ABB REF542plus Protection Relays

REF542 plus

Bay Protection and Control Unit

3

Table of Contents

1 General 4

2 Functions 8

2.1 Configuration 6

2.2 Operation 6

2.2.1 LCD display 7

2.2.2 Status Indication 8

2.2.2.1 Operational status 8

2.2.2.2 Communication status 8

2.2.2.3 Alarm indication 8

2.2.2.4 Interlocking status 8

2.2.3 LED Indication 8

2.2.4 Bar displays 8

2.2.5 Control push buttons 8

2.2.6 Electronic key 8

2.3 Measurement 9

2.3.1 Values measured directly 9

2.3.2 Calculated values 9

2.3.3 Other values 9

2.4 Protection 9

2.5 Control 10

2.6 Event recording 10

2.7 Fault recording 11

2.8 Real time clock 11

2.9 Process interface 12

2.9.1 Analog inputs 12

2.9.2 Binary inputs and outputs 13

3 Diagnosis and monitoring 13

4 Analog output 13

5 Communication 14

6 Housing 15

7 Mechanical design 157.1 REF542 plus

standard case version 15

7.2 REF542 pluswide case version 15

7.3 Analog inputs 15

8 List of theprotection functions 16

9 Technical data 189.1 Analog input channels 18

9.1.1 With currentand voltage transformer 18

9.1.2 With currentand voltage sensor 18

9.2 Binary inputs and outputs 18

9.2.1 With mechanical relays(BIO 3) 18

9.2.2 With static outputs 19

9.3 Interface 19

9.3.1 HMI Control Unit 19

9.3.2 Central Unit 19

9.4 Analog output board(optional) 20

9.5 Communication (optional) 20

9.6 Power supply 20



9.7 Temperature range 20

9.8 Degree of protection 20



10 Type test 2010.1 EMC 20

10.2 Insulation 21

10.3 Mechanical robustness 21

10.4 Climatic conditions 21

11 Connection Diagram 2111.1 Connector Plate 21

11.2 HMI Control Unit 21

11.3 REF542 plus withmechanical binary I/O 22

11.4 REF542 plus withsolid state binary I/O 23

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REF542 plus. Bay Protection and Control unit

1 General

The REF542 plus is a SwitchbayProtection and Control Unit andis the further development ofthe former REF542 multi-functional unit. Like its prede-cessor, it features the followingfunctions:

Protection

Measurement

Control

Monitoring

All functions mentioned aboveand also power quality functionsare integrated in a programmableenvironment. The exceptionalflexibility and scalability ofthese new generation devicesmake it possible to integrate allthe secondary functions in aunique device, leading to a

The REF542 plus is based on areal-time microprocessor system.The measurement and protectionfunctions are executed by aDigital Signal Processor (DSP)and the Micro Controller (MC)is responsible for the controlfunctions. Due to this task separa-tion there is no impact betweenthe start and the trip behavior of theprotection scheme implementedif the control scheme is modified.The Communication Processor(CP) is needed for adaptation toa station automation system.A block diagram of the REF542plus is shown in figure 3.

Figure 1: REF542 plusinstalled in

gas-insulatedswitchgears (GIS)

Figure 2: REF542 plusinstalled in anair -insulatedswitchgear (AIS)

smart and clean solution wherethe traditional approach isineffective and expensive.The following figures showexamples of the installation ofthe REF542 plus in severalswitchgears for the switchbay.

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The REF542 plus, as shown infigure 3, consists of two parts,a Central Unit and a separateHuman Machine Interface(HMI) as the Control Unit.The Central Unit contains thepower supply, processor andanalog and binary Input andOutput (I/O) modules, as wellas optional modules for supple-mentary functions.The HMI Control Unit is astand-alone unit with its ownpower supply. It can be installedon the Low Voltage (LV) com-partment door or in a dedicatedcompartment close to theCentral Unit. The HMI is nor-mally used to set the protectionparameters and to locallyoperate the switching devicesin the switchbay. The HMI is

Figure 3: Block diagramof REF542 plus

Figure 4: Mounting of the CentralUnit in the LV compartment and

the HMI on the door

connected to the Central Unitby a shielded, isolated twistedpair according to the RS485standard interface. Figure 4shows an installation of theCentral Unit and the HMIControl Unit in the LV compart-ment of a switchboard for theswitchbay.

The HMI Control Unit, asshown in figure 5, features aback-illuminated Liquid CrystalDisplay (LCD), eight pushbuttons, several LEDs and anelectronic key interface. Thelanguage of the display can beselected via the related configu-ration software tool, which isalso used to define the protec-tion and the control scheme.

Figure 5: View of the HMI Control Unit

HMIHuman Machine

Interfeace

Interbay bus

CPCommunication

Processor

Analoginputs

DSPProtection andMeasurement

Processor

MCControl andCommandProcessor

BinaryInputs

BinaryOutputs

AnalogOutputs

Central unit

Control unit

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The left half of the LCD displayis reserved for the Single Linediagram. The right half is usedto display the appropriate menuor submenu as determined bythe user. Two different electronickeys with different access rightsare available. Each of the keysare programmed to permiteither:

the parameterization of theprotection functions

the mode selection of thecontrol functions

Three freely programmable LEDbars have been provided on thefront of the HMI Control Unit.Each LED bar consists of tengreen and two red LEDs and isuser configurable to display anymeasurement value required.The red LEDs are used to indi-cate values above the ratedvalue.

The functions of the REF542plus can be tailored to therequirements of the system byapplication of a user-specificconfiguration. The user-specificconfiguration is loaded duringcommissioning. For that purposethe configuration computer,normally a personal computer(notebook) running WindowsNT, is connected to the opticalinterface on the front side ofthe HMI Control Unit.The interface of the multi-functional unit REF542 plus tothe Medium Voltage (MV)system as the primaryprocess is as follows:

Analog inputs to measurecurrent and voltage signalsfrom conventional currentand voltage measurementtransformers or from currentand voltage measurementsensors

Binary inputs with opticalcouplers for the galvanicseparation of the externalsignals to be processed

Binary outputs with conven-tional mechanical relays orstatic outputs for the controlof switching devices in thecompartment of the switch-board

Optional four channelanalog outputs 0 to 20mA or4 to 20 mA

Optional connection to ABBor third party station auto-mation system.

2 FunctionsThe REF542plus SwitchbayProtection and Control Unitintegrates all of the secondaryfunctions in a single unit. Thismultifunctional unit also fea-tures a self-monitoring function.All functions are designed asfreely configurable softwaremodules. Therefore, a widerange of operation require-ments in MV stations can bemet without any problems.The versatility of the softwaremakes it possible to use theREF542 plus on every switch-board irrespective of thespecific application required.

2.1 ConfigurationEach application for protectionand control can easily beconfigured by software functionmodules, which make arbitrarydefinition of the followingfeatures as part of the secondarysystem possible: LED’s (assignment and

colors) for local indication Single Line diagram to show

the status of the switchingdevices

Protection schemes asrequired

Control schemes as needed Interlocking schemes Automation sequences


All functions in the switchbaycan be specified in collaborationwith ABB. The result of theconfiguration is saved anddelivered together with theswitchboard to the users.The configuration softwareis also provided to the user tomake available the full potentialof the multifunctional unit tothe field operators. Thanksto a „Functional block“ Pro-gramming Language (FUPLA)the REF542 plus SwitchbayProtection and Control Unitoffers engineers, especiallythose who are not softwareexperts, the opportunity ofeasily updating the operationand handling of the switchbayusing a personal computer.

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2.2 OperationA wide range of functions can generally be controlled and opera-ted using the simple, user-friendly interface on the HMI ControlUnit. This user-friendly interface is shown in the following figure.

The HMI consists of the following features:

With the REF542 plus the userhas the benefit of a secondarysystem that is fully integrated ina true programmable controller.This flexibility is very advantage-ous for defining controlfunctions for automationsequences, which can, forexample, include theinterlok-king of the switching devices,blocking the release of specificprotection functions, as wellas starting switching sequences.The new REF542 plus multi-functional unit provides a widerange of logical functions sothat each required controlschemes can be configured.The range of logical functionsincludes: AND logic gate NAND logic gate OR logic gate NOR logic gate XOR logic gate Bistable and

monostable flip flop Counters Timers Pulse generators Memories

Similar to the free definitionof the control scheme, eachrequired protection scheme canbe configured by the combinati-on of the available protectionfunction modules. For example,the following protectionfunctions are foreseen: Definite time overcurrent

protection Inverse time overcurrent

protection Directional overcurrent

protection

Under- respectivelyovervoltage protection

Distance protection Differential protection for

transformer and motor Thermal protection for cable,

transformer and motor Reverse power protection Synchronism check

Note

The specific softwareconfiguration of the requiredprotection scheme can only becarried out in-house at ABB.

The protection scheme parameterscan be changed via the HMIControl Unit without using apersonal computer. But userscan additionally perform certainfunctions on site by means of apersonal computer (notebook),which is connected to theoptical interface on the front ofthe HMI Control Unit and theprovided configuration software.These functions include: Parameterization of the

protection scheme, Read-out of the current

measurement values, Read-out of the status of the

binary inputs and outputs, Read-out of the fault

recorder and Viewing of the FUPLA

logic I/O states

Figure 6: HMI as Control Unit

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2.2.1 LCD displayThe back-illuminated LCDdisplay of the HMI providesa graphical display of the swit-ching devices in the switchbaycontrolled by the REF542 plus.The intensity and the durationof the illumination can be setas required. The Single Linediagram shows the currentstatus of all the switchingdevices. The right half of theLCD display is for plain text,such as measurement values,main menu and submenusdescriptions, protectionsignals and event recording.

On the LCD display, the follo-wing can be shown: Up to eight switching device

icons (when the binaryI/O boards with mechanicalrelays are used, a maximumof seven switching devicescan be controlled)

Various icons for motors,transformers, sensors,transducers

A maximum of 40 individuallines.

2.2.2 Status IndicationFour system LEDs indicate thestatus of the REF542 plus.These LEDs are:

2.2.2.1 Operational statusOn the HMI front panel, theoperational status is called‚Ready‘ and is displayed by agreen LED. The unit is notoperational if this LED is off,and this occurs for exampleduring the downloading of theconfiguration for the operationof the switchbay or if a fault isdetected in the Central Unit.

2.2.2.2 CommunicationstatusOn the HMI front panel, thiscommunication status is called‚Network Communication‘.If the REF542 plus is to beconnected to a station auto-mation system, an extensionwith an appropriate communi-cations board is required.In this case a green LED isused to indicate the correctoperational status of theoptional board. The LED colorchanges to red if a communica-tion failure has occurred.

2.2.2.3 Alarm indicationSeveral arbitrary alarm con-ditions can be defined andconfigured by the user.If one of these conditions isfulfilled, the red LED will be on.

2.2.2.4 Interlocking statusThe LED is green if no interlok-king conditions have beenviolated. In case of a switchingaction, which violates theinterlock conditions such asswitching a disconnector intheclosed condition of theCircuit Breaker (CB), the colorwill change temporarily to red.

2.2.3 LED IndicationEight freely programmable,three color LED’s are providedfor local indication. Thenumber of LED display optionscan be quadrupled through themenu structure. As a result,a total of 32 indication optionsare available for status indicationregarding protection, control,monitoring and supervisionfunctions.

2.2.4 Bar displaysThree freely programmable LEDbars are provided for showingthe measurement values.The LED bars are used to displayarbitrary measurement values asrequired. Each bar consists often green and two red LEDs.The nominal values of each LEDbar, which corresponds to theten green LEDs are defined bythe configuration software.If the measurement values arehigher than the rated values,the red LEDs will lightindicating an overload situation.

2.2.5 Control push buttonsThe control push buttons areused for operation of theswitching devices during localcontrol. A total of eight pushbuttons are available, four forcommanding the primaryequipment and four forbrowsing the display.Also configured is a situationwhereby an emergency pushbutton pressed simultaneouslywith a normal Circuit Breaker(CB) push button opens the CBin the event of an emergency.

2.2.6 Electronic keyTwo different electronic keysare provided. One key can onlybe used for the parameterizationof the protection scheme.The other one is for the selectionof the control modes which canbe switched off or in one of thethree other modes provided:local, remote or local/remotecontrol mode. By using thesetwo keys a certain separationbetween protection and controloperation can be achieved.If required a general key thatpermits access to both modes isprovided. The sensor for re-

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cognizing which electronic keyhas been used is located on thefront panel of the HMI ControlUnit.

2.3 MeasurementThe REF542 plus SwitchbayProtection and Control Unitconsists of eight analog inputsfor measuring current andvoltage signals. These areorganized into four groups withtwo groups of three inputseach, one input for current orvoltage measurement regardingto earth faults detection orvoltage measurement forsynchronism checking, and afurther input only for measure-ment purposes. Every groupcan measure voltage or current.As well as six-phase voltagemeasurement for the applicationin a measurement switchbay,six phase current measurementsfor transformer differentialprotection is also possible.The most common configurati-on uses three current and threevoltage inputs and one earthfault current input. All valuesare shown on the display asprimary values. The valuesregistered over an extendedtime period, for example ener-gy, number of CB operations,maximum and measurementvalues are permanently saved.Even after power interruptionsthis data is still available. Usingthis common configuration, thefollowing measured values aredisplayed:

2.3.1 Values measureddirectly Line currents, three phases Phase voltages, three phases Earth current or residual

voltage FrequencyFrom the above measuredquantities the following valuescan be calculated:

2.3.2 Calculated values Line voltages, three phases Earth current or residual

voltage Average value/maximum

value current, three-phase(determined over severalminutes)

Apparent, active and reactivepower

Power factor Active and reactive energyMoreover, the following quanti-ties for monitoring purposescan be provided:

2.3.3 Other values Operating hours Switching cycles Total switched currents Metering pulses from an

external metering device(up to 10)

2.4 ProtectionThe REF542 plus offers a widerange of functions for protection.As has previously been mentio-ned, a wide range of protectionschemes for the protection ofseveral system components canbe configured. The availableprotection functions can becombined together to form aprotection scheme as required.But the combination possibilities

are limited by the computingcapacity of the DSP, as eachprotection function increasesthe DSP load. The maximumload applied by all of theprotection functions may notexceed the 100% DSP computingcapacity. Figure 7 shows anexample of a configuredprotection scheme.

Figure 7: FUPLAprotection scheme

BLFAULTRECORDER

OVERFLOW

(14) START IDMT>>

(18) START I>>>

(14) START IDMT>>

(18) START I>>>

(20) TRIP IDMT>>>

(15)(16)

(17)

(19) TRIP IDMT>>

(11)(12)

(13)

(21)

(14) START IDMT>>

(18) START I>>>

START

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2.5 ControlThe REF542 plus permits convenient localoperation with full interlocking againstswitching errors. The switch position of thevarious switching devices in the switchbaycan be shown on the LCD display of theHMI Control Unit. If local control mode isselected, switching actions can be inputlocally using the control push buttons onthe HMI Control Unit. Switching to anothercontrol mode can only be achieved byusing the correct electronic key.In remote control mode, only switchingactions via a remote control unit like astation automation system is feasible. Aspecial control mode, Local and Remote, isprovided for users who want to performsimultaneous Local and Remote switching.Interlocking between the switchbaysconnected to the same bus bar system canalso be taken into account. This requiresthe availability of status information of the

switching devices to and fromother switchbays. The statusinformation must be providedeither by a conventional, hardwired ring bus system or by the

more sophisticated ABB station-automation system. Figure 8shows an example of aconfigured control scheme ofthe Circuit Breaker.

2.6 Event recordingThe last 50 recorded events canbe shown locally on the LCDdisplay of the HMI unit.The events are mostly related toprotection activities. As well asdisplaying the event name,additional information aboutthe event, time, date and theRMS value of the short circuitcurrent switched off by theCircuit Breaker are provided.Each event is stamped with thetime and date. The time is takenfrom the internal clock on theREF542 plus, which can besynchronized by the GPS clockor the station automation system.In the next figure, a list ofrecorded events is shown.

Figure 8: FUPLA control scheme

Figure 9: List of events on the LCD of the HMI


(25) INTERLOCKING OPEN

(31) INTERLOCKING CLOSE

CIRCUIT BREAKER

(34) CB DEF OPENED(35) CB DEF CLOSED

(34) RELEASE

(33) CB OPEN COMMAND

(32) CB CLOSE COMMAND

(22) RELEASE

(26)

(29)

(23) KEY REMOTE

(30) CB CLOSE

(23) KEY REMOTE

(24) CB OPEN

(28)

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2.7 Fault recordingThe multifunctional unitREF542 plus also consists of afault recorder module, whichrecord and encode analog andbinary data. The number of datachannels recorded dependson the initial configuration.Up to seven signals of the analogchannels and 32 binary signalscan be recorded. The analoginput signals are recorded witha sampling rate of 1.2 kHz for aperiod of at least 1-second andfor a maximum of 5 seconds.The recording time is a combina-tion of pre- and post fault time.The records are saved using atypical ring buffer process, i.e.the oldest fault record is alwaysoverwritten with a new one.The number of saved fault recordsdepends on the record time.For example, a maximum of5 fault records can be savedwith a recording time of 1s.The fault records can be exportedand converted by the configura-tion software. The transfer of thefault records via the interbay bususing the foreseen communicationprotocols is also possible. Figure10 shows a record of a crosscountry fault in an earth faultcompensated MV system startingwith the earth fault.

2.8 Real time clockThe internal clock is not buffered by batteries but bya special capacitor. In case of DC power supply failure,the stored electrical energy in the capacitor ensurescontinued operation of the internal clock for at leastanother two hours. The date and time of the clockcan be set via the HMI Control Unit.If required, as shown in the next figure, the clockcan be synchronized by an external master clock(e.g. GPS) through a standard IRIG B interface. Usingthis, a real time accuracy of up to 1ms can be achieved.

NoteThe standard IRIG B - Interface will be available fromthird quarter 2001!

Figure 10: Record of a cross country fault in an MV system

In case of connection to a station automationsystem, an ABB or a third party automationsystem, the synchronization of theREF542 plus internal clock to the systemclock is performed by the correspondingcommunication bus.

xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx

REF542 plus REF542 plus REF542 plus

GPS Clock

RER111 Starcoupler

1.25 MB/s LON LAG 1.4 (optical interface)

Figure 11: Synchronization ofthe internal clock by a GPSmaster clock

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The current sensor is based onthe principle of the Rogowskicoil and consists of a singleair-cored coil. Due to the lackof an iron core, the saturationeffects of conventional currenttransformers do not existanymore. Current sensors arethus well suited for the deploy-ment of distance protection anddifferential protection functions.The current sensor measuresthe current value using a voltagesignal that is proportional to thederivative of the primary currentbeing measured. The numericalintegration of the signal isperformed using the DSP in theREF542 plus unit. The current

Thanks to their small dimensions,both current and voltagesensors can be integratedas a combined sensor in asingle resin unit.A capacitive divider is incorpo-rated in the combined sensorto provide a power supply forpower on indicator lamps.The output signals of the currentand voltage sensors are connecteddirectly to the Central Unit ofthe REF542 plus. In the case of

2.9 Process interfaceTo carry out the protection,measurement and controlschemes, an interface to theprimary process is needed.As well as the analog systemquantities like the primarycurrent and voltage quantities,the binary status informationof the switching device in theswitchbay is also required inorder to carry out the imple-mented task. Furthermorebinary outputs for operatingthe Circuit Breaker and otherswitching devices must alsobe considered.The process interface will bedescribed in the followingparagraphs:

2.9.1 Analog inputsThe REF542 plus SwitchbayProtection and Control Unit isdesigned for connection tomodern current and voltagesensors as well as to conventionalmeasurement transformers.Thanks to their linear characte-ristic, these modern current andvoltage sensors provide greateraccuracy and reliability in themeasurement of signals. Com-pared to conventional measure-ment transformers, the newsensors have the followingadvantages: High accuracy Compact dimensions Wide dynamic range Easy integration in the

switchboard

Figure 12: Combined sensor

sensors cover a range between0.5 to 2.0 of the rated current.The 80 A current sensors are forexample very suitable forapplications between a currentrange of 40 A to 160 A.The voltage sensor is based onthe principle of the resistivedivider from which the signal isobtained and is of a type thatcannot be saturated. Thereforethe voltage sensor is linearthroughout the measuringrange. The output signal is avoltage that is directly propor-tional to the primary voltage.The next figures show a photo-graph of the combined sensors.

connections to conventionalmeasurement transformers theuse of supplementary interme-diate converters in the CentralUnit are required. By usingeither modern sensors orconventional measurementtransformers, the accuracy class1 can be fulfilled, on conditionthat the current and voltagemeasuring values are in therange of the correspondingrated values.

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2.9.2 Binary inputs and outputs

The primary switching devicesare monitored either throughthe auxiliary contacts or throu-gh the related sensors, whichprovide the status informationof all the switching compart-ments in the switchbay. Besidesthat, signals coming fromauxiliary components are alsomonitored. Consequently at thisinterface the following actionsare achieved: Control and interlocking of

the primary switching devicein the switchbay

Control the Circuit Breakers,disconnectors, earthingswitches

Supervision of the springstatus, the continuity ofCircuit Breaker open coil,the status of the switchingdevice.

Providing output pulsesignals for external energycounting systems .

Control the drive motors ofthe disconnectors

Providing the informationregarding internal failure(watchdog).

The interface to the processbinary I/O boards is conside-red. The inputs of the binarysignals are isolated by an opto-coupler. In most applicationsmechanical relays can be provi-ded as binary outputs. But inhigh level applications, like aswitchboard in which motorsare driven directly, static poweroutputs are required. A maxi-mum of 3 binary I/O board canbe installed.


4 Analog outputAn optional analog output board with four configurable outputs canbe used. The output signal of this board can be set in the rangefrom 0 to 20 mA or 4 to 20 mA. Each of the four channels can beindependently activated and parameterized by the configurationsoftware. The following analog output quantities are selectable: All voltage quantities directly from the analog inputs All current quantities directly from the analog inputs Calculated residual currents Calculated residual voltages Calculated apparent, active and reactive power Calculated power factor

3 Diagnosis and monitoringThe REF542 plus is in a position to monitor the condition of thesystem, including the switching devices. Maintenance require-ments can thus be adapted to the actual system condition in orderto reduce down times. The following table shows the parametersmonitored by the REF542 plus. All the parameters are transmittedto the central control system where they are analyzed and processed,so that the diagnostic systems can be provided with data forreliability calculation in order to predict the remainingservice life and maintenance required.

Type Parameters monitored

Software Diagnostic of the REF542 plus unit

Electrical Auxiliary voltage circuits

Power supply to motor operators of the

switching device

Continuity of coil windings of the Circuit Breaker

Mechanical components State of Circuit Breaker

operating mechanism springs

Number of mechanical operations

Gas pressure respectively density

Time Count of hours the switching device board in

operation.

Contact switching time (from closed to open)

using events

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5 CommunicationAn optional communicationsboard is provided for communi-cation with the station automa-tion system. This can be anABB station automation system ora third party system. When usingthe ABB station automationsystem, all of the informationprovided by the REF542 plus canbe completely accessed so thatthe following centralized remotefunctions can be realized: Remote monitoring Remote control Remote setting of protection

parameters Remote measurement Events recording Monitoring of all switching

device Analyze of fault recorder dataThe following protocols forconnection to ABB stationautomation system are available: Figure 13: Connection of the

RE542 plus in an ABB stationautomation system

SPA-bus LON-bus per ABB Lon Appli-

cation Guide (LAG) 1.4definitions

In case of connection to ABBstation automation systems withLON-Bus per LAG1.4, in which aMicroScada“ system is present, therelated library LIB542 can beprovided. The next figure showsan example of the connection ofREF542 plus multifunctional unitsin an ABB station automationsystem using LON per LAG1.4communication protocol.When a communication to athird party station automationsystem has to be realized, anoptional interface complyingwith the following protocolsare considered:


6 Mechanicaldesign

6.1 REF542 plus standardcase version:

2 I/O plug-in boards for con-trol of up to 5 switchingdevices.

1 optional plug-in communica-tion board as an interface tothe ABB-system bus (SPABUSor LON as defined in LAG1.4)or as well to the StandardIEC 60870-5-103 extendedaccording to VDEW as also tostandardize MODBUS RTU.

6.2 REF542 plus widecase version:

3 I/O plug-in boards forcontrol up to 8 switchingdevices (with static I/O board,only 7 switching devices withmechanical I/O board).

1 optional plug-in board foroutput of 4 configurableanalog signals 0 to 20 mAor 4 to 20 mA.

1 optional communicationboard as an interface toABB-system bus (SPABUS orLON as defined in LAG1.4)or as well to StandardIEC 60870-5-103 extendedaccording to VDEW as alsoto standardize MODBUS RTU.

IEC 60870-5-103 standardincluding the extensionaccording to VDEW (Vereini-gung Deutscher Elektrizitäts-werke = association ofGerman utilities)

Dual MODBUS RTUThe optional communicationboard for MODBUS RTU isavailable in two hardwareversions: The first one withtwo redundant RS485 commu-nication ports and the secondone with two optical, glass fibercommunication ports havingstandard ST connectors.

MicroScadastation control

xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx

REF542 plus REF542 plus REF542 plus

GPS Clock

RER111 Starcoupler

1.25 MB/s LON LAG 1.4 (optical interface)

Ethernet (LAN)

Remote control centres

COM 5XX

6.3 Analog inputsThe analog inputs of REF542 plusare available in different versionand can be equipped with thefollowing combination of trans-posing current and/or voltagetransformer: 3 or 6 current transformers for

phase currents 3 or 6 voltage transformers for

phase voltages 2 current or voltage transfor-

mer for the residual current orvoltage

In case of application of combinedsensors are used, the signals areconnected by Twincam ST plugs.

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7 HousingThe REF542 plus housing for theCentral Unit is made from sheetmetal. Its exterior chromatized toprotect the housing againstcorrosion and simultaneously togain the shielding againstEMC disturbances. The CentralUnit is very suitable for safeintegration into a switchboard.A standard and a wide caseversion, as shown in the follo-wing figures are available.In the standard case version,two binary I/O boards andan optional communicationsboard can be used. The widecase version contains an additio-nal binary I/O board andthe analog output board.

Figure 14: Dimension of the HMI Control UnitThe dimension of the HMI Con-trol Unit is shown in the nextfigure.

(PA

NE

L C

UT

OU

T12

1

)

119

13 44

130

Interlocking ErrorAlarmNetwork CommunicationReady

OpenCB

CONNECTOR

CONNECTOR

(PANEL CUT OUT

204

215

REF542 plus

M1

0 100%

Menu

M2

M3

0 100%

0 100%

35

42

1

206 )±0,5

±0,5

SPACE FORCONNECTORS

10 233,5 18

M4

75,5

75,5

FIXINGTOP

ca. 70 261,5

244,

8

M4

106,

3

140 1233

185

106,

3

244,

8

FIXINGBACK

10 18

BOTTOMFIXING

233,5

M4

75,5

75,5

±0,1

±0,1

±0,1

±0,1

±0,1

±0,1

±0,1

±0,1

±0,1

SPACE FORCONNECTORS

10 233,5 18

FIXINGTOP

M4

97,5

97,5

M4

106,

3

184 1233

229

106,

3

244,

8

FIXINGBACK

ca. 70 261,5

244,

8

97,5

97,5

10 233,5 18

M4

FIXINGBOTTOM

±0,1

±0,1

±0,1

±0,1

±0,1

±0,1

±0,1

±0,1

±0,1Figure 15: Dimension

of the standard caseversion

Figure 16: Dimensionof the wide caseversion

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ANSI Protection Function and DSP LoadCode the Setting Parameter in %

Digital Filtering as basic load 16

68 Inrush stabilization(Only in connection with I>> and I>) 3N = 2.0 ... 8.0M = 3.0 ... 4.0Time = 220 ... 100.000 ms

67 Overcurrent directional high 7I>> = 0,05 ... 40 Int = 70 ... 300.000 ms

67 Overcurrent directional low 7I > = 0,05 ... 40 Int = 220 ... 300.000 ms

50 Overcurrent instantaneous 3I>>> = 0,10 ... 40 Int = 15 ... 300.000 ms

51 Overcurrent high 2I>> = 0,05 ... 40 Int = 40 ... 300.000 ms

51 Overcurrent low 2I > = 0,05 ... 40 Int = 40 ... 300.000 ms

51 IDMT 3Normal-, Very-, Extremely- orLongtime- inverse time characteristicIe = 0,05 ... 40 InK = 0,05 ... 1,5

51N Earth fault high 3

IE>> = 0,05 ... 40 In

t = 70 ... 100.000 ms

51N Earth fault low 3IE> = 0,05 ... 40 Int = 70 ... 100.000 ms

67N Earth fault directional high 3

IE>> = 0,05 ... 40 In

t = 40 ... 100.000 ms

forward- / backward direction

isolated (sin w) and earthed (cos w)

67N Earth fault directional low 3IE> = 0,05 ... 40 Int = 40 ... 300.000 msforward- / backward directionisolated (sin w) and earthed (cos w)

67N Earth fault directional sensitive 12

IE> = 0,05 ... 2 In

t = 120 ... 100.000 ms, for- / backward

Slope angle a = 0 ... 20°,Slope angle d = - 180 ... 180°UNE> = 0,05 ...0,7 Un

51N Earth fault IDMT 3Standard, very, extremely orlong time inversetime characteristic,Ie = 0,05 ... 40 InK = 0,05 ... 1,5


59 Overvoltage instantaneous 2U>>> = 0,10 ... 3 Unt = 20 ... 300.000 ms

59 Overvoltage high 2U>> = 0,10 ... 3 Unt = 70 ... 300.000 ms

59 Overvoltage low 2U> = 0,10 ... 3 Unt = 70 ... 300.000 ms

27 Undervoltage instantaneous 2U<<< = 0,10 ... 1,2 Unt = 50 ... 300.000 ms

27 Undervoltage high 2U<< = 0,1 ... 1,2 Unt = 70 ... 300.000 ms

27 Undervoltage low 2U< = 0,1 ... 1,2 Unt = 70 ... 300.000 ms

59N Residual overvoltage high 2UNE>> = 0,05 ... 3 Unt = 40 ... 300.000 ms

59N Residual overvoltage low 2UNE> = 0,05 ... 3 Unt = 40 ... 300.000 ms

49 Thermal overload protection (thermal 3equation 1st orderwith complete memory function)Tn = 50 ... 400 °C (nominal temperature at In)In (Mot) = 1 ... 10000 A(primary value of the nominal motorcurrent)Tini = 50 ... 120 % Tn(initial temperature at power on)tcool = 10 ... 20.000 s(time constant at I< 0.1 In and n = 0)twarm = 10 ... 20.000 s (time constant normal)twarm = 10 ... 20.000 s (time constant at I > 2 In)Tmax = 20 ... 400 °C (maximal temperature)Twarn = 20 ... 400 °C (warn temperature)Tenvi = 50 ... Tini (environment temperature)

51 Motor start protection 2(adiabatic characteristic)Ie = 0,3 ... 1,2 In (motor current)Is = 1,00 ... 20 Ie (start value)t = 70 ... 300.000 msI> = 0,6 ... 0,8 Is (motor start)

51LR Blocking rotor (definite time characteristic) 3Ie = 0,3 ... 1,2 In (motor current)Is = 1,00 ... 20 Ie (start value)t = 70 ... 300.000 ms

66 Number of starts 0n(warm) = 1 ...10 (number of warm starts)n(cold) = 1 ...10 (number of cold starts)t = 1.02 .. 7200 sT (warm) = 20 ... 200 °C(temperature limit warm start)

8 List of the protection functions

17


21+79 Distance protection with autoreclosing 18System earthing = high/low ohmicct - grounding = line side, bus bar sidewith/without earth startswitching onto faults = normal, overreachzone, trip after startSignal comparison overreachscheme time set = 30 .... 300.000 msU / I- Start characteristic:I>, IE> and IF> = 0,05 ... 4 InUF< = 0,05 ... 0,9 UnPhase selection = cyclic/acyclicEarth factor:k = 0,00 ... 10,00w (k) = -60 ... 60°3 Impedance- and 1 overreachstage:R = 0,05 ... 120 Ω (secondary values)X = 0,05 ... 120 Ω (secondary values)t = 20 ... 10.000 ms1 directional stageDirection 0 ... 90 bzw.-45 ... 135°t = 25 ... 10.000 ms1 non directional staget = 25 ... 10.000 ms2 shots AR with short/long time reclosing

87 Differential protection 22Transformer group = 0 ... 11Transformer earthing = primary andor secondary sideNom. current In on the primary/secondaryside of the transformer = 0.00 ... 100.000A(prim value)Threshold current = 0,10 ... 0,50 InUnbiased region limit = 0.50 ... 5 InSlightly biased region threshold = 0,20 ... 2 InSlightly biased region limit = 1,00 ... 10,0 InSlope = 0,40 ... 1,00Trip with Id> = 5,00 ... 40 InBlocking by 2nd harmonic = 0.10 ... 0.30 InBlocking by 5th harmonic = 0.10 ... 0.30 In

46 Unbalance load 9Is = 0,05 ... 0,3 In(start value of the negative phase sequence)K = 2 ... 30tReset = 0 ... 200 sTimer decreasing rate = 0 ... 100%

32 Directional power 2Nominal real power Pn = 1 ... 1000.000 kW(primary values)Max.reverse load P> = 1 ... 50 % Pnt = 1,02 ... 1000 s

37 Low load 2Nominal real power Pn = 50 ... 1000.000 kW(primary values)Minimal load P< = 5 ... 100% PnMinimal current I< = 2 ... 20 % Int = 1 ... 1000 s


81 Frequency monitoring 2Start at ∆f = 0,04 ... 5 Hzt = 1,02 ... 300 s

25 Synchronism check 2∆ U = 0,02 ... 0,4 Unt = 0,52 ... 1000 s∆ w = 5 ... 50°

55 Power factor controller 0Power factor = 0,70 ... 1,00QC0 = 1,000 ... 20000,000 kVArSeries of banks = 1:1:1:1 ... 1:2:4:8Number of banks : 1 ... 4Insensitivity = 105 ... 200 % QC0Threshold = 0 ... 100 % QC0Switching program = sequential/circuitswitching

Fault recorder 2Recording time = 1000 ... 5000 msPre fault time: = 100 ... 2000 msPost fault setting = 100 ... 4900 msMax. 5 records

Note

Due to the limitation of the DSP calculationpower not all function blocks can be combi-ned without restrictions. Please refer to thefollowing table for applicable restrictions

Function block Restrictions

Protection functions Max. 12 protection functions

Max. 120 protection parameters

Max. 120 protection parameters

100% DSP load

Fault recorder Max. 1 fault recorder and

Min. 1 configured protection function

Cycle time of application Max. 30 ms

Memory object Max. 1

Power counter Max. 15

Switching object Max. 62

Threshold object Max. 10 per analog input

Direct write-read command Max. 100

Connections Max. 700, number of connections 502

Signaling LED’s Max. 32 on 4 sides of 8 LED’s each

18

9 Technical data9.1 Analog input channelsAccuracy for measurement including the current/voltage sensors class 1.Accuracy for protection class 3.

9.1.1 With current and voltage transformer:Rated current In 1 A or 5 ARated voltage Un 100 V / ö3 or 100 V (also suitable for 110 V)Rated frequency fn 50 Hz / 60 Hz

Thermal load capacityCurrent path 4 In continuous, 100 In for 1 s,

250 In (peak value) dynamicVoltage path 2 Un /ö3 continuous.Consumption

Current path ≤ 0,1 VA with InVoltage path ≤ 0,25 VA with Un

9.1.2 With current and voltage sensorRated current In 150 mV (rms)Rated voltage Un 2 V (rms)Rated frequency fn 50 Hz or 60 Hz

9.2 Binary inputs and outputsEach binary I/O board has the following number of inputs and outputs:

9.2.1 With mechanical relays (BIO 3)14 inputs for auxiliary voltage

20 ... 90 V DC (threshold 14 V DC)80 ... 250 V DC (threshold 50 V DC)

Each input has a fixed filter time of 1 ms and can be extendedby corresponding configuration.

5 power outputsMaximal Operation voltage 250 V AC/DCMake current 20 ALoad current 12 ABreaking capacity 300 W at L/R = 15 msOperation time 9 ms


18

19

2 signal outputs and 1 Watchdog - outputOperation voltage 250 V AC/DCLoad current 2 AOperation time 5 ms

1 Static output (optionally)Maximal Operation voltage 250 V AC/DCOperation time 1 ms

1 switch circuit monitoring

9.2.2 With static outputs14 inputs for auxiliary voltage

48 ... 265 V DC (Threshold 35 V DC)

Each input has a fixed filter time of 1 ms and can be extended bycorresponding configuration.

2 power outputsOperation voltage 48 ... 265 V DCMake current 70 A for t ≤ 10 msLoad current 12 A for t ≤ 30 sOperation time 1 ms

4 power outputsOperation voltage 48 ... 265 V DCMake current 16 A for t ≤ 10 msLoad current 10 A for t ≤ 30 sOperation time 1 ms

2 Signal outputs and 1 Watchdog - outputOperation voltage 48 ... 250 V DCMake current 0,3 AOperation time 1 ms

1 switch circuit monitoring

9.3 Interface9.3.1 HMI Control Unit Optical interface to the

Notebook PC (at the front) Electrical isolated interface

according to RS485 to theCentral Unit (at the rear)

9.3.2 Central Unit: Electrical isolated interface

according to RS485 to theHMI

Electrical interface accordingto RS232 for updating thefirmware

19

20

9.4 Analog output board (optional)Four channel 0 to 20 mA or 4 to 20 mA

9.5 Communication(optional)

SPABUS, electrical with RS232 interface or opticalconnector snap-in type for plastic respectivelystandard SMA type for glass fiber

LON (according to LAG1.4), optical with standardST connector for glass fiber

IEC 60870-5-103 with extension according toVDEW for controlling, optical with standard STconnector for glass fiber

Dual MODBUS RTU, electrical with two RS485interfaces or optical with two standard STconnector for glass fiber

9.6 Power supply9.6.1 Central UnitRated voltage 48 ... 220 V DC (-15%, +10%) or

selectable10 V DC (-15%, +10%) respectively,220 V DC (-15%, +10%).

Power consumption ≤ 18 WInrush current ≤ 10 A peak value

9.6.2 HMI Control UnitRated voltage: 48 ... 110 V DC (-15%, +10%) or

110 ... 220 V DC (-15%, +10%)Power consumption ≤ 6 W

9.7 Temperature rangeOperation -5 ... + 55 °CTransport and storing -20 ... +70 °C

9.8 Degree of protection9.8.1 Central UnitHousing IP20

9.8.2 HMI Control UnitFront IP 54Rear IP 22

10 Type testAll relevant tests according tothe standard IEC 60255,EN 61000 respectively to the newproduct standard EN 50263

10.1 EMC Interference suppression per

EN 55022 respectively.IEC CISPR 11, Group 1

Immunity to electrostaticdischarge per IEC 61000-4-2,level 3

Immunity to radiated electro-magnetic energy perIEC 61000-4-3, level 3

Electrical fast transient orburst per IEC 61000-4-4,level 3

Surge immunity tests perIEC 61000-4-5, level 3

Immunity to conducteddisturbances induced byradio frequency fields perIEC 61000-4-6, level 3

Power frequency magneticfield immunity perIEC 61000-4-8, level 5

Pulse magnetic field immuni-ty per IEC 61000-4-9, level 5

Damped oscillatory magne-tic field immunity perIEC 61000-4-10, level 5

Oscillatory waves immunityper IEC 61000-4-12, level 3

Oscillatory waves immunityin the range from 0 to 150kHz per IEC 61000-4-16,level 3

Ripple on DC input powerport immunity perIEC 61000-4-17, level 3

Voltage dips, short interrupti-ons and voltage variationson DC input power ports perIEC 61000-4-29, 50 ms.


20

21

X80

- +X10

X20

X30

X60

X70X71X72

X81X83X85X86 X84 X82

X73X74X76 X75X77

X65 X64 X63 X62 X61

X31

X21

23

64

7 11 15 19

2022

23

2410 14

1618

128

3 2 1

1

23

5

64

79

1113

1517

19

2022

23

24

21

10 1416

18128

X80

- +X10

X20

X30

X41

X50

X40

X60

X70X71X72

X81X83X85X86 X84 X82

X73X74X76 X75X77

X65 X64 X63 X62 X61

X31

X21

1

23

5

64

79

1113

1517

19

2022

23

24

21

10 1416

18128

3 2 1

10.2 Insulation Voltage test per IEC 60255-5

with 2 kV RMS, 50 Hzduring 1 Min

Impulse voltage withstandtest per IEC 60255-5 with5 kV 1,2/50 µs.

11 Connection Diagram11.1 Connector Plate

10.3 Mechanical robustness

Vibration test perIEC 60255-21-1

Shock response and with-stand test per IEC 60068-2-2

Seismic test per IEC 60068-2-30

10.4 Climatic conditions Cold test per IEC 60068-2-1 Dry heat test per

IEC 60068-2-2 Damp Heat and Cycling test

per IEC 60068-2-30

REF542 plus Mixed Connector plate for thewide case version

REF542 plus Mixed connector plate for thestandard case version

1

23

5

64

79

1113

1517

19

2022

23

24

21

10 1416

18128

TRANSFORMER STANDARD AND WIDE CASE VERSION

X81X83X85X86 X84 X82X87X88

11.2 HMI Control UnitPower Supply and communication connectionfor HMI Control Unit

- X10: Power Supply- X20: RS 485 to Central Unit

3 5421

X10X20

REF542 plus Sensor plate version for thestandard and wide case

REF542 plus Transformer plate version forthe standard and wide case

22

11.3 REF542 plus with mechanical binary I/OExample of REF542 plus base version with one mechanical binary I/O version 3 (BIO3). Extension up to twoadditional mechanical binary I/O version 3 (BIO3) possible. Other configuration of the analog input boardavailable, e.g mixed configuration for transformers and sensors connection.

Note: Please connect the right polarityon Binary output BO02.

DC

DC

+ -1 2 3-X10:

z28d26d28

d24z24z26

d18d20

z18d22

z22

z14z16

d14d16

z10z12

d10d12

d06d08

z06z08

d02d04

z02z04

d02z02

BI01

d04z04

BI02

d06z06 BI03

d08z08

BI04

d10z10

BI05

d12z12

BI06

d14z14

BI07

d16z16

BI08

d18z18

BI09

d20z20

BI10

d22z22

BI11

d24z24

BI12

d26z26

BI13

d28z28

BI14

-X21:-X20: +

-

+-

+-

+

-+

-

+-

+-

+-

+-

+-

+-

+-

+-

+-

-

+

-

+

z20

d30z30z32

WD1

-X80:

1A5A

AI 05

AI 03

AI 02

AI 01

1A5A

AI 06

100/110V100/110V

100/110V

100/110V

1107

03221814

060221170501

1923

10

242016

1A5A

AI 04T4

T5

T6

T1

T2

T31A5A

AI 07T7

1A5A

AI 08T8 e.g. CT 1/5 A

120804

d30z30z32

z28d26d28

d24z24z26BO15

BO16

WD2

BO13

BO14

d18d20

z18d22

z22

z14z16

BO12d14d16

z10z12

BO11d10d12

d06d08

BO10z06z08

d02d04

BO09z02z04

d02z02

BI15

d04z04

BI16

d06z06

BI17

d08z08

BI18

d10z10

BI19

d12z12

BI20

d14z14

BI21

d16z16

BI22

d18z18

BI23

d20z20

BI24

d22z22 BI25

d24z24

BI26

d26z26

BI27

d28z28

BI28

-X31:-X30:+-

+-

+-

+

-+

-

+-

+-

+-

+-

+-

+-

+-

+-

+-

-

+

z20

d30z30z32

z28d26d28

d24z24z26BO23

BO24

WD3

BO21

BO22

d18d20

z18d22

z22

z14z16

BO20d14d16

z10z12

BO19d10d12

d06d08

BO18z06z08

d02d04

BO17z02z04

d02z02

BI29

d04z04

BI30

d06z06

BI31

d08z08

BI32

d10z10

BI33

d12z12

BI34

d14z14

BI35

d16z16

BI36

d18z18

BI37

d20z20

BI38

d22z22 BI39

d24z24

BI40

d26z26

BI41

d28z28

BI42

-X41:-X40:+-

+-

+-

+

-+

-

+-

+-

+-

+-

+-

+-

+-

+-

+-

-

+

z20

Extension with third additionalmechanical binary I/O version 3 (BIO3)

Extension with second additionalmechanical binary I/O version 3 (BIO3)

22

23

11.4 REF542 plus with solid state binary I/OExample of REF542 plus base version for sensor connection with one solid state binary I/O version 3. Extensionup to two additional solid state binary I/O possible. Other configuration of the analog input board available, e.gmixed configuration for transformers and sensors connection.

Note: Please connect the right polarity

DC

DC

+ -1 2 3-X10:

-X81: AD Sensor 1

AD Sensor 2

AD Sensor 3

AD Sensor 4

AD Sensor 5

AD Sensor 6

AD Sensor 7

AD Sensor 8

-X82:

-X83:

-X84:

-X85:

-X86:

-X87:

-X88:

d30z32

z20z22z18

WD1

z10z12

d10d12

d02z02

BI01

d04z04

BI02

d06z06

BI03

d08z08

BI04

d10z10

BI05

d12z12

BI06

d14z14

BI07

d16z16

BI08

d18z18

BI09

d20z20

BI10

d22z22

BI11

d24z24

BI12

d26z26

BI13

d28z28

BI14

-X21:-X20:+-

+-

+-

+

-+

-

+-

+-

+-

+-

+-

+-

+-

+-

+-

z28d28

d24z26

+

+

+

d18d20d22

+

++

+

-

z06z08

d06d08

-

+

z02z04

d02d04

-

+

d30z32

z20z22z18

BO20

WD2

z10z12

BO16d10d12

d02z02

BI15

d04z04

BI16

d06z06

BI17

d08z08

BI18

d10z10

BI19

d12z12

BI20

d14z14

BI21

d16z16

BI22

d18z18

BI23

d20z20

BI24

d22z22 BI25

d24z24

BI26

d26z26

BI27

d28z28

BI28

-X31:-X30:+-

+-

+-

+

-+

-

+-

+-

+-

+-

+-

+-

+-

+-

+-

z28d28BO18

d24z26BO17

+

+

+

BO13

d18d20d22BO14

BO12+

++

+

-

z06z08

BO11d06d08

-

+

z02z04

BO10d02d04

-

+

d30z32

z20z22z18

BO24

WD3

z10z12

BO25d10d12

d02z02

BI29

d04z04

BI30

d06z06

BI31

d08z08

BI32

d10z10

BI33

d12z12

BI34

d14z14

BI35

d16z16

BI36

d18z18

BI37

d20z20

BI38

d22z22 BI39

d24z24

BI40

d26z26

BI41

d28z28

BI42

-X41:-X40:+-

+-

+-

+

-+

-

+-

+-

+-

+-

+-

+-

+-

+-

+-

z28d28BO27

d24z26BO26

+

+

+

BO22

d18d20d22BO23

BO21+

++

+

-

z06z08

BO20d06d08

-

+

z02z04

BO20d02d04

-

+


Extension with second additionalsolid state binary I/O.

Extension with third additionalsolid state binary I/O

23

ABB Calor Emag Mittelspannung GmbH ABB Sace T.M.S. S.p.A

Oberhausener Strasse 33 Petzower Strasse 8 Via Friuli, 4D-40472 Ratingen D-14542 Glindow I-24044 Dalmine

Phone: +49(0)21 02/12-12 30, Fax: +49(0)21 02/12-19 16 Phone: +39 035/395111, Fax: +39 035/395874E-mail: [email protected] E-mail: [email protected]: http://www.abb.de/calor Internet: http://www.abb.com

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ABB REF542plus Protection Relays

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