ABB 1MRK000167-GDr00 Retrofit Module for REX REC Series

ABB 1MRK000167-GDr00 Retrofit Module for REX REC Series

The ABB 1MRK000167-GDr00 (paired reference 1MRK000005-258) is a retrofit-compatible configuration and firmware module designed for ABB’s REX and REC series Intelligent Electronic Devices (IEDs). These protection relays are widely deployed in medium-voltage switchgear panels, substation automation systems, and industrial power distribution networks. As legacy REX 521, REX 522, REC 523, and REC 670 units approach end-of-life or require firmware-level upgrades, sourcing the correct module with verified compatibility becomes a critical step in any modernization or maintenance program.

For maintenance engineers managing aging protection relay infrastructure, the 1MRK000167-GDr00 module addresses a common retrofit challenge: updating or restoring the functional configuration of an IED without replacing the entire relay chassis. This approach significantly reduces downtime, preserves existing panel wiring, and avoids costly re-engineering of protection schemes. Procurement engineers benefit from a single-source supply with a confirmed 12-month warranty and pre-shipment functional testing, reducing the risk of receiving uncertified or counterfeit components.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

Replacing or upgrading a protection relay module in an active substation or industrial power panel requires careful pre-work to avoid protection gaps and unplanned outages. When integrating the 1MRK000167-GDr00 into an existing REX or REC series IED, engineers should begin by auditing the current firmware version and parameter set stored in the relay. ABB’s PCM600 (Protection and Control IED Manager) software is the standard tool for reading, backing up, and restoring IED configurations — ensuring that the existing protection logic, setting groups, and GOOSE messaging links are preserved through the module swap.

Beyond the relay module itself, a thorough retrofit plan should account for the surrounding control circuit. The REC 670 and REC 615 series, for example, rely on dedicated binary input/output modules — such as the BIO 210 or BIO 220 I/O expansion cards — to interface with external trip coils, circuit breaker auxiliary contacts, and alarm annunciators. These I/O modules should be inspected for contact wear and firmware compatibility before the main module is replaced. Similarly, the LDCM (Line Data Communication Module) or LDCM-E used for teleprotection signaling must be verified against the new firmware baseline to prevent communication link failures after the upgrade.

Power supply integrity is another critical checkpoint. ABB’s PSM 24/48 or PSM 110/220 auxiliary power supply modules, commonly installed in the same relay panel, should be load-tested to confirm they can sustain the IED’s inrush current during a cold restart following module replacement. Loose terminal connections on the DC supply rail — a frequent cause of relay maloperation after maintenance — should be re-torqued to manufacturer specifications.

For sites running IEC 61850-based substation automation, the engineering team must also verify that the SCL (Substation Configuration Language) files — specifically the ICD and CID files associated with the relay — are updated to reflect any changes introduced by the new module version. The station-level IEC 61850 gateway or RTU560 remote terminal unit may require a configuration reload to re-establish GOOSE and MMS data flows. HMI screens on the MicroSCADA Pro or third-party SCADA platforms should be validated post-upgrade to confirm that all signal mappings, alarm texts, and analog display values remain accurate.

Where the retrofit involves migrating from an older REX 521 to a newer REC 615 platform, engineers should also plan for terminal adapter wiring — the rear connector pinout differs between generations, and a wiring adapter or terminal block re-labeling exercise is typically required. Signal isolators may be needed on analog current and voltage inputs if the new relay’s input impedance differs from the legacy unit.

Downtime Control During System Migration

Minimizing protection outage windows is the primary operational constraint in any IED retrofit. The recommended approach for replacing the 1MRK000167-GDr00 module or performing a full IED swap in a live substation environment follows a structured sequence: first, coordinate with the system operator to obtain a planned outage window aligned with low-load periods; second, pre-configure the replacement IED or module offline using PCM600 with the backed-up parameter file; third, perform a bench test of the pre-configured unit against the original protection settings before installation.

During the physical swap, the existing CT and VT secondary wiring should be shorted and earthed before disconnection to prevent open-circuit CT hazards. Binary output wiring to trip relays, lockout relays (86 devices), and alarm circuits should be tagged and photographed before removal. After installation of the new module, a secondary injection test using a relay test set — such as the OMICRON CMC 356 or equivalent — should be performed to verify that all protection functions operate within the specified pickup and timing tolerances.

For sites where a full outage is not feasible, a staged migration approach can be used: the new IED is installed in parallel with the existing relay, with its outputs wired but not yet connected to the trip circuit. This allows the engineering team to verify communication links, SCADA data, and HMI displays under live conditions before the final cutover. This approach is particularly effective when migrating from legacy REX 521 units to modern REC 615 or REC 670 platforms, where the protection philosophy and setting methodology may differ significantly.

NINERMAS maintains ready stock of the 1MRK000167-GDr00 and associated REX/REC series components to support urgent retrofit projects. All units are functionally tested before shipment and covered by a 12-month warranty, with long-term supply commitments available for customers managing multi-site modernization programs.

Retrofit Support FAQ

Q1: Is the 1MRK000167-GDr00 a direct replacement for all REX and REC series IEDs?
The 1MRK000167-GDr00 is compatible with specific variants within the REX 521, REX 522, REC 523, REC 615, and REC 670 families. Compatibility depends on the relay’s hardware revision and existing firmware version. Please provide your relay’s nameplate data and current firmware version when inquiring, and our technical team will confirm the correct module variant and any required parameter migration steps.

Q2: What pre-shipment testing is performed on this module?
Every unit undergoes functional verification prior to dispatch, including power-on self-test, communication interface check, and where applicable, firmware version confirmation. A test report is available upon request. All units are shipped with a 12-month warranty covering manufacturing defects and functional failures under normal operating conditions.

Q3: Can NINERMAS support the full retrofit — including wiring adaptation and PCM600 configuration?
NINERMAS specializes in spare parts supply and pre-shipment testing. For on-site commissioning, wiring adaptation, and PCM600 parameter migration, we recommend engaging a certified ABB service partner or your in-house protection engineering team. We can provide technical documentation, firmware version guidance, and compatibility confirmation to support your engineering team’s retrofit planning.

Q4: What is the lead time and long-term supply availability?
The 1MRK000167-GDr00 is currently in stock and typically ships within 3–5 business days. For customers managing multi-site retrofit programs or requiring scheduled deliveries over 12–24 months, NINERMAS offers long-term supply agreements with reserved stock allocation. Contact our sales team to discuss volume pricing and delivery scheduling.