REF542 plus

Bay Protection and Control Unit

Table of Contents
1

General

Functions

2.1

Configuration

2.2

Operation

2.2.1

List of the
protection functions

16

9
9.1

Technical data
Analog input channels

18
18

LCD display

9.1.1

2.2.2

Status Indication

With current
and voltage transformer

18

2.2.2.1

Operational status

With current
and voltage sensor

18

9.1.2

2.2.2.2 Communication status

9.2

Binary inputs and outputs

18

2.2.2.3 Alarm indication

9.2.1

2.2.2.4 Interlocking status

With mechanical relays

(BIO 3)

18

2.2.3

LED Indication

9.2.2

With static outputs

19

2.2.4

Bar displays

9.3

Interface

19

2.2.5

Control push buttons

9.3.1

HMI Control Unit

19

2.2.6

Electronic key

9.3.2

Central Unit

19

2.3

Measurement

9.4

2.3.1

Values measured directly

Analog output board

(optional)

20

2.3.2

Calculated values

9.5

Communication (optional)

20

2.3.3

Other values

9.6

Power supply

20

2.4

Protection

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

2.9.2

Binary inputs and outputs

13

10
10.1

Type test
EMC

20
20

Diagnosis and monitoring

13

10.2

Insulation

21

Analog output

13

10.3

Mechanical robustness

21

Communication

14

10.4

Climatic conditions

21

Housing

15

7
7.1

Mechanical design
REF542 plus
standard case version

15

11
11.1

Connection Diagram
Connector Plate

21
21

11.2

HMI Control Unit

21

15

11.3

REF542 plus
wide case version

REF542 plus with

mechanical binary I/O

22

15

11.4

Analog inputs

15

REF542 plus with

solid state binary I/O

23

7.2
7.3

REF542 plus. Bay Protection

and Control unit
1 General
The REF542 plus is a Switchbay
Protection and Control Unit and
is the further development of
the former REF542 multifunctional unit. Like its predecessor, it features the following
functions:

Protection

Measurement

Control

Monitoring

All functions mentioned above

and also power quality functions
are integrated in a programmable
environment. The exceptional
flexibility and scalability of
these new generation devices
make it possible to integrate all
the secondary functions in a
unique device, leading to a

smart and clean solution where

the traditional approach is
ineffective and expensive.
The following figures show
examples of the installation of
the REF542 plus in several
switchgears for the switchbay.

Figure 1: REF542 plus

installed in
gas-insulated
switchgears (GIS)

Figure 2: REF542 plus

installed in an
air -insulated
switchgear (AIS)

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 separation 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
(CP) is needed for adaptation to
a station automation system.
A block diagram of the REF542
plus is shown in figure 3.

Figure 3: Block diagram

of REF542 plus

Interbay bus

HMI
Human Machine
Interfeace

The REF542 plus, as shown in

figure 3, consists of two parts,
a Central Unit and a separate
Human Machine Interface
(HMI) as the Control Unit.
The Central Unit contains the
power supply, processor and
analog and binary Input and
Output (I/O) modules, as well
as optional modules for supplementary functions.
The HMI Control Unit is a
stand-alone unit with its own
power supply. It can be installed
on the Low Voltage (LV) compartment door or in a dedicated
compartment close to the
Central Unit. The HMI is normally used to set the protection
parameters and to locally
operate the switching devices
in the switchbay. The HMI is

CP
Communication
Processor

Control unit

Analog
inputs

DSP

MC

Protection and
Measurement
Processor

Control and
Command
Processor

Binary
Inputs

Binary
Outputs

Analog
Outputs

Central unit

connected to the Central Unit

by a shielded, isolated twisted
pair according to the RS485
standard interface. Figure 4
shows an installation of the
Central Unit and the HMI
Control Unit in the LV compartment of a switchboard for the
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 configuration software tool, which is
also used to define the protection and the control scheme.
Figure 5: View of the HMI Control Unit

REF542 plus. Bay Protection

and Control unit
The left half of the LCD display
is reserved for the Single Line
diagram. The right half is used
to display the appropriate menu
or submenu as determined by
the user. Two different electronic
keys with different access rights
are available. Each of the keys
are programmed to permit
either:
the parameterization of the
protection functions
the mode selection of the
control functions
Three freely programmable LED
bars have been provided on the
front of the HMI Control Unit.
Each LED bar consists of ten
green and two red LEDs and is
user configurable to display any
measurement value required.
The red LEDs are used to indicate values above the rated
value.

2 Functions
The REF542plus Switchbay
Protection and Control Unit
integrates all of the secondary
functions in a single unit. This
multifunctional unit also features a self-monitoring function.
All functions are designed as
freely configurable software
modules. Therefore, a wide
range of operation requirements in MV stations can be
met without any problems.
The versatility of the software
makes it possible to use the
REF542 plus on every switchboard irrespective of the
specific application required.

The functions of the REF542

plus can be tailored to the
requirements of the system by
application of a user-specific
configuration. The user-specific
configuration is loaded during
commissioning. For that purpose
the configuration computer,
normally a personal computer
(notebook) running Windows
NT, is connected to the optical
interface on the front side of
the HMI Control Unit.
The interface of the multifunctional unit REF542 plus to
the Medium Voltage (MV)
system as the primary
process is as follows:

Analog inputs to measure

current and voltage signals
from conventional current
and voltage measurement
transformers or from current
and voltage measurement
sensors
Binary inputs with optical
couplers for the galvanic
separation of the external
signals to be processed
Binary outputs with conventional mechanical relays or
static outputs for the control
of switching devices in the
compartment of the switchboard
Optional four channel
analog outputs 0 to 20mA or
4 to 20 mA
Optional connection to ABB
or third party station automation system.

2.1 Configuration
Each application for protection
and control can easily be
configured by software function
modules, which make arbitrary
definition of the following
features as part of the secondary
system possible:
LEDs (assignment and
colors) for local indication
Single Line diagram to show
the status of the switching
devices
Protection schemes as
required
Control schemes as needed
Interlocking schemes
Automation sequences

All functions in the switchbay

can be specified in collaboration
with ABB. The result of the
configuration is saved and
delivered together with the
switchboard to the users.
The configuration software
is also provided to the user to
make available the full potential
of the multifunctional unit to
the field operators. Thanks
to a Functional block Programming Language (FUPLA)
the REF542 plus Switchbay
Protection and Control Unit
offers engineers, especially
those who are not software
experts, the opportunity of
easily updating the operation
and handling of the switchbay
using a personal computer.

With the REF542 plus the user

has the benefit of a secondary
system that is fully integrated in
a true programmable controller.
This flexibility is very advantageous for defining control
functions for automation
sequences, which can, for
example, include theinterlokking of the switching devices,
blocking the release of specific
protection functions, as well
as starting switching sequences.
The new REF542 plus multifunctional unit provides a wide
range of logical functions so
that each required control
schemes can be configured.
The range of logical functions
includes:
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 definition
of the control scheme, each
required protection scheme can
be configured by the combination 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

Under- respectively
overvoltage protection
Distance protection
Differential protection for
transformer and motor
Thermal protection for cable,
transformer and motor
Reverse power protection
Synchronism check

Note
The specific software
configuration of the required
protection scheme can only be
carried out in-house at ABB.

The protection scheme parameters

can be changed via the HMI
Control Unit without using a
personal computer. But users
can additionally perform certain
functions on site by means of a
personal computer (notebook),
which is connected to the
optical interface on the front of
the HMI Control Unit and the
provided 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

2.2 Operation
A wide range of functions can generally be controlled and operated using the simple, user-friendly interface on the HMI Control
Unit. This user-friendly interface is shown in the following figure.

Figure 6: HMI as Control Unit

The HMI consists of the following features:

7

2.2.1 LCD display

The back-illuminated LCD
display of the HMI provides
a graphical display of the switching devices in the switchbay
controlled by the REF542 plus.
The intensity and the duration
of the illumination can be set
as required. The Single Line
diagram shows the current
status of all the switching
devices. The right half of the
LCD display is for plain text,
such as measurement values,
main menu and submenus
descriptions, protection
signals and event recording.
On the LCD display, the following can be shown:
Up to eight switching device
icons (when the binary
I/O boards with mechanical
relays are used, a maximum
of seven switching devices
can be controlled)
Various icons for motors,
transformers, sensors,
transducers
A maximum of 40 individual
lines.

2.2.2 Status Indication

Four system LEDs indicate the
status of the REF542 plus.
These LEDs are:

2.2.2.1 Operational status

On the HMI front panel, the
operational status is called
Ready and is displayed by a
green LED. The unit is not
operational if this LED is off,
and this occurs for example
during the downloading of the
configuration for the operation
of the switchbay or if a fault is
detected in the Central Unit.
8

2.2.2.2 Communication
status

2.2.4 Bar displays

On the HMI front panel, this

communication status is called
Network Communication.
If the REF542 plus is to be
connected to a station automation system, an extension
with an appropriate communications board is required.
In this case a green LED is
used to indicate the correct
operational status of the
optional board. The LED color
changes to red if a communication failure has occurred.

Three freely programmable LED

bars are provided for showing
the measurement values.
The LED bars are used to display
arbitrary measurement values as
required. Each bar consists of
ten green and two red LEDs.
The nominal values of each LED
bar, which corresponds to the
ten green LEDs are defined by
the configuration software.
If the measurement values are
higher than the rated values,
the red LEDs will light
indicating an overload situation.

2.2.2.3 Alarm indication

2.2.5 Control push buttons

Several arbitrary alarm conditions can be defined and

configured by the user.
If one of these conditions is
fulfilled, the red LED will be on.

The control push buttons are

used for operation of the
switching devices during local
control. A total of eight push
buttons are available, four for
commanding the primary
equipment and four for
browsing the display.
Also configured is a situation
whereby an emergency push
button pressed simultaneously
with a normal Circuit Breaker
(CB) push button opens the CB
in the event of an emergency.

2.2.2.4 Interlocking status

The LED is green if no interlokking conditions have been
violated. In case of a switching
action, which violates the
interlock conditions such as
switching a disconnector in
theclosed condition of the
Circuit Breaker (CB), the color
will change temporarily to red.

2.2.3 LED Indication

Eight freely programmable,
three color LEDs are provided
for local indication. The
number of LED display options
can be quadrupled through the
menu structure. As a result,
a total of 32 indication options
are available for status indication
regarding protection, control,
monitoring and supervision
functions.

2.2.6 Electronic key

Two different electronic keys
are provided. One key can only
be used for the parameterization
of the protection scheme.
The other one is for the selection
of the control modes which can
be switched off or in one of the
three other modes provided:
local, remote or local/remote
control mode. By using these
two keys a certain separation
between protection and control
operation can be achieved.
If required a general key that
permits access to both modes is
provided. The sensor for re-

cognizing which electronic key

has been used is located on the
front panel of the HMI Control
Unit.

2.3.1 Values measured

directly
Line currents, three phases
Phase voltages, three phases
Earth current or residual
voltage
Frequency
From the above measured
quantities the following values
can be calculated:

2.3 Measurement
The REF542 plus Switchbay
Protection and Control Unit
consists of eight analog inputs
for measuring current and
voltage signals. These are
organized into four groups with
two groups of three inputs
each, one input for current or
voltage measurement regarding
to earth faults detection or
voltage measurement for
synchronism checking, and a
further input only for measurement purposes. Every group
can measure voltage or current.
As well as six-phase voltage
measurement for the application
in a measurement switchbay,
six phase current measurements
for transformer differential
protection is also possible.
The most common configuration uses three current and three
voltage inputs and one earth
fault current input. All values
are shown on the display as
primary values. The values
registered over an extended
time period, for example energy, number of CB operations,
maximum and measurement
values are permanently saved.
Even after power interruptions
this data is still available. Using
this common configuration, the
following measured values are
displayed:

Apparent, active and reactive

power
Power factor
Active and reactive energy
Moreover, the following quantities for monitoring purposes
can be provided:

2.3.3 Other values

2.3.2 Calculated values

Line voltages, three phases

Earth current or residual
voltage
Average value/maximum
value current, three-phase
(determined over several
minutes)

Operating hours
Switching cycles
Total switched currents
Metering pulses from an
external metering device
(up to 10)

2.4 Protection
The REF542 plus offers a wide
range of functions for protection.
As has previously been mentioned, a wide range of protection
schemes for the protection of
several system components can
be configured. The available
protection functions can be
combined together to form a
protection scheme as required.
But the combination possibilities

(11)
(12)

are limited by the computing

capacity of the DSP, as each
protection function increases
the DSP load. The maximum
load applied by all of the
protection functions may not
exceed the 100% DSP computing
capacity. Figure 7 shows an
example of a configured
protection scheme.

(14) START IDMT>>

(14) START IDMT>>

BL
FAULTRECORDER

(18) START I>>>

(13)

(19) TRIP IDMT>>

(15)
(16)

(18) START I>>>

(17)

OVERFLOW

(14) START IDMT>>

(20) TRIP IDMT>>>

(18) START I>>>

(21)

START

Figure 7: FUPLA
protection scheme
9

REF542 plus. Bay Protection

and Control unit
2.5 Control
The REF542 plus permits convenient local
operation with full interlocking against
switching errors. The switch position of the
various switching devices in the switchbay
can be shown on the LCD display of the
HMI Control Unit. If local control mode is
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
using the correct electronic key.
In remote control mode, only switching
actions via a remote control unit like a
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.
Interlocking between the switchbays
connected to the same bus bar system can
also be taken into account. This requires
the availability of status information of the

(25) INTERLOCKING OPEN

(31) INTERLOCKING CLOSE
(28)
(24) CB OPEN
CIRCUIT BREAKER

(23) KEY REMOTE

(29)
(30) CB CLOSE
(23) KEY REMOTE

(34) CB DEF OPENED

(35) CB DEF CLOSED

(26)
(22) RELEASE

(34) RELEASE

(33) CB OPEN COMMAND

(32) CB CLOSE COMMAND

Figure 8: FUPLA control scheme

switching devices to and from

other switchbays. The status
information must be provided
either by a conventional, hard
wired ring bus system or by the

more sophisticated ABB stationautomation system. Figure 8

shows an example of a
configured control scheme of
the Circuit Breaker.

2.6 Event recording

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

10

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
synchronized by the GPS clock
or the station automation system.
In the next figure, a list of
recorded events is shown.

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 combination of pre- and post fault time.
The records are saved using a
typical ring buffer process, i.e.
the oldest fault record is always
overwritten with a new one.
The number of saved fault records
depends on the record time.
For example, a maximum of
5 fault records can be saved
with a recording time of 1s.
The fault records can be exported
and converted by the configuration software. The transfer of the
fault records via the interbay bus
using the foreseen communication
protocols is also possible. Figure
10 shows a record of a cross
country fault in an earth fault
compensated MV system starting
with the earth fault.

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

2.8 Real time clock

The internal clock is not buffered by batteries but by
a special capacitor. In case of DC power supply failure,
the stored electrical energy in the capacitor ensures
continued operation of the internal clock for at least
another two hours. The date and time of the clock
can be set via the HMI Control Unit.
If required, as shown in the next figure, the clock
can be synchronized by an external master clock
(e.g. GPS) through a standard IRIG B interface. Using
this, a real time accuracy of up to 1ms can be achieved.
Note
The standard IRIG B - Interface will be available from
third quarter 2001!

GPS Clock

1.25 MB/s LON LAG 1.4 (optical interface)

xxx

xxx

xxx

xxx

xxx

xxx

xxx

xxx

xxx

In case of connection to a station automation

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
communication bus.

xxx xxx xxx

RER111 Starcoupler

REF542 plus

REF542 plus

REF542 plus

Figure 11: Synchronization of

the internal clock by a GPS
master clock
11

2.9 Process interface

To carry out the protection,
measurement and control
schemes, an interface to the
primary process is needed.
As well as the analog system
quantities like the primary
current and voltage quantities,
the binary status information
of the switching device in the
switchbay is also required in
order to carry out the implemented task. Furthermore
binary outputs for operating
the Circuit Breaker and other
switching devices must also
be considered.
The process interface will be
described in the following
paragraphs:

The current sensor is based on

the principle of the Rogowski
coil and consists of a single
air-cored coil. Due to the lack
of an iron core, the saturation
effects of conventional current
transformers do not exist
anymore. Current sensors are
thus well suited for the deployment of distance protection and
differential protection functions.
The current sensor measures
the current value using a voltage
signal that is proportional to the
derivative of the primary current
being measured. The numerical
integration of the signal is
performed using the DSP in the
REF542 plus unit. The current

sensors cover a range between

0.5 to 2.0 of the rated current.
The 80 A current sensors are for
example very suitable for
applications between a current
range of 40 A to 160 A.
The voltage sensor is based on
the principle of the resistive
divider from which the signal is
obtained and is of a type that
cannot be saturated. Therefore
the voltage sensor is linear
throughout the measuring
range. The output signal is a
voltage that is directly proportional to the primary voltage.
The next figures show a photograph of the combined sensors.

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 characteristic, these modern current and
voltage sensors provide greater
accuracy and reliability in the
measurement of signals. Compared to conventional measurement transformers, the new
sensors have the following
advantages:
High accuracy
Compact dimensions
Wide dynamic range
Easy integration in the
switchboard

12

Figure 12: Combined sensor

Thanks to their small dimensions,

both current and voltage
sensors can be integrated
as a combined sensor in a
single resin unit.
A capacitive divider is incorporated in the combined sensor
to provide a power supply for
power on indicator lamps.
The output signals of the current
and voltage sensors are connected
directly to the Central Unit of
the REF542 plus. In the case of

connections to conventional
measurement transformers the
use of supplementary intermediate converters in the Central
Unit are required. By using
either modern sensors or
conventional measurement
transformers, the accuracy class
1 can be fulfilled, on condition
that the current and voltage
measuring values are in the
range of the corresponding
rated values.

REF542 plus. Bay Protection

and Control unit
2.9.2 Binary inputs and
outputs
The primary switching devices
are monitored either through
the auxiliary contacts or through the related sensors, which
provide the status information
of all the switching compartments in the switchbay. Besides
that, signals coming from
auxiliary components are also
monitored. Consequently at this
interface the following actions
are achieved:
Control and interlocking of
the primary switching device
in the switchbay
Control the Circuit Breakers,
disconnectors, earthing
switches
Supervision of the spring
status, the continuity of
Circuit Breaker open coil,
the status of the switching
device.
Providing output pulse
signals for external energy
counting systems .
Control the drive motors of
the disconnectors
Providing the information
regarding internal failure
(watchdog).
The interface to the process
binary I/O boards is considered. The inputs of the binary
signals are isolated by an optocoupler. In most applications
mechanical relays can be provided as binary outputs. But in
high level applications, like a
switchboard in which motors
are driven directly, static power
outputs are required. A maximum of 3 binary I/O board can
be installed.

3 Diagnosis and monitoring

The REF542 plus is in a position to monitor the condition of the
system, including the switching devices. Maintenance requirements can thus be adapted to the actual system condition in order
to reduce down times. The following table shows the parameters
monitored by the REF542 plus. All the parameters are transmitted
to the central control system where they are analyzed and processed,
so that the diagnostic systems can be provided with data for
reliability calculation in order to predict the remaining
service 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

4 Analog output
An optional analog output board with four configurable outputs can
be used. The output signal of this board can be set in the range
from 0 to 20 mA or 4 to 20 mA. Each of the four channels can be
independently activated and parameterized by the configuration
software. 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

13

REF542 plus. Bay Protection

and Control unit
5 Communication
An optional communications
board is provided for communication with the station automation system. This can be an
ABB station automation system or
a third party system. When using
the ABB station automation
system, all of the information
provided by the REF542 plus can
be completely accessed so that
the following centralized remote
functions 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 data
The following protocols for
connection to ABB station
automation system are available:

6 Mechanical
design

SPA-bus
LON-bus per ABB Lon Application Guide (LAG) 1.4
definitions
In case of connection to ABB
station automation systems with
LON-Bus per LAG1.4, in which a
MicroScada system is present, the
related library LIB542 can be
provided. The next figure shows
an example of the connection of
REF542 plus multifunctional units
in an ABB station automation
system using LON per LAG1.4
communication protocol.
When a communication to a
third party station automation
system has to be realized, an
optional interface complying
with the following protocols
are considered:

14

2 I/O plug-in boards for control of up to 5 switching

devices.
1 optional plug-in communication board as an interface to
the ABB-system bus (SPABUS
or LON as defined in LAG1.4)
or as well to the Standard
IEC 60870-5-103 extended
according to VDEW as also to
standardize MODBUS RTU.

MicroScada
station control

Remote control centres

Ethernet (LAN)

COM 5XX

GPS Clock

1.25 MB/s LON LAG 1.4 (optical interface)

Figure 13: Connection of the

RE542 plus in an ABB station
automation system

6.2 REF542 plus wide

case version:

6.1 REF542 plus standard

case version:

IEC 60870-5-103 standard

including the extension
according to VDEW (Vereinigung Deutscher Elektrizittswerke = association of
German utilities)
Dual MODBUS RTU
The optional communication
board for MODBUS RTU is
available in two hardware
versions: The first one with
two redundant RS485 communication ports and the second
one with two optical, glass fiber
communication ports having
standard ST connectors.

3 I/O plug-in boards for

control up to 8 switching
devices (with static I/O board,
only 7 switching devices with
mechanical I/O board).
1 optional plug-in board for
output of 4 configurable
analog signals 0 to 20 mA
or 4 to 20 mA.
1 optional communication
board as an interface to
ABB-system bus (SPABUS or
LON as defined in LAG1.4)
or as well to Standard
IEC 60870-5-103 extended
according to VDEW as also
to standardize MODBUS RTU.

xxx

xxx

xxx

xxx

xxx

xxx

xxx

xxx

xxx

xxx xxx xxx

RER111 Starcoupler

REF542 plus

REF542 plus

6.3 Analog inputs

The analog inputs of REF542 plus
are available in different version
and can be equipped with the
following combination of transposing current and/or voltage
transformer:
3 or 6 current transformers for
phase currents
3 or 6 voltage transformers for
phase voltages
2 current or voltage transformer for the residual current or
voltage
In case of application of combined
sensors are used, the signals are
connected by Twincam ST plugs.

REF542 plus

7 Housing

204
(PANEL CUT OUT 206 0,5 )
13

44

REF542 plus
Network Communication

Alarm

Interlocking Error

M1

CONNECTOR

100%

M2
0

100%

119

Open
CB

M3

1 2 3 4 5

100%

CONNECTOR

Menu

Figure 14: Dimension of the HMI Control Unit

97,5 0,1
97,5 0,1

75,5 0,1

M4

233,5 0,1

10

M4

18

233,5 0,1

10
FIXING
BOTTOM

ca. 70

33

261,5

SPACE FOR
CONNECTORS

FIXING
BACK

184 0,1

12

229

233,5 0,1

10

18

FIXING
BACK

75,5 0,1
75,5 0,1

Figure 15: Dimension

of the standard case
version

ca. 70

261,5

SPACE FOR
CONNECTORS
233,5 0,1

10

18

97,5 0,1

12

185

244,8

106,3 0,1

M4

Figure 16: Dimension

of the wide case
version

M4

FIXING
TOP

97,5 0,1

140 0,1

244,8

244,8

106,3 0,1

106,3 0,1
244,8

33

18

FIXING
BOTTOM

106,3 0,1

M4

(PANEL CUT OUT121 0,5 )

Ready

75,5 0,1

The dimension of the HMI Control Unit is shown in the next

figure.

215

130

The REF542 plus housing for the

Central Unit is made from sheet
metal. Its exterior chromatized to
protect the housing against
corrosion and simultaneously to
gain the shielding against
EMC disturbances. The Central
Unit is very suitable for safe
integration into a switchboard.
A standard and a wide case
version, as shown in the following figures are available.
In the standard case version,
two binary I/O boards and
an optional communications
board can be used. The wide
case version contains an additional binary I/O board and
the analog output board.

M4

FIXING
TOP

15

8 List of the protection functions

ANSI
Code

Protection Function and

the Setting Parameter

DSP Load
in %

Digital Filtering as basic load

16

68

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

ANSI
Code

Protection Function and

the Setting Parameter

59

Overvoltage instantaneous
U>>> = 0,10 ... 3 Un
t = 20 ... 300.000 ms

59

Overvoltage high
U>> = 0,10 ... 3 Un
t = 70 ... 300.000 ms

DSP Load
in %

67

Overcurrent directional high

I>> = 0,05 ... 40 In
t = 70 ... 300.000 ms

59

Overvoltage low
U> = 0,10 ... 3 Un
t = 70 ... 300.000 ms

67

Overcurrent directional low

I > = 0,05 ... 40 In
t = 220 ... 300.000 ms

27

Undervoltage instantaneous
U<<< = 0,10 ... 1,2 Un
t = 50 ... 300.000 ms

50

Overcurrent instantaneous
I>>> = 0,10 ... 40 In
t = 15 ... 300.000 ms

27

Undervoltage high
U<< = 0,1 ... 1,2 Un
t = 70 ... 300.000 ms

51

Overcurrent high
I>> = 0,05 ... 40 In
t = 40 ... 300.000 ms

27

Undervoltage low
U< = 0,1 ... 1,2 Un
t = 70 ... 300.000 ms

51

Overcurrent low
I > = 0,05 ... 40 In
t = 40 ... 300.000 ms

59N

Residual overvoltage high

UNE>> = 0,05 ... 3 Un
t = 40 ... 300.000 ms

51

IDMT
Normal-, Very-, Extremely- or
Longtime- inverse time characteristic
Ie = 0,05 ... 40 In
K = 0,05 ... 1,5

59N

Residual overvoltage low

UNE> = 0,05 ... 3 Un
t = 40 ... 300.000 ms

49

Earth fault high

Thermal overload protection (thermal

equation 1st order
with 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

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

51LR

Blocking rotor (definite time characteristic)

Ie = 0,3 ... 1,2 In (motor current)
Is = 1,00 ... 20 Ie (start value)
t = 70 ... 300.000 ms

66

Number of starts
n(warm) = 1 ...10 (number of warm starts)
n(cold) = 1 ...10 (number of cold starts)
t = 1.02 .. 7200 s
T (warm) = 20 ... 200 C
(temperature limit warm start)

51N

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

t = 70 ... 100.000 ms
51N

67N

Earth fault low

IE> = 0,05 ... 40 In
t = 70 ... 100.000 ms

Earth fault directional high

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

t = 40 ... 100.000 ms
forward- / backward direction
isolated (sin w) and earthed (cos w)
67N

67N

Earth fault directional low

IE> = 0,05 ... 40 In
t = 40 ... 300.000 ms
forward- / backward direction
isolated (sin w) and earthed (cos w)
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

16

Earth fault IDMT

Standard, very, extremely or
long time inversetime characteristic,
Ie = 0,05 ... 40 In
K = 0,05 ... 1,5

ANSI
Code

Protection Function and

the Setting Parameter

21+79

Distance protection with autoreclosing

System earthing = high/low ohmic
ct - grounding = line side, bus bar side
with/without earth start
switching onto faults = normal, overreach
zone, trip after start
Signal comparison overreach
scheme time set = 30 .... 300.000 ms
U / I- Start characteristic:
I>, IE> and IF> = 0,05 ... 4 In
UF< = 0,05 ... 0,9 Un
Phase selection = cyclic/acyclic
Earth factor:
k = 0,00 ... 10,00
w (k) = -60 ... 60
3 Impedance- and 1 overreachstage:
R = 0,05 ... 120 (secondary values)
X = 0,05 ... 120 (secondary values)
t = 20 ... 10.000 ms
1 directional stage
Direction 0 ... 90 bzw.-45 ... 135
t = 25 ... 10.000 ms
1 non directional stage
t = 25 ... 10.000 ms
2 shots AR with short/long time reclosing

18

Differential protection
Transformer group = 0 ... 11
Transformer earthing = primary and
or secondary side
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
Slope = 0,40 ... 1,00
Trip with Id> = 5,00 ... 40 In
Blocking by 2nd harmonic = 0.10 ... 0.30 In
Blocking by 5th harmonic = 0.10 ... 0.30 In

22

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

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

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

87

46

32

37

DSP Load
in %

ANSI
Code

Protection Function and

the Setting Parameter

81

Frequency monitoring
Start at f = 0,04 ... 5 Hz
t = 1,02 ... 300 s

25

Synchronism check
U = 0,02 ... 0,4 Un
t = 0,52 ... 1000 s
w = 5 ... 50
Power factor controller
Power factor = 0,70 ... 1,00
QC0 = 1,000 ... 20000,000 kVAr
Series of banks = 1:1:1:1 ... 1:2:4:8
Number of banks : 1 ... 4
Insensitivity = 105 ... 200 % QC0
Threshold = 0 ... 100 % QC0
Switching program = sequential/circuit
switching

Fault recorder
Recording time = 1000 ... 5000 ms
Pre fault time: = 100 ... 2000 ms
Post fault setting = 100 ... 4900 ms
Max. 5 records

55

DSP Load
in %

Note
Due to the limitation of the DSP calculation
power not all function blocks can be combined without restrictions. Please refer to the
following 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 LEDs

Max. 32 on 4 sides of 8 LEDs 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
Rated voltage Un
Rated frequency fn

1 A or 5 A
100 V / 3 or 100 V (also suitable for 110 V)
50 Hz / 60 Hz

Thermal load capacity

Current path

4 In continuous, 100 In for 1 s,

250 In (peak value) dynamic
2 Un /3 continuous.

Voltage path
Consumption

0,1 VA with In
0,25 VA with Un

Current path
Voltage path

9.1.2 With current and voltage sensor

Rated current In
Rated voltage Un
Rated frequency fn

150 mV (rms)
2 V (rms)
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)
Four channel 0 to 20 mA or 4 to 20 mA

9.5 Communication
(optional)

SPABUS, electrical with RS232 interface or optical

connector snap-in type for plastic respectively
standard SMA type for glass fiber
LON (according to LAG1.4), optical with standard
ST connector for glass fiber
IEC 60870-5-103 with extension according to
VDEW for controlling, optical with standard ST
connector for glass fiber
Dual MODBUS RTU, electrical with two RS485
interfaces or optical with two standard ST
connector for glass fiber

10 Type test
All relevant tests according to
the standard IEC 60255,
EN 61000 respectively to the new
product standard EN 50263

10.1 EMC

9.6 Power supply

9.6.1 Central Unit

Rated voltage

48 ... 220 V DC (-15%, +10%) or

selectable
10 V DC (-15%, +10%) respectively,
220 V DC (-15%, +10%).
Power consumption
18 W
Inrush current
10 A peak value

9.6.2 HMI Control Unit

Rated voltage:
Power consumption

48 ... 110 V DC (-15%, +10%) or

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

9.7 Temperature range

Operation
Transport and storing

-5 ... + 55 C
-20 ... +70 C

9.8 Degree of protection

9.8.1 Central Unit
Housing

20

IP20

9.8.2 HMI Control Unit

Front
Rear

IP 54
IP 22

Interference suppression per

EN 55022 respectively.
IEC CISPR 11, Group 1
Immunity to electrostatic
discharge per IEC 61000-4-2,
level 3
Immunity to radiated electromagnetic energy per
IEC 61000-4-3, level 3
Electrical fast transient or
burst per IEC 61000-4-4,
level 3
Surge immunity tests per
IEC 61000-4-5, level 3
Immunity to conducted
disturbances induced by
radio frequency fields per
IEC 61000-4-6, level 3
Power frequency magnetic
field immunity per
IEC 61000-4-8, level 5
Pulse magnetic field immunity per IEC 61000-4-9, level 5
Damped oscillatory magnetic field immunity per
IEC 61000-4-10, level 5
Oscillatory waves immunity
per IEC 61000-4-12, level 3
Oscillatory waves immunity
in the range from 0 to 150
kHz per IEC 61000-4-16,
level 3
Ripple on DC input power
port immunity per
IEC 61000-4-17, level 3
Voltage dips, short interruptions and voltage variations
on DC input power ports per
IEC 61000-4-29, 50 ms.

10.2 Insulation

10.4 Climatic conditions

10.3 Mechanical
robustness
Voltage test per IEC 60255-5
with 2 kV RMS, 50 Hz
during 1 Min
Impulse voltage withstand
test per IEC 60255-5 with
5 kV 1,2/50 s.

Vibration test per

IEC 60255-21-1
Shock response and withstand test per IEC 60068-2-2
Seismic test per IEC 60068-2-30

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

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

REF542 plus Mixed connector plate for the

standard case version

X80

X80

1 5 9 13 17 21
3 7 11 15 19 23
2 6 10 14 18 22
4 8 12 16 20 24

1 5 9 13 17 21
3 7 11 15 19 23
2 6 10 14 18 22
4 8 12 16 20 24

X77 X76 X75 X74

X65

X64

X63

X86

X85

X84
X72

X73
X62

X83

X82

X81

X70

X71

X61

X60

X77 X76 X75 X74

X65

X64

X50
X41

X40

X31

X30

X21

X20

X63

X86

X85

X73
X62

X84

X83

X72

X82

X81

X70

X71

X61

X60

X31

X30

X21

X20

X10

X10

REF542 plus Sensor plate version for the

standard and wide case

X88

X87

X86

X85

X84

X83

X82

11.2 HMI Control Unit

Power Supply and communication connection
for HMI Control Unit

X81

1 2 3 4 5

REF542 plus Transformer plate version for

the
standard and
wide AND
caseWIDE CASE VERSION
TRANSFORMER
STANDARD
1 5 9 13 17 21
3 7 11 15 19 23
2 6 10 14 18 22
4 8 12 16 20 24

X20

X10

- X10: Power Supply

- 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.
Extension with second additional
mechanical binary I/O version 3 (BIO3)

Note: Please connect the right polarity

on Binary output BO02.
-X80:
1A
11
5A
07
03
1A
22
5A
18
14
1A
10
5A
06
02
100/110V
21
17
100/110V
05
01
100/110V
23
19
1A
24
5A
20
16
1A
12
5A
08
04
-X20:
+
d02
z02
+
d04
z04
+
d06
z06
+
d08
z08
+
d10
z10
+
d12
z12
+
d14
z14
+
d16
z16
+
d18
z18
+
d20
z20
+
d22
z22
+
d24
z24
+
d26
z26
+
d28
z28

-X10:

+
AI 04

AI 05

AI 06
AI 01
AI 02
AI 03

T4

3
-X30:
d02
z02

DC

d04
z04

DC

T5

d06
z06
d08
z08

T6

d10
z10

T1
T2

d12
z12

T3

d14
z14

T7

d16
z16

AI 07

d18
z18

T8 e.g. CT 1/5 A
-X21:

AI 08
+
BI01
-

BI02

+
BI03

BI04
BI05
BI06
BI07
BI08
BI09

z20
z22
d24
z24
z26

BI10
BI11
BI12
BI13
BI14

z02
z04
d02
d04
z06
z08
d06
d08
d10
d12
z10
z12
d14
d16
z14
z16
d18
d20
d22
z18

WD1

z28
d26
d28
d30
z30
z32

d20
z20
d22
z22
d24
z24
d26
z26
d28
z28

BI15

+
-

BI16

+
-

BI17

+
-

BI18

+
-

BI19

+
-

BI20

+
-

BI21

+
-

BI22

+
-

BI23

+
-

BI24

+
-

BI25

+
-

BI26

+
-

BI27

+
-

BI28

BO09

+
BO10
-

BO11

BO12

BO13
BO14

z02
z04
d02
d04
z06
z08
d06
d08
d10
d12
z10
z12
d14
d16
z14
z16
d18
d20
d22
z18
z20
z22
d24
z24
z26

BO15

z28
d26
d28
d30
z30
z32

BO16

WD2

Extension with third additional

mechanical binary I/O version 3 (BIO3)
-X40:
d02
z02
d04
z04
d06
z06
d08
z08
d10
z10
d12
z12
d14
z14
d16
z16
d18
z18
d20
z20
d22
z22
d24
z24
d26
z26
d28
z28

22
22

-X31:
+
-

-X41:
+
-

BI29

+
-

BI30

+
-

BI31

+
-

BI32

+
-

BI33

+
-

BI34

+
-

BI35

+
-

BI36

+
-

BI37

+
-

BI38

+
-

BI39

+
-

BI40

+
-

BI41

+
-

BI42

BO17

+
BO18
-

BO19

BO20

BO21
BO22

BO23

BO24

WD3

z02
z04
d02
d04
z06
z08
d06
d08
d10
d12
z10
z12
d14
d16
z14
z16
d18
d20
d22
z18
z20
z22
d24
z24
z26
z28
d26
d28
d30
z30
z32

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

-X10:

+
-X81:
-X82:
-X83:
-X84:
-X85:
-X86:
-X87:
-X88:

-X20:
+
d02
z02
+
d04
z04
+
d06
z06
+
d08
z08
+
d10
z10
+
d12
z12
+
d14
z14
+
d16
z16
+
d18
z18
+
d20
z20
+
d22
z22
+
d24
z24
+
d26
z26
+
d28
z28

A
A
A
A
A
A
A
A

Sensor 1

Sensor 2

DC
DC

Sensor 3

Sensor 4

Sensor 5

D Sensor 6
D
D

Sensor 7
Sensor 8

-X21:
BI01
BI02

BI03
BI04
+

BI05

d02
d04
z02
z04
d06
d08

Extension with second additional

solid state binary I/O.
-X30:
+
d02
z02
+
d04
z04
+
d06
z06
+
d08
z08
+
d10
z10
+
d12
z12
+
d14
z14
+
d16
z16
+
d18
z18
+
d20
z20
+
d22
z22
+
d24
z24
+
d26
z26
+
d28
z28

-X31:
BI15
BI16

+
BO10

BI17
BI18
+

BI19
BO11

d02
d04
z02
z04
d06
d08

BI20
BI21
+
BI22

BO16
-

BI23
+
BI24
BI25

BO12
BO14
BO13
BO20

BI26

+
+
+

BO17
BI27

+
BO18

BI28

+
WD2

z06
z08
d10
d12
z10
z12
d18
d20
d22
z20
z22
z18
d24
z26
z28
d28
d30
z32

BI06
BI07
+
BI08
BI09
+
BI10
+
+

BI11
BI12

BI13

BI14

+
WD1

z06
z08
d10
d12
z10
z12
d18
d20
d22
z20
z22
z18
d24
z26
z28
d28
d30
z32

Extension with third additional

solid state binary I/O
-X40:
+
d02
z02
+
d04
z04
+
d06
z06
+
d08
z08
+
d10
z10
+
d12
z12
+
d14
z14
+
d16
z16
+
d18
z18
+
d20
z20
+
d22
z22
+
d24
z24
+
d26
z26
+
d28
z28

-X41:
BI29
BI30

+
BO20

BI31
BI32
+

BI33
BO20

d02
d04
z02
z04
d06
d08

BI34
BI35
+
BI36

BO25
-

BI37
+
BI38
BI39

BO21
BO23
BO22
BO24

BI40

+
+
+

BO26
BI41

+
BO27

BI42

+
WD3

z06
z08
d10
d12
z10
z12
d18
d20
d22
z20
z22
z18
d24
z26
z28
d28
d30
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
D-40472 Ratingen

Via Friuli, 4
I-24044 Dalmine

Petzower Strasse 8
D-14542 Glindow

Phone: +49(0)21 02/12-12 30, Fax: +49(0)21 02/12-19 16

E-mail: calor.info@de.abb.com
Internet: http://www.abb.de/calor

Phone: +39 035/395111, Fax: +39 035/395874

E-mail: sacetms.tipm@it.abb.com
Internet: http://www.abb.com