & paper, etc.

• Infrastructure

  • Data centers (critical loads requiring fast switching)

  • Marine/offshore (ships, platforms)

  • Transportation (rail, infrastructure substations)

5. Precautions / Usage Considerations

• Choose between the standard 7-slot or narrow 5-slot hardware variant based on available cabinet space. ABB Group

• Confirm the required communication protocols (e.g., IEC 61850, IEC 60870-5-104, DNP3) before ordering and configure accordingly.

• Use the BIO-Tester during commissioning to simulate binary I/O and verify correct wiring and logic. ABB Group

• Thoroughly design and test the High-Speed Transfer (HST) function to ensure reliable switching under fault conditions.

• Regularly monitor and test the trip circuit supervision channel to ensure the trip circuit remains intact. abb-drive.com

• Enable and configure cybersecurity features (e.g., IEC 62351) to protect against unauthorized access.

• When performing firmware or hardware upgrades, follow ABB’s recommended procedures, and maintain backup of configurations.

The structure and details of the product：

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