REF542 plus

Bay Protection and Control Unit

2
Table of Contents

1 General 4 8 List of the

2 Functions 8 protection functions 16

2.1 Configuration 6 9 Technical data 18

2.2 Operation 6 9.1 Analog input channels 18
2.2.1 LCD display 7 9.1.1 With current
and voltage transformer 18
2.2.2 Status Indication 8
9.1.2 With current
2.2.2.1 Operational status 8 and voltage sensor 18
2.2.2.2 Communication status 8 9.2 Binary inputs and outputs 18
2.2.2.3 Alarm indication 8 9.2.1 With mechanical relays
2.2.2.4 Interlocking status 8 (BIO 3) 18
2.2.3 LED Indication 8 9.2.2 With static outputs 19
2.2.4 Bar displays 8 9.3 Interface 19
2.2.5 Control push buttons 8 9.3.1 HMI Control Unit 19
2.2.6 Electronic key 8 9.3.2 Central Unit 19
2.3 Measurement 9 9.4 Analog output board
2.3.1 Values measured directly 9 (optional) 20

2.3.2 Calculated values 9 9.5 Communication (optional) 20

2.3.3 Other values 9 9.6 Power supply 20

2.4 Protection 9 9.6.1 Central Unit 20

2.5 Control 10 9.6.2 HMI Control Unit 20

2.6 Event recording 10 9.7 Temperature range 20

2.7 Fault recording 11 9.8 Degree of protection 20

2.8 Real time clock 11 9.8.1 Central Unit 20

2.9 Process interface 12 9.8.2 HMI Control Unit 20

2.9.1 Analog inputs 12 10 Type test 20

2.9.2 Binary inputs and outputs 13 10.1 EMC 20
10.2 Insulation 21
3 Diagnosis and monitoring 13
10.3 Mechanical robustness 21
4 Analog output 13
10.4 Climatic conditions 21
5 Communication 14
11 Connection Diagram 21
6 Housing 15
11.1 Connector Plate 21
7 Mechanical design 15
11.2 HMI Control Unit 21
7.1 REF542 plus
standard case version 15 11.3 REF542 plus with
mechanical binary I/O 22
7.2 REF542 plus
wide case version 15 11.4 REF542 plus with
solid state binary I/O 23
7.3 Analog inputs 15

3
 REF542 plus. Bay Protection
and Control unit
1 General
The REF542 plus is a Switchbay All functions mentioned above smart and clean solution where
Protection and Control Unit and and also power quality functions the traditional approach is
is the further development of are integrated in a programmable ineffective and expensive.
the former REF542 multi- environment. The exceptional The following figures show
functional unit. Like its prede- flexibility and scalability of examples of the installation of
cessor, it features the following these new generation devices the REF542 plus in several
functions: make it possible to integrate all switchgears for the switchbay.
the secondary functions in a
● Protection
unique device, leading to a
● Measurement
● Control
● Monitoring

Figure 1: REF542 plus

installed in
gas-insulated
switchgears (GIS)

The REF542 plus is based on a

real-time microprocessor system.
The measurement and protection
functions are executed by a
Digital Signal Processor (DSP)
and the Micro Controller (MC)
is responsible for the control
functions. Due to this task separa-
tion there is no impact between
the start and the trip behavior of the
protection scheme implemented
if the control scheme is modified.
The Communication Processor
Figure 2: REF542 plus (CP) is needed for adaptation to
installed in an a station automation system.
air -insulated
A block diagram of the REF542
switchgear (AIS)
plus is shown in figure 3.

4
 Figure 3: Block diagram
of REF542 plus Interbay bus
HMI
Human Machine
Interfeace CP
Communication
Processor
The REF542 plus, as shown in Control unit
figure 3, consists of two parts,
a Central Unit and a separate DSP MC
Analog Protection and Control and
Human Machine Interface inputs Measurement Command
(HMI) as the Control Unit. Processor Processor

The Central Unit contains the

power supply, processor and Binary Binary Analog
analog and binary Input and Inputs Outputs Outputs

Output (I/O) modules, as well

as optional modules for supple- Central unit
mentary functions.
The HMI Control Unit is a
stand-alone unit with its own
power supply. It can be installed connected to the Central Unit
on the Low Voltage (LV) com- by a shielded, isolated twisted
partment door or in a dedicated pair according to the RS485
compartment close to the standard interface. Figure 4
Central Unit. The HMI is nor- shows an installation of the
mally used to set the protection Central Unit and the HMI
parameters and to locally Control Unit in the LV compart-
operate the switching devices ment of a switchboard for the
in the switchbay. The HMI is switchbay.
Figure 4: Mounting of the Central
Unit in the LV compartment and
the HMI on the door

The HMI Control Unit, as

shown in figure 5, features a
back-illuminated Liquid Crystal
Display (LCD), eight push
buttons, several LEDs and an
electronic key interface. The
language of the display can be
selected via the related configu-
ration software tool, which is
also used to define the protec-
tion and the control scheme.
Figure 5: View of the HMI Control Unit

5
 REF542 plus. Bay Protection
and Control unit
The left half of the LCD display The functions of the REF542 ● Analog inputs to measure
is reserved for the Single Line plus can be tailored to the current and voltage signals
diagram. The right half is used requirements of the system by from conventional current
to display the appropriate menu application of a user-specific and voltage measurement
or submenu as determined by configuration. The user-specific transformers or from current
the user. Two different electronic configuration is loaded during and voltage measurement
keys with different access rights commissioning. For that purpose sensors
are available. Each of the keys the configuration computer, ● Binary inputs with optical
are programmed to permit normally a personal computer couplers for the galvanic
either: (notebook) running Windows separation of the external
NT, is connected to the optical signals to be processed
● the parameterization of the
interface on the front side of
protection functions ● Binary outputs with conven-
the HMI Control Unit.
● the mode selection of the tional mechanical relays or
The interface of the multi-
control functions static outputs for the control
functional unit REF542 plus to
of switching devices in the
Three freely programmable LED the Medium Voltage (MV)
compartment of the switch-
bars have been provided on the system as the primary
board
front of the HMI Control Unit. process is as follows:
Each LED bar consists of ten ● Optional four channel
green and two red LEDs and is analog outputs 0 to 20mA or
user configurable to display any 4 to 20 mA
measurement value required. ● Optional connection to ABB
The red LEDs are used to indi- or third party station auto-
cate values above the rated mation system.
value.

2 Functions 2.1 Configuration

The REF542plus Switchbay Each application for protection All functions in the switchbay
Protection and Control Unit and control can easily be can be specified in collaboration
integrates all of the secondary configured by software function with ABB. The result of the
functions in a single unit. This modules, which make arbitrary configuration is saved and
multifunctional unit also fea- definition of the following delivered together with the
tures a self-monitoring function. features as part of the secondary switchboard to the users.
All functions are designed as system possible: The configuration software
freely configurable software ● LED’s (assignment and is also provided to the user to
modules. Therefore, a wide colors) for local indication make available the full potential
range of operation require- of the multifunctional unit to
● Single Line diagram to show
ments in MV stations can be the field operators. Thanks
the status of the switching
met without any problems. to a „Functional block“ Pro-
devices
The versatility of the software gramming Language (FUPLA)
makes it possible to use the ● Protection schemes as the REF542 plus Switchbay
REF542 plus on every switch- required Protection and Control Unit
board irrespective of the ● Control schemes as needed offers engineers, especially
specific application required. ● Interlocking schemes those who are not software
experts, the opportunity of
● Automation sequences
easily updating the operation
and handling of the switchbay
using a personal computer.

6
With the REF542 plus the user ● Under- respectively The protection scheme parameters
has the benefit of a secondary overvoltage protection can be changed via the HMI
system that is fully integrated in ● Distance protection Control Unit without using a
a true programmable controller. personal computer. But users
● Differential protection for
This flexibility is very advantage- can additionally perform certain
transformer and motor
ous for defining control functions on site by means of a
functions for automation ● Thermal protection for cable, personal computer (notebook),
sequences, which can, for transformer and motor which is connected to the
example, include theinterlok- ● Reverse power protection optical interface on the front of
king of the switching devices, ● Synchronism check the HMI Control Unit and the
blocking the release of specific provided configuration software.
protection functions, as well These functions include:
Note
as starting switching sequences. ● Parameterization of the
The new REF542 plus multi- The specific software protection scheme,
functional unit provides a wide configuration of the required
● Read-out of the current
range of logical functions so protection scheme can only be
measurement values,
that each required control carried out in-house at ABB.
schemes can be configured. ● Read-out of the status of the
The range of logical functions binary inputs and outputs,
includes: ● Read-out of the fault
● AND logic gate recorder and
● NAND logic gate ● Viewing of the FUPLA
logic I/O states
● OR logic gate
● NOR logic gate
● XOR logic gate
● Bistable and 2.2 Operation
monostable flip flop A wide range of functions can generally be controlled and opera-
● Counters ted using the simple, user-friendly interface on the HMI Control
● Timers Unit. This user-friendly interface is shown in the following figure.
● Pulse generators
● Memories

Similar to the free definition

of the control scheme, each
required protection scheme can
be configured by the combinati-
on of the available protection
function modules. For example,
the following protection
functions are foreseen:
● Definite time overcurrent
protection
● Inverse time overcurrent
protection
● Directional overcurrent
protection Figure 6: HMI as Control Unit

The HMI consists of the following features:

7
 2.2.1 LCD display 2.2.2.2 Communication 2.2.4 Bar displays
The back-illuminated LCD status Three freely programmable LED
display of the HMI provides On the HMI front panel, this bars are provided for showing
a graphical display of the swit- communication status is called the measurement values.
ching devices in the switchbay ‚Network Communication‘. The LED bars are used to display
controlled by the REF542 plus. If the REF542 plus is to be arbitrary measurement values as
The intensity and the duration connected to a station auto- required. Each bar consists of
of the illumination can be set mation system, an extension ten green and two red LEDs.
as required. The Single Line with an appropriate communi- The nominal values of each LED
diagram shows the current cations board is required. bar, which corresponds to the
status of all the switching In this case a green LED is ten green LEDs are defined by
devices. The right half of the used to indicate the correct the configuration software.
LCD display is for plain text, operational status of the If the measurement values are
such as measurement values, optional board. The LED color higher than the rated values,
main menu and submenus changes to red if a communica- the red LEDs will light
descriptions, protection tion failure has occurred. indicating an overload situation.
signals and event recording.
2.2.2.3 Alarm indication 2.2.5 Control push buttons
On the LCD display, the follo-
wing can be shown: Several arbitrary alarm con- The control push buttons are
ditions can be defined and used for operation of the
● Up to eight switching device
configured by the user. switching devices during local
icons (when the binary
If one of these conditions is control. A total of eight push
I/O boards with mechanical
fulfilled, the red LED will be on. buttons are available, four for
relays are used, a maximum
commanding the primary
of seven switching devices
equipment and four for
can be controlled) 2.2.2.4 Interlocking status browsing the display.
● Various icons for motors, The LED is green if no interlok- Also configured is a situation
transformers, sensors, king conditions have been whereby an emergency push
transducers violated. In case of a switching button pressed simultaneously
● A maximum of 40 individual action, which violates the with a normal Circuit Breaker
lines. interlock conditions such as (CB) push button opens the CB
switching a disconnector in in the event of an emergency.
2.2.2 Status Indication theclosed condition of the
Circuit Breaker (CB), the color 2.2.6 Electronic key
Four system LEDs indicate the will change temporarily to red.
status of the REF542 plus. Two different electronic keys
These LEDs are: are provided. One key can only
2.2.3 LED Indication be used for the parameterization
2.2.2.1 Operational status Eight freely programmable, of the protection scheme.
three color LED’s are provided The other one is for the selection
On the HMI front panel, the for local indication. The of the control modes which can
operational status is called number of LED display options be switched off or in one of the
‚Ready‘ and is displayed by a can be quadrupled through the three other modes provided:
green LED. The unit is not menu structure. As a result, local, remote or local/remote
operational if this LED is off, a total of 32 indication options control mode. By using these
and this occurs for example are available for status indication two keys a certain separation
during the downloading of the regarding protection, control, between protection and control
configuration for the operation monitoring and supervision operation can be achieved.
of the switchbay or if a fault is functions. If required a general key that
detected in the Central Unit.
permits access to both modes is
provided. The sensor for re-
8
cognizing which electronic key 2.3.1 Values measured ● Apparent, active and reactive
has been used is located on the directly power
front panel of the HMI Control ● Power factor
Unit. ● Line currents, three phases
● Active and reactive energy
● Phase voltages, three phases
Moreover, the following quanti-
2.3 Measurement ● Earth current or residual
ties for monitoring purposes
The REF542 plus Switchbay voltage
can be provided:
Protection and Control Unit ● Frequency
consists of eight analog inputs From the above measured 2.3.3 Other values
for measuring current and quantities the following values
voltage signals. These are ● Operating hours
can be calculated:
organized into four groups with ● Switching cycles
two groups of three inputs ● Total switched currents
each, one input for current or 2.3.2 Calculated values
● Metering pulses from an
voltage measurement regarding ● Line voltages, three phases external metering device
to earth faults detection or ● Earth current or residual (up to 10)
voltage measurement for voltage
synchronism checking, and a
further input only for measure- ● Average value/maximum
ment purposes. Every group value current, three-phase
can measure voltage or current. (determined over several
As well as six-phase voltage minutes)
measurement for the application
in a measurement switchbay,
six phase current measurements
for transformer differential
protection is also possible. 2.4 Protection
The most common configurati- The REF542 plus offers a wide are limited by the computing
on uses three current and three range of functions for protection. capacity of the DSP, as each
voltage inputs and one earth As has previously been mentio- protection function increases
fault current input. All values ned, a wide range of protection the DSP load. The maximum
are shown on the display as schemes for the protection of load applied by all of the
primary values. The values several system components can protection functions may not
registered over an extended be configured. The available exceed the 100% DSP computing
time period, for example ener- protection functions can be capacity. Figure 7 shows an
gy, number of CB operations, combined together to form a example of a configured
maximum and measurement protection scheme as required. protection scheme.
values are permanently saved. But the combination possibilities
Even after power interruptions
this data is still available. Using
this common configuration, the
BL
following measured values are (11)
(12)
(14) START IDMT>> (14) START IDMT>> FAULTRECORDER

(18) START I>>>

displayed: (13)

(19) TRIP IDMT>>

(15) (18) START I>>>

(16)
(17) OVERFLOW

(14) START IDMT>>

(21)
(18) START I>>> START
(20) TRIP IDMT>>>
Figure 7: FUPLA
protection scheme

9
 REF542 plus. Bay Protection
and Control unit

2.5 Control (25) INTERLOCKING OPEN

(31) INTERLOCKING CLOSE

The REF542 plus permits convenient local
operation with full interlocking against (28)

switching errors. The switch position of the (24) CB OPEN

CIRCUIT BREAKER
various switching devices in the switchbay (23) KEY REMOTE
(29)
(34) CB DEF OPENED
(35) CB DEF CLOSED
can be shown on the LCD display of the (30) CB CLOSE
HMI Control Unit. If local control mode is (23) KEY REMOTE
(26)
(22) RELEASE (34) RELEASE
selected, switching actions can be input
locally using the control push buttons on
the HMI Control Unit. Switching to another
control mode can only be achieved by (33) CB OPEN COMMAND

using the correct electronic key. (32) CB CLOSE COMMAND

In remote control mode, only switching
actions via a remote control unit like a
Figure 8: FUPLA control scheme
station automation system is feasible. A
special control mode, Local and Remote, is
provided for users who want to perform
simultaneous Local and Remote switching. switching devices to and from more sophisticated ABB station-
Interlocking between the switchbays other switchbays. The status automation system. Figure 8
connected to the same bus bar system can information must be provided shows an example of a
also be taken into account. This requires either by a conventional, hard configured control scheme of
the availability of status information of the wired ring bus system or by the the Circuit Breaker.

2.6 Event recording

The last 50 recorded events can
be shown locally on the LCD
display of the HMI unit.
The events are mostly related to
protection activities. As well as
displaying the event name,
additional information about
the event, time, date and the
RMS value of the short circuit
current switched off by the
Circuit Breaker are provided.
Each event is stamped with the
time and date. The time is taken
from the internal clock on the
REF542 plus, which can be
Figure 9: List of events on the LCD of the HMI synchronized by the GPS clock
or the station automation system.
In the next figure, a list of
recorded events is shown.

10
 2.7 Fault recording
The multifunctional unit
REF542 plus also consists of a
fault recorder module, which
record and encode analog and
binary data. The number of data
channels recorded depends
on the initial configuration.
Up to seven signals of the analog
channels and 32 binary signals
can be recorded. The analog
input signals are recorded with
a sampling rate of 1.2 kHz for a
period of at least 1-second and
for a maximum of 5 seconds.
The recording time is a combina-
tion of pre- and post fault time.
The records are saved using a
typical ring buffer process, i.e.
the oldest fault record is always Figure 10: Record of a cross country fault in an MV system
overwritten with a new one.
The number of saved fault records
depends on the record time.
For example, a maximum of
2.8 Real time clock
5 fault records can be saved The internal clock is not buffered by batteries but by
with a recording time of 1s. a special capacitor. In case of DC power supply failure,
The fault records can be exported the stored electrical energy in the capacitor ensures
and converted by the configura- continued operation of the internal clock for at least
tion software. The transfer of the another two hours. The date and time of the clock
fault records via the interbay bus can be set via the HMI Control Unit.
using the foreseen communication If required, as shown in the next figure, the clock
protocols is also possible. Figure can be synchronized by an external master clock
10 shows a record of a cross (e.g. GPS) through a standard IRIG B interface. Using
country fault in an earth fault this, a real time accuracy of up to 1ms can be achieved.
compensated MV system starting Note
with the earth fault.
The standard IRIG B - Interface will be available from
third quarter 2001!

In case of connection to a station automation

GPS Clock
system, an ABB or a third party automation
system, the synchronization of the
REF542 plus internal clock to the system
clock is performed by the corresponding
1.25 MB/s LON LAG 1.4 (optical interface) communication bus.
xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx xxx

RER111 Starcoupler

Figure 11: Synchronization of

REF542 plus REF542 plus REF542 plus the internal clock by a GPS
master clock
11
 2.9 Process interface The current sensor is based on sensors cover a range between
the principle of the Rogowski 0.5 to 2.0 of the rated current.
To carry out the protection,
coil and consists of a single The 80 A current sensors are for
measurement and control
air-cored coil. Due to the lack example very suitable for
schemes, an interface to the
of an iron core, the saturation applications between a current
primary process is needed.
effects of conventional current range of 40 A to 160 A.
As well as the analog system
transformers do not exist The voltage sensor is based on
quantities like the primary
anymore. Current sensors are the principle of the resistive
current and voltage quantities,
thus well suited for the deploy- divider from which the signal is
the binary status information
ment of distance protection and obtained and is of a type that
of the switching device in the
differential protection functions. cannot be saturated. Therefore
switchbay is also required in
The current sensor measures the voltage sensor is linear
order to carry out the imple-
the current value using a voltage throughout the measuring
mented task. Furthermore
signal that is proportional to the range. The output signal is a
binary outputs for operating
derivative of the primary current voltage that is directly propor-
the Circuit Breaker and other
being measured. The numerical tional to the primary voltage.
switching devices must also
integration of the signal is The next figures show a photo-
be considered.
performed using the DSP in the graph of the combined sensors.
The process interface will be
REF542 plus unit. The current
described in the following
paragraphs:

2.9.1 Analog inputs

The REF542 plus Switchbay
Protection and Control Unit is
designed for connection to
modern current and voltage
sensors as well as to conventional
measurement transformers.
Thanks to their linear characte-
ristic, these modern current and
voltage sensors provide greater
accuracy and reliability in the
measurement of signals. Com-
pared to conventional measure-
ment transformers, the new Figure 12: Combined sensor
sensors have the following
advantages:
● High accuracy
Thanks to their small dimensions, connections to conventional
both current and voltage measurement transformers the
● Compact dimensions
sensors can be integrated use of supplementary interme-
● Wide dynamic range as a combined sensor in a diate converters in the Central
● Easy integration in the single resin unit. Unit are required. By using
switchboard A capacitive divider is incorpo- either modern sensors or
rated in the combined sensor conventional measurement
to provide a power supply for transformers, the accuracy class
power on indicator lamps. 1 can be fulfilled, on condition
The output signals of the current that the current and voltage
and voltage sensors are connected measuring values are in the
directly to the Central Unit of range of the corresponding
the REF542 plus. In the case of rated values.

12
 REF542 plus. Bay Protection
and Control unit
2.9.2 Binary inputs and
outputs
The primary switching devices
are monitored either through
3 Diagnosis and monitoring
the auxiliary contacts or throu- The REF542 plus is in a position to monitor the condition of the
gh the related sensors, which system, including the switching devices. Maintenance require-
provide the status information ments can thus be adapted to the actual system condition in order
of all the switching compart- to reduce down times. The following table shows the parameters
ments in the switchbay. Besides monitored by the REF542 plus. All the parameters are transmitted
that, signals coming from to the central control system where they are analyzed and processed,
auxiliary components are also so that the diagnostic systems can be provided with data for
monitored. Consequently at this reliability calculation in order to predict the remaining
interface the following actions service life and maintenance required.
are achieved:
● Control and interlocking of
the primary switching device Type Parameters monitored
in the switchbay
Software Diagnostic of the REF542 plus unit
● Control the Circuit Breakers,
disconnectors, earthing Electrical Auxiliary voltage circuits
switches Power supply to motor operators of the
● Supervision of the spring switching device
status, the continuity of Continuity of coil windings of the Circuit Breaker
Circuit Breaker open coil, Mechanical components State of Circuit Breaker
the status of the switching
operating mechanism springs
device.
Number of mechanical operations
● Providing output pulse
Gas pressure respectively density
signals for external energy
counting systems . Time Count of hours the switching device board in
● Control the drive motors of operation.
the disconnectors Contact switching time (from closed to open)
● Providing the information using events
regarding internal failure
(watchdog).
The interface to the process 4 Analog output
binary I/O boards is conside-
An optional analog output board with four configurable outputs can
red. The inputs of the binary
be used. The output signal of this board can be set in the range
signals are isolated by an opto-
from 0 to 20 mA or 4 to 20 mA. Each of the four channels can be
coupler. In most applications
independently activated and parameterized by the configuration
mechanical relays can be provi-
software. The following analog output quantities are selectable:
ded as binary outputs. But in
high level applications, like a ● All voltage quantities directly from the analog inputs
switchboard in which motors ● All current quantities directly from the analog inputs
are driven directly, static power ● Calculated residual currents
outputs are required. A maxi-
● Calculated residual voltages
mum of 3 binary I/O board can
be installed. ● Calculated apparent, active and reactive power
● Calculated power factor

13
 REF542 plus. Bay Protection
and Control unit
5 Communication
An optional communications ● SPA-bus ● IEC 60870-5-103 standard
board is provided for communi- ● LON-bus per ABB Lon Appli- including the extension
cation with the station automa- cation Guide (LAG) 1.4 according to VDEW (Vereini-
tion system. This can be an definitions gung Deutscher Elektrizitäts-
ABB station automation system or werke = association of
In case of connection to ABB
a third party system. When using German utilities)
station automation systems with
the ABB station automation ● Dual MODBUS RTU
LON-Bus per LAG1.4, in which a
system, all of the information
MicroScada“ system is present, the The optional communication
provided by the REF542 plus can
related library LIB542 can be board for MODBUS RTU is
be completely accessed so that
provided. The next figure shows available in two hardware
the following centralized remote
an example of the connection of versions: The first one with
functions can be realized:
REF542 plus multifunctional units two redundant RS485 commu-
● Remote monitoring in an ABB station automation nication ports and the second
● Remote control system using LON per LAG1.4 one with two optical, glass fiber
● Remote setting of protection communication protocol. communication ports having
parameters When a communication to a standard ST connectors.
third party station automation
● Remote measurement
system has to be realized, an MicroScada
station control

● Events recording
Remote control centres
optional interface complying
● Monitoring of all switching with the following protocols
device are considered: GPS Clock
Ethernet (LAN)
COM 5XX

● Analyze of fault recorder data

The following protocols for
connection to ABB station 1.25 MB/s LON LAG 1.4 (optical interface)

automation system are available:

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

Figure 13: Connection of the RER111 Starcoupler

RE542 plus in an ABB station

automation system REF542 plus REF542 plus REF542 plus

6 Mechanical 6.2 REF542 plus wide 6.3 Analog inputs

case version: The analog inputs of REF542 plus
design ● 3 I/O plug-in boards for are available in different version
control up to 8 switching and can be equipped with the
6.1 REF542 plus standard following combination of trans-
devices (with static I/O board,
case version: only 7 switching devices with posing current and/or voltage
● 2 I/O plug-in boards for con- mechanical I/O board). transformer:
trol of up to 5 switching ● 1 optional plug-in board for ● 3 or 6 current transformers for
devices. output of 4 configurable phase currents
● 1 optional plug-in communica- analog signals 0 to 20 mA ● 3 or 6 voltage transformers for
tion board as an interface to or 4 to 20 mA. phase voltages
the ABB-system bus (SPABUS ● 1 optional communication ● 2 current or voltage transfor-
or LON as defined in LAG1.4) board as an interface to mer for the residual current or
or as well to the Standard ABB-system bus (SPABUS or voltage
IEC 60870-5-103 extended LON as defined in LAG1.4)
according to VDEW as also to or as well to Standard In case of application of combined
standardize MODBUS RTU. IEC 60870-5-103 extended sensors are used, the signals are
according to VDEW as also connected by Twincam ST plugs.
to standardize MODBUS RTU.
14
7 Housing
The REF542 plus housing for the
Central Unit is made from sheet 215

metal. Its exterior chromatized to

protect the housing against
corrosion and simultaneously to
gain the shielding against
EMC disturbances. The Central 204
Unit is very suitable for safe (PANEL CUT OUT 206 ±0,5 )

integration into a switchboard. 13 44

A standard and a wide case REF542 plus

version, as shown in the follo- Ready Network Communication Alarm Interlocking Error

(PANEL CUT OUT121 ±0,5 )

M1
CONNECTOR
wing figures are available. 0 100%

M2
In the standard case version, Open
0 100%

119
130

CB

two binary I/O boards and M3

0 100%

an optional communications
1 2 3 4 5

Menu
CONNECTOR

board can be used. The wide

case version contains an additio-
nal binary I/O board and
the analog output board.
Figure 14: Dimension of the HMI Control Unit
The dimension of the HMI Con-
trol Unit is shown in the next
figure.
75,5 ±0,1

97,5 ±0,1
75,5 ±0,1

97,5 ±0,1

M4

M4

10 233,5 ±0,1 18
10 233,5 ±0,1 18
FIXING
BOTTOM FIXING
BOTTOM
106,3 ±0,1

106,3 ±0,1
244,8
244,8

244,8

244,8
106,3 ±0,1

106,3 ±0,1

M4 M4

33 140 ±0,1 12 ca. 70 261,5 33 184 ±0,1 12 ca. 70 261,5

SPACE FOR SPACE FOR

185 CONNECTORS 229 CONNECTORS
FIXING FIXING 10 233,5 ±0,1 18
BACK BACK
10 233,5 ±0,1 18
97,5 ±0,1
75,5 ±0,1

Figure 15: Dimension Figure 16: Dimension

75,5 ±0,1

97,5 ±0,1

M4
of the standard case of the wide case M4
version version
FIXING
TOP FIXING
TOP

15
8 List of the protection functions
ANSI Protection Function and DSP Load ANSI Protection Function and DSP Load
Code the Setting Parameter in % Code the Setting Parameter in %
Digital Filtering as basic load 16 59 Overvoltage instantaneous 2
68 Inrush stabilization U>>> = 0,10 ... 3 Un
(Only in connection with I>> and I>) 3 t = 20 ... 300.000 ms
N = 2.0 ... 8.0 59 Overvoltage high 2
M = 3.0 ... 4.0 U>> = 0,10 ... 3 Un
Time = 220 ... 100.000 ms t = 70 ... 300.000 ms
67 Overcurrent directional high 7 59 Overvoltage low 2
I>> = 0,05 ... 40 In U> = 0,10 ... 3 Un
t = 70 ... 300.000 ms t = 70 ... 300.000 ms
67 Overcurrent directional low 7 27 Undervoltage instantaneous 2
I > = 0,05 ... 40 In U<<< = 0,10 ... 1,2 Un
t = 220 ... 300.000 ms t = 50 ... 300.000 ms
50 Overcurrent instantaneous 3 27 Undervoltage high 2
I>>> = 0,10 ... 40 In U<< = 0,1 ... 1,2 Un
t = 15 ... 300.000 ms t = 70 ... 300.000 ms
51 Overcurrent high 2 27 Undervoltage low 2
I>> = 0,05 ... 40 In U< = 0,1 ... 1,2 Un
t = 40 ... 300.000 ms t = 70 ... 300.000 ms
51 Overcurrent low 2 59N Residual overvoltage high 2
I > = 0,05 ... 40 In UNE>> = 0,05 ... 3 Un
t = 40 ... 300.000 ms t = 40 ... 300.000 ms
51 IDMT 3 59N Residual overvoltage low 2
Normal-, Very-, Extremely- or UNE> = 0,05 ... 3 Un
Longtime- inverse time characteristic t = 40 ... 300.000 ms
Ie = 0,05 ... 40 In
K = 0,05 ... 1,5 49 Thermal overload protection (thermal 3
equation 1st order
51N Earth fault high 3
with complete memory function)
IE>> = 0,05 ... 40 In Tn = 50 ... 400 °C (nominal temperature at In)
t = 70 ... 100.000 ms In (Mot) = 1 ... 10000 A
51N Earth fault low 3 (primary value of the nominal motorcurrent)
IE> = 0,05 ... 40 In Tini = 50 ... 120 % Tn
t = 70 ... 100.000 ms (initial temperature at power on)
67N Earth fault directional high 3 tcool = 10 ... 20.000 s
IE>> = 0,05 ... 40 In (time constant at I< 0.1 In and n = 0)
t = 40 ... 100.000 ms twarm = 10 ... 20.000 s (time constant normal)
twarm = 10 ... 20.000 s (time constant at I > 2 In)
forward- / backward direction
Tmax = 20 ... 400 °C (maximal temperature)
isolated (sin w) and earthed (cos w)
Twarn = 20 ... 400 °C (warn temperature)
67N Earth fault directional low 3 Tenvi = 50 ... Tini (environment temperature)
IE> = 0,05 ... 40 In
t = 40 ... 300.000 ms 51 Motor start protection 2
forward- / backward direction (adiabatic characteristic)
isolated (sin w) and earthed (cos w) Ie = 0,3 ... 1,2 In (motor current)
Is = 1,00 ... 20 Ie (start value)
67N Earth fault directional sensitive 12 t = 70 ... 300.000 ms
IE> = 0,05 ... 2 In I> = 0,6 ... 0,8 Is (motor start)
t = 120 ... 100.000 ms, for- / backward 51LR Blocking rotor (definite time characteristic) 3
Slope angle a = 0 ... 20°, Ie = 0,3 ... 1,2 In (motor current)
Slope angle d = - 180 ... 180° Is = 1,00 ... 20 Ie (start value)
UNE> = 0,05 ...0,7 Un t = 70 ... 300.000 ms
51N Earth fault IDMT 3 66 Number of starts 0
Standard, very, extremely or n(warm) = 1 ...10 (number of warm starts)
long time inversetime characteristic, n(cold) = 1 ...10 (number of cold starts)
Ie = 0,05 ... 40 In t = 1.02 .. 7200 s
K = 0,05 ... 1,5 T (warm) = 20 ... 200 °C
(temperature limit warm start)

16
ANSI Protection Function and DSP Load ANSI Protection Function and DSP Load
Code the Setting Parameter in % Code the Setting Parameter in %
21+79 Distance protection with autoreclosing 18 81 Frequency monitoring 2
System earthing = high/low ohmic Start at ∆f = 0,04 ... 5 Hz
ct - grounding = line side, bus bar side t = 1,02 ... 300 s
with/without earth start 25 Synchronism check 2
switching onto faults = normal, overreach ∆ U = 0,02 ... 0,4 Un
zone, trip after start t = 0,52 ... 1000 s
Signal comparison overreach ∆ w = 5 ... 50°
scheme time set = 30 .... 300.000 ms 55 Power factor controller 0
U / I- Start characteristic: Power factor = 0,70 ... 1,00
I>, IE> and IF> = 0,05 ... 4 In QC0 = 1,000 ... 20000,000 kVAr
UF< = 0,05 ... 0,9 Un Series of banks = 1:1:1:1 ... 1:2:4:8
Phase selection = cyclic/acyclic Number of banks : 1 ... 4
Earth factor: Insensitivity = 105 ... 200 % QC0
k = 0,00 ... 10,00 Threshold = 0 ... 100 % QC0
w (k) = -60 ... 60° Switching program = sequential/circuit
3 Impedance- and 1 overreachstage: switching
R = 0,05 ... 120 Ω (secondary values) Fault recorder 2
X = 0,05 ... 120 Ω (secondary values) Recording time = 1000 ... 5000 ms
t = 20 ... 10.000 ms Pre fault time: = 100 ... 2000 ms
1 directional stage Post fault setting = 100 ... 4900 ms
Max. 5 records
Direction 0 ... 90 bzw.-45 ... 135°
t = 25 ... 10.000 ms
1 non directional stage
t = 25 ... 10.000 ms
Note
2 shots AR with short/long time reclosing
87 Differential protection 22 Due to the limitation of the DSP calculation
Transformer group = 0 ... 11 power not all function blocks can be combi-
Transformer earthing = primary and ned without restrictions. Please refer to the
or secondary side following table for applicable restrictions
Nom. current In on the primary/secondary
side of the transformer = 0.00 ... 100.000A
(prim value)
Threshold current = 0,10 ... 0,50 In
Unbiased region limit = 0.50 ... 5 In
Slightly biased region threshold = 0,20 ... 2 In
Slightly biased region limit = 1,00 ... 10,0 In Function block Restrictions
Slope = 0,40 ... 1,00
Trip with Id> = 5,00 ... 40 In Protection functions Max. 12 protection functions
Blocking by 2nd harmonic = 0.10 ... 0.30 In Max. 120 protection parameters
Blocking by 5th harmonic = 0.10 ... 0.30 In
Max. 120 protection parameters
46 Unbalance load 9
Is = 0,05 ... 0,3 In 100% DSP load
(start value of the negative phase sequence) Fault recorder Max. 1 fault recorder and
K = 2 ... 30
Min. 1 configured protection function
tReset = 0 ... 200 s
Timer decreasing rate = 0 ... 100% Cycle time of application Max. 30 ms
32 Directional power 2 Memory object Max. 1
Nominal real power Pn = 1 ... 1000.000 kW
(primary values) Power counter Max. 15
Max.reverse load P> = 1 ... 50 % Pn
t = 1,02 ... 1000 s Switching object Max. 62
37 Low load 2 Threshold object Max. 10 per analog input
Nominal real power Pn = 50 ... 1000.000 kW
(primary values) Direct write-read command Max. 100
Minimal load P< = 5 ... 100% Pn Connections Max. 700, number of connections 502
Minimal current I< = 2 ... 20 % In
t = 1 ... 1000 s Signaling LED’s Max. 32 on 4 sides of 8 LED’s each
17
 REF542 plus. Bay Protection
and Control unit

9 Technical data
9.1 Analog input channels
Accuracy 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 A
Rated voltage Un 100 V / ö3 or 100 V (also suitable for 110 V)
Rated frequency fn 50 Hz / 60 Hz
Thermal load capacity
Current path 4 In continuous, 100 In for 1 s,
250 In (peak value) dynamic
Voltage path 2 Un /ö3 continuous.
Consumption
Current path ≤ 0,1 VA with In
Voltage path ≤ 0,25 VA with Un

9.1.2 With current and voltage sensor

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

9.2 Binary inputs and outputs

Each 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 extended

by corresponding configuration.

5 power outputs
Maximal Operation voltage 250 V AC/DC
Make current 20 A
Load current 12 A
Breaking capacity 300 W at L/R = 15 ms
Operation time 9 ms

18
2 signal outputs and 1 Watchdog - output
Operation voltage 250 V AC/DC
Load current 2 A
Operation time 5 ms
1 Static output (optionally)
Maximal Operation voltage 250 V AC/DC
Operation time 1 ms
1 switch circuit monitoring

9.2.2 With static outputs

14 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 by
corresponding configuration.
2 power outputs
Operation voltage 48 ... 265 V DC
Make current 70 A for t ≤ 10 ms
Load current 12 A for t ≤ 30 s
Operation time 1 ms
4 power outputs
Operation voltage 48 ... 265 V DC
Make current 16 A for t ≤ 10 ms
Load current 10 A for t ≤ 30 s
Operation time 1 ms
2 Signal outputs and 1 Watchdog - output
Operation voltage 48 ... 250 V DC
Make current 0,3 A
Operation time 1 ms
1 switch circuit monitoring

9.3 Interface
9.3.1 HMI Control Unit
● Optical interface to the
Notebook PC (at the front)
● Electrical isolated interface
according to RS485 to the
Central Unit (at the rear)
9.3.2 Central Unit:
● Electrical isolated interface
according to RS485 to the
HMI
● Electrical interface according
to RS232 for updating the
firmware

19
 REF542 plus. Bay Protection
and Control unit
9.4 Analog output board (optional) 10 Type test
Four channel 0 to 20 mA or 4 to 20 mA
All relevant tests according to
the standard IEC 60255,
9.5 Communication EN 61000 respectively to the new
(optional) product standard EN 50263
● SPABUS, electrical with RS232 interface or optical
connector snap-in type for plastic respectively 10.1 EMC
standard SMA type for glass fiber ● Interference suppression per
● LON (according to LAG1.4), optical with standard EN 55022 respectively.
ST connector for glass fiber IEC CISPR 11, Group 1
● IEC 60870-5-103 with extension according to ● Immunity to electrostatic
VDEW for controlling, optical with standard ST discharge per IEC 61000-4-2,
connector for glass fiber level 3
● Dual MODBUS RTU, electrical with two RS485 ● Immunity to radiated electro-
interfaces or optical with two standard ST magnetic energy per
connector for glass fiber IEC 61000-4-3, level 3
● Electrical fast transient or
burst per IEC 61000-4-4,
9.6 Power supply level 3
9.6.1 Central Unit ● Surge immunity tests per
Rated voltage 48 ... 220 V DC (-15%, +10%) or IEC 61000-4-5, level 3
selectable ● Immunity to conducted
10 V DC (-15%, +10%) respectively, disturbances induced by
220 V DC (-15%, +10%). radio frequency fields per
Power consumption ≤ 18 W IEC 61000-4-6, level 3
Inrush current ≤ 10 A peak value ● Power frequency magnetic
field immunity per
9.6.2 HMI Control Unit IEC 61000-4-8, level 5
● Pulse magnetic field immuni-
Rated voltage: 48 ... 110 V DC (-15%, +10%) or ty per IEC 61000-4-9, level 5
110 ... 220 V DC (-15%, +10%)
Power consumption ≤6W ● Damped oscillatory magne-
tic field immunity per
IEC 61000-4-10, level 5
9.7 Temperature range ● Oscillatory waves immunity
Operation -5 ... + 55 °C per IEC 61000-4-12, level 3
Transport and storing -20 ... +70 °C ● Oscillatory waves immunity
in the range from 0 to 150
9.8 Degree of protection kHz per IEC 61000-4-16,
level 3
9.8.1 Central Unit
● Ripple on DC input power
Housing IP20 port immunity per
IEC 61000-4-17, level 3
9.8.2 HMI Control Unit ● Voltage dips, short interrupti-
ons and voltage variations
Front IP 54 on DC input power ports per
Rear IP 22 IEC 61000-4-29, 50 ms.
20
10.2 Insulation 10.3 Mechanical 10.4 Climatic conditions
● Voltage test per IEC 60255-5 robustness ● Cold test per IEC 60068-2-1
with 2 kV RMS, 50 Hz ● Vibration test per ● Dry heat test per
during 1 Min IEC 60255-21-1 IEC 60068-2-2
● Impulse voltage withstand ● Shock response and with- ● Damp Heat and Cycling test
test per IEC 60255-5 with stand test per IEC 60068-2-2 per IEC 60068-2-30
5 kV 1,2/50 µs.
● Seismic test per IEC 60068-2-30

11 Connection Diagram
11.1 Connector Plate
REF542 plus Mixed Connector plate for the REF542 plus Mixed connector plate for the
wide case version standard case version

X80 X80
1 5 9 13 17 21 1 5 9 13 17 21
3 7 11 15 19 23 3 7 11 15 19 23
2 6 10 14 18 22 2 6 10 14 18 22
4 8 12 16 20 24 X86 X85 X84 X83 X82 X81 4 8 12 16 20 24 X86 X85 X84 X83 X82 X81

X77 X76 X75 X74 X73 X72 X70 X73 X72 X70
X71 X77 X76 X75 X74 X71

X65 X64 X63 X62 X61 X60 X65 X64 X63 X62 X61 X60

X50 X31 X30

X41 X40 X21 X20

X31 X30
3 2 1
X21 X20
X10
- +
3 2 1

X10
- +

REF542 plus Sensor plate version for the 11.2 HMI Control Unit
standard and wide case
Power Supply and communication connection
for HMI Control Unit

X88 X87 X86 X85 X84 X83 X82 X81

1 2 3 4 5

REF542 plus Transformer plate version for X20 X10

the standard and
TRANSFORMER wide AND
STANDARD caseWIDE CASE VERSION
1 5 9 13 17 21
3 7 11 15 19 23
- X10: Power Supply
2 6 10 14 18 22
4 8 12 16 20 24
- X20: RS 485 to Central Unit

21
11.3 REF542 plus with mechanical binary I/O
Example of REF542 plus base version with one mechanical binary I/O version 3 (BIO3). Extension up to two
additional mechanical binary I/O version 3 (BIO3) possible. Other configuration of the analog input board
available, e.g mixed configuration for transformers and sensors connection.

Note: Please connect the right polarity Extension with second additional
on Binary output BO02. mechanical binary I/O version 3 (BIO3)

-X10: 1 2 3
-X80: -X30: -X31:
1A + - +
11 d02
5A - BI15 z02
07 T4 z02 BO09
AI 04 DC + z04
03 d04 d02
1A - BI16
22 z04
5A DC d04
18 T5 + +
d06 z06
AI 05 - BI17 BO10
14 z06 z08
1A + -
10 d08 d06
5A - BI18
06 T6 z08 d08
AI 06 +
02 d10 d10
100/110V BI19 BO11
21 - d12
z10
AI 01 T1 z10
17 +
100/110V d12
05 - BI20 z12
AI 02 T2 z12
01 d14
+ BO12
100/110V d14 d16
23 - BI21
AI 03 T3 z14 z14
19 +
1A d16 z16
24 - BI22
5A T7 z16 d18
20 + BO13
AI 07 d18 d20
16 - BI23
1A z18 d22
12 BO14
5A T8 e.g. CT 1/5 A + z18
08 d20
AI 08 -X21: - BI24 z20
04 z20
-X20: + z22
+ + d22
d02 z02 - BI25 d24
- BI01 z04
z22
z02 z24
+ BO15
+ d02 d24 z26
d04 - - BI26
- BI02 d04 z24
z04 z28
+ +
+ z06 d26 d26
d06 - BI27 BO16
- BI03 z08 z26 d28
z06 - +
d06 d28 d30
+ - BI28
d08 d08 z28 z30
- BI04 WD2
z08 d10 z32
+
d10 d12
- BI05
z10 z10
+ z12
d12
- BI06 d14
z12
d14
+
BI07
d16 Extension with third additional
- z14
z14
d16
+ z16 mechanical binary I/O version 3 (BIO3)
- BI08 d18
z16
d20
+
d18 d22
- BI09 -X41:
z18 z18 -X40:
+ +
d20 d02
z20 - BI29 z02
- BI10 z02 BO17
z20 z22 z04
+
+ d24 d04 d02
d22 - BI30
- BI11 z24 z04 d04
z22 +
d06 + z06
+ z26
d24 - BI31 BO18
- BI12 z06 z08
z24 z28 + -
+ d26 d08 d06
d26 - BI32
BI13 z08 d08
- d28
z26 + d10
d30 d10 BO19
+ - BI33 d12
d28 z10
- BI14 WD1 z30
z28 + z10
z32 d12
- BI34 z12
z12
d14
+ BO20
d14 d16
- BI35
z14 z14
+
d16 z16
- BI36
z16 d18
+ BO21
d18 d20
- BI37 d22
z18
BO22
+ z18
d20
- BI38 z20
z20
+ z22
d22
- BI39 d24
z22
+ z24
d24 BO23
BI40 z26
-
z24
z28
+
d26 d26
- BI41 BO24
z26 d28
+
d28 d30
- BI42
z28 WD3 z30
z32

22
22
 REF542 plus. Bay Protection
and Control unit
11.4 REF542 plus with solid state binary I/O
Example of REF542 plus base version for sensor connection with one solid state binary I/O version 3. Extension
up to two additional solid state binary I/O possible. Other configuration of the analog input board available, e.g
mixed configuration for transformers and sensors connection.

Note: Please connect the right polarity Extension with second additional
solid state binary I/O.

-X10: 1 2 3 -X31:
-X30:
+ - +
d02
A Sensor 1 - BI15
-X81: D z02
DC d04
+
A Sensor 2 - BI16
-X82: D z04 +
DC d02
+ BO10
A d06 d04
-X83: D Sensor 3 z06
- BI17
+ -
A d08 z02
-X84: D Sensor 4 - BI18
z08 z04
+
A d10
-X85: D Sensor 5 - BI19 +
z10 d06
+ BO11
A d12 d08
-X86: D Sensor 6 z12
- BI20
-
A + z06
-X87: Sensor 7 d14
D - BI21 z08
z14
A + +
-X88: Sensor 8 d16 d10
D - BI22 BO16
z16 d12
+ -
d18 z10
- BI23 z12
-X20: -X21: z18
+ + +
d02 d20 d18
- BI01 - BI24 BO12
z02 z20 d20
BO14
+ + d22
d04 d22 BO13 +
- BI02 - BI25 z20
z04 + z22 BO20 +
d02 + z22
+ d24
d06 d04 - BI26 z18
- BI03 z24 +
z06 d24
- + BO17
+ d26 z26
d08 z02 - BI27
- BI04 z26 +
z08 z04 z28
+ BO18
+ d28 d28
d10 - BI28 +
- BI05 + z28 d30
z10 d06 WD2
z32
+ d08
d12
- BI06
z12
-
+ z06
d14
- BI07 z08
z14
d16
+
- BI08
+
d10 Extension with third additional
z16 d12
d18
+ -
z10 solid state binary I/O
- BI09 z12
z18
+ +
d20 d18
- BI10 d20
z20 -X40: -X41:
+ d22 +
d22 + d02
- BI11 z20 - BI29
z22 + z02
+ z22 +
d24 d04
- BI12 z18 - BI30 +
z24 + z04 d02
d24 + BO20
+ d06 d04
d26 z26 - BI31
- BI13 + z06
z26 z28 -
+ z02
+ d08
d28 d28 - BI32
- BI14 + z08 z04
z28 d30 +
WD1 d10
z32 - BI33 +
z10 d06
+ BO20
d12 d08
- BI34
z12
-
+ z06
d14
- BI35 z08
z14
+ +
d16 d10
- BI36 BO25
z16 d12
+ -
d18 z10
- BI37 z12
z18
+ +
d20 d18
- BI38 BO21
z20 d20
BO23
+ d22
d22 BO22 +
- BI39 z20
z22 BO24 +
+ z22
d24
- BI40 z18
z24 +
d24
+ BO26
d26 z26
- BI41 +
z26 z28
+ BO27
d28 d28
- BI42 +
z28 d30
WD3
z32

23
 We reserve the right to make changes in the course of technical development.
Leaflet no. DECMS 2285 01 E Printed in Germany (04.01-1000-PPI)

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

Oberhausener Strasse 33 Petzower Strasse 8 Via Friuli, 4
D-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: +39 035/395874
E-mail: [email protected] E-mail: [email protected]
Internet: http://www.abb.de/calor Internet: http://www.abb.com