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The ABB REX521GHHPSH06G is a high-performance, multifunctional feeder protection and control relay designed for comprehensive protection of overhead lines and cable feeders in medium-voltage distribution networks. As a specialized variant within ABB's REX521 series, the REX521GHHPSH06G integrates protection, control, measurement, communication, monitoring, and arc-flash protection functions into a single platform based on the IEC 61850 standard .

The ABB REX521GHHPSH06G serves as primary protection for distribution feeders and backup protection for transformers and other substation equipment. The REX521GHHPSH06G is widely deployed in power substations, power plants, and industrial applications including cement, metallurgy, petrochemical, automotive, semiconductor, paper, and tobacco industries, as well as municipal infrastructure, airports, ports, and commercial facilities 

Model Number REX521GHHPSH06G

Series ABB REX 500 Series

Protection Type Feeder protection with arc-flash detection

Rated Current 1A/5A configurable (dual-rated CT inputs)

Rated Voltage 100-120V AC (VT secondary)

Frequency 50/60 Hz

Operating Temperature -20°C to +60°C (standard)

Storage Temperature -55°C to +85°C

Auxiliary Power 24-60V DC or 100-240V AC/DC

Display Large graphical LCD with single-line diagram

Mounting Flush panel mounting, withdrawable design

Communication IEC 61850-8-1, Modbus TCP/RTU, IEC 60870-5-103

Arc-Flash Inputs 3-channel light sensor inputs (optional)

Dimensions 177 × 265 × 230 mm (H × W × D)

Weight Approximately 4.1 kg

Enclosure Rating IP54 (front panel)

The REX521GHHPSH06G offers comprehensive protection capabilities specifically optimized for Chinese market requirements:

Overcurrent Protection: Directional and non-directional phase overcurrent (50/51) with multiple stages and time-current characteristics

Earth-Fault Protection: Directional/non-directional earth-fault protection (50N/51N), sensitive earth-fault protection, and high-speed earth-fault protection including intermittent earth-fault detection

Voltage Protection: Overvoltage (59), undervoltage (27), and residual overvoltage (59N/3U0) protection

Thermal Overload Protection (49): Real-time thermal modeling with exponential cooldown curves

Arc-Flash Protection: Three-channel arc-light detection integrated directly into the REX521GHHPSH06G for circuit breaker, cable, and busbar compartment protection—no separate arc-flash unit required

Auto-Reclosing: Flexible multi-shot auto-reclose function with pre-acceleration, post-acceleration, and manual close acceleration capabilities 

Configuration Steps

Software Setup: Install ABB CAP501 or CAP505 software tool for relay configuration, or use PCM600 for newer implementations. The REX521GHHPSH06G supports parameterization via front panel or remote communication

Communication Configuration: Configure IEC 61850-8-1 protocol for horizontal GOOSE communication between IEDs, or Modbus TCP/RTU for SCADA integration. The REX521GHHPSH06G implements IEC 61850 natively without protocol converters

Protection Settings: Access the hierarchical menu structure through the graphical LCD to configure overcurrent curves, earth-fault sensitivity, and auto-reclose sequences

Arc-Flash Setup: Connect light sensors to X13, X14, and X15 terminals for three-channel arc-flash protection. Configure trip logic for selective arc-fault detection

User Access Control: Configure four-level user access hierarchy—Browser, Operator, Engineer, and Administrator—with individual passwords for local panel, web access, and PCM600 tool

Daily Operation

Monitor the large graphical LCD displaying real-time single-line diagrams, measured values, and protection status

Use the REX521GHHPSH06G front panel pushbuttons for local breaker control with select-before-operate interlocking

Access remote monitoring via web interface or SCADA using IEC 61850 reporting and GOOSE messaging 

Pre-Installation Requirements

Mount the ABB REX521GHHPSH06G in a clean, dry switchgear compartment with ambient temperature between -20°C and +60°C

Ensure minimum clearances for ventilation and maintenance access

Verify that CT and VT ratios match the REX521GHHPSH06G configuration

Hardware Installation

Panel Cutout: Prepare panel cutout of 135 × 255 mm for flush mounting. The REX521GHHPSH06G uses withdrawable design with fixing brackets

CT/VT Connections: Connect current transformer secondaries (1A or 5A) and voltage transformer secondaries (100V) to rear terminals. Follow polarity markings strictly

Binary I/O Wiring: Connect binary inputs for status monitoring and binary outputs for tripping. The REX521GHHPSH06G supports high-speed outputs (HSPO) for fast arc-flash tripping

Arc-Flash Sensors: Connect optical light sensors to dedicated terminals (X13, X14, X15) for arc-flash detection. Use shielded cables to prevent false triggering

Communication Cabling: Connect Ethernet cables for IEC 61850 station bus or RS-485 for Modbus. Implement proper shielding and grounding

Pre-Energization Checks

Verify all terminal connections for tightness and correct polarity

Check insulation resistance >100 MΩ at 500V DC per IEC 60255-5

Confirm auxiliary voltage matches the REX521GHHPSH06G rating (24-60V DC or 100-240V AC/DC)

Validate arc-flash sensor functionality using test mode

Power-On Sequence: Apply auxiliary power and observe startup sequence: green Ready LED flashes, LCD displays ABB logo, self-test patterns execute, then measurements view appears

Parameter Configuration: Load protection settings using CAP505 or PCM600. Upload configuration via front optical port or Ethernet

Communication Testing:

Verify IEC 61850 GOOSE messaging with adjacent IEDs

Test Modbus register mapping with SCADA master

Validate horizontal communication for interlocking schemes

Protection Testing:

Perform secondary injection testing for overcurrent and earth-fault elements

Test arc-flash protection using light source simulation

Verify auto-reclose timing and acceleration logic

Functional Testing: Test trip and close operations, verify breaker failure protection, and confirm user access control levels

Routine Inspection (Quarterly)

Inspect the REX521GHHPSH06G front panel for dust accumulation; clean LCD display if necessary

Verify all LED indicators function correctly: Ready (green), Start (yellow), Trip (red), internal fault (flashing green)

Check communication cable connections and Ethernet link status

Review event logs for abnormal indications

Annual Maintenance

Perform secondary injection testing to verify protection settings and trip times

Test arc-flash detection system using calibrated light sources

Verify output contacts for proper operation

Update firmware to access latest features and cybersecurity patches

Long-Term Maintenance

5-Year Cycle: Replace electrolytic capacitors if operating in high-temperature environments

No Battery Required: Settings stored in non-volatile memory; no battery backup needed for configuration retention

Retrofit Consideration: Note that the REX521GHHPSH06G is a legacy product. ABB offers REX521RRP (Relay Retrofit Program) to replace aging REX521 units with modern 615 series relays using existing cutouts and wiring

Condition Monitoring

The ABB REX521GHHPSH06G provides continuous self-diagnostics including:

Circuit breaker condition monitoring (operation counters, contact wear)

CT/VT supervision (fuse failure, open circuit detection)

Trip circuit supervision (TCS) with broken wire detection

Arc-flash sensor health monitoring

Internal self-supervision with IRF (Internal Relay Fault) indication 

Four-Level Access Control: The REX521GHHPSH06G implements Browser, Operator, Engineer, and Administrator privilege levels with password protection for all access methods—local panel, web interface, and PCM600 tool

IEC 61850 Security: Supports secure authentication and encrypted communication per IEC 62351 standards

Arc-Flash Safety: Integrated arc-flash protection eliminates need for separate units, reducing wiring complexity and improving response time (<10ms typical)

Non-Volatile Memory: All settings retained without battery backup; event logs maintained during power outages

Retrofit Safety: When upgrading via REX521RRP, follow ABB's detailed installation manual to ensure proper cutout modification and wiring transfer 

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