Protection relay: REF 542 plus

Manufacturer: ABB
Relay description: Bay control and protection unit
Protection functions:
Current Protection Functions:
􀁺 Inrush (68)
􀁺 Overcurrent instantaneous (50)
􀁺 Overcurrent definite time and IDMT (51High, 51 Low, 51 IDMT)
􀁺 Directional Overcurrent protection (67High, 67 Low)
􀁺 Earthfault protection definite time and IDMT (51N High, 51N Low, 51N IDMT)
􀁺 Directional earth fault protection (67N High, 67N Low, 67N sensitive, 67N sector)

Voltage Protection Functions:

􀁺 Undervoltage instantaneous (27)
􀁺 Undervoltage definite time (27 High, 27 Low)
􀁺 Overvoltage instantaneous (59)
􀁺 Overvoltage definite time (59 High, 59 Low)
􀁺 Residual Overvoltage definite time (59N High, 59N Low)

Motor Protection Functions:

􀁺 Number of starts (66)
􀁺 Motor Start (51 MS)
􀁺 Locked Rotor (51 LR)
􀁺 Thermal Overload (49)
􀁺 Unbalanced Load (46)
􀁺 Directional Power (32)
􀁺 Low Load (37)

Other protection, control and supervision functions:

􀁺 Differential (87)
􀁺 Restricted earth fault (87N)
􀁺 Distance protection (21)
􀁺 Synchrocheck (25)
􀁺 Auto re-closing (79)
􀁺 Fault recorder
􀁺 Interlocking
􀁺 PLC-like automation functions
􀁺 Measurements
􀁺 Switch gear monitoring
􀁺 Self-diagnosis
􀁺 CAN
ELNG applications:
Protection functions used:
Ref used to protect all feeders and transformers against
 Over current
 Earth fault
 Over voltage
 Under voltage
Ref used to protect motor loads against
 Over current
 Earth fault
 Over voltage
 Under voltage
 Motor start protection
 Blocked rotor
 Number of starts
 Thermal over load
 Unbalanced load

REF 542plus exists in MV switchgears (11 KV and 3.3 KV)

It fed from:
1. Secondary terminals of CT's on feeders, transformers and motors.
2. Secondary terminals of PT's on busbars.
3. Ring core on feeders, transformers and motors feeders.
 Settings and locations:

 N.I. (Normally inverse) K = Transformer feeders.

 E.I. (Extremely inverse) K = Generators

fault high
 V.I. (Very inverse) K = 11 KV feeders

current

current
instantan
IDMT- over Over Earth Unde

setting

voltag
e low r
eous

g settin
I/I K ID St Ti St Ti S T

In * e lu va art

In * e lu va art
pe ty T M

(s) e m

(s) e m
n

e u l a v t r a t

) s ( e mi
*
n I

0. 0. 0. 0. 0. 0. 0 0
0 :4 05

5 :1. 05

00 :3 02

0 :4 05

00 :1 07
40 1:

2 . 1 : 1 .

0 0 3 : 5 0 .

CT GCT
Ratio Ratio K

1 1600/1 K1 1 0.5 N.I D D D D 0.4 5

e at tiv ac e-

e at tiv ac e-

e at tiv ac e-

e at tiv ac e-
0 1 0 1 - S E

1600/1 K2 1 0.5 N.I 0.4 5

1600/1 K3 1 0.5 N.I 0.4 5

1600/1 K4 1 0.5 N.I 0.4 5

 1 1500/1 K3 0.7 0.3 .N.I De-activate De-activate 0.4 5
1600/1 K4 0.9 0.38 .N.I De-activate 0.08 0.7 0.4 5
1 1 0 1 - S E

200/1 50/1 K5 1 0.8 .E.I 15.1 0.02 0.2 0.1 0.4 2

100/1 50/1 K6 1.3 0.9 .E.I 21.3 0.02 0.2 0.1 0.4 2
100/1 50/1 K7 1.3 0.9 .E.I 21.3 0.02 0.2 0.1 0.4 2
500/1 50/1 K8 1 0.25 .N.I 15.2 0.02 0.2 0.1 0.4 2
100/1 50/1 K9 1.3 0.9 .E.I 21.3 0.02 0.2 0.1 0.4 2
200/1 50/1 K10 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K11 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K12 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
250/1 50/1 K13 0.82 0.65 .V.I 19 0.02 0.2 0.1 0.4 2
200/1 50/1 K14 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K15 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
1 1500/1 K3 0.7 0.3 .N.I De-activate De-activate 0.4 5
1600/1 K4 0.9 0.38 .N.I De-activate 0.08 0.7 0.4 5
2 1 0 1 - S E

100/1 50/1 K5 1.3 0.9 .E.I 21.3 0.02 0.2 0.1 0.4 2
500/1 50/1 K6 1 0.25 .N.I 15.2 0.02 0.2 0.1 0.4 2
100/1 50/1 K7 1.3 0.9 .E.I 21.3 0.02 0.2 0.1 0.4 2
200/1 50/1 K8 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K9 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K10 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
250/1 50/1 K11 0.82 0.65 .V.I 19 0.02 0.2 0.1 0.4 2
200/1 50/1 K12 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K13 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K14 1 0.9 .E.I 21.5 0.02 0.2 0.1 0.4 2
1 1500/1 K3 0.7 0.3 .N.I De-activate De-activate 0.4 5
1600/1 K4 0.9 0.38 .N.I De-activate 0.08 0.7 0.4 5
3 1 0

1600/1 K5 0.81 0.25 .N.I De-activate De-activate 0.4 5

2 1600/1 K3 0.81 0.81 .N.I De-activate 0.08 0.7 0.4 5

100/1 50/1 K4 1.3 0.9 .E.I 21.3 0.02 0.2 0.1 0.4 2
A 3 1 0 1 - S E

200/1 50/1 K5 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2

200/1 50/1 K6 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K7 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
250/1 50/1 K8 0.82 0.65 .V.I 19 0.02 0.2 0.1 0.4 2
200/1 50/1 K9 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K10 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
2 1500/1 K3 0.7 0.3 .N.I De-activate De-activate 0.4 5
1600/1 K4 0.9 0.38 .N.I De-activate 0.08 0.7 0.4 5
0 1 - S E

200/1 50/1 K5 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2

200/1 50/1 K6 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K7 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
250/1 50/1 K8 0.82 0.65 .V.I 19 0.02 0.2 0.1 0.4 2
 1 200/1 50/1 K9 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
200/1 50/1 K10 1 0.7 .E.I 15.1 0.02 0.2 0.1 0.4 2
4

REF setting for 3.3 KV feeders

SWG 1ES-0121 1ES-0721 2ES-0221

121-M1 121-M2 721-M1 721-M2 221-M1 221-M2
CT Ratio 800/1 800/1 1600/1 1600/1 800/1 800/1
GCT Ratio 50/1 50/1 50/1 50/1 50/1 50/1
Protection Range Setting Setting Setting Setting Setting Setting
IDMT V.I V.I V.I V.I V.I V.I
Type
I/In 0.05:40 0.73 0.73 0.86 0.86 0.73 0.73
K 0.05:1.5 0.45 0.45 0.2 0.2 0.45 0.45
Earth fault
Start value 0.05:40 0.3 0.3 0.3 0.3 0.3 0.3
Time (s) 0.07:100 0.4 0.4 0.4 0.4 0.4 0.4
Under voltage
Start value 0.1:1.2 0.6 0.6 0.6 0.6 0.6 0.6
Time (s) 0.05:300 1 1 1 1 1 1
 Train1 REF settings:

1PK-3502 A-CM-01AAnd1PK-3502 A-CM-01A

1421/1511/1521/1611/1621And1TC-1411-M-10
1P-1601B - M-01BAnd1P-1601A - M-01A
1P-1202B -M-01Band1P-1202A -M-01A

B/C/D/E/F/G/HAnd1P-2401A -M-01A

1C-2401 -M-01
1C-1301 -M-01

Equipment No. Range

CT ratio 80/1 100/1 80/1 80/1 150/1 150/1 250/1

GCT ratio 50/1 50/1 50/1 50/1 50/1 50/1 50/1
IDMT
Type N.I N.I N.I N.I L.I N.I L.I
I/In 0.05:40 0.71 0.67 0.68 0.78 0.8 0.73 0.78
K 0.05:1.5 1 1.1 1 1.3 0.2 1 0.2
Earth fault
Start value*In 0.05:40 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Time (s) 0.07:100 0.1 0.1 0.1 0.1 0.1 0.1 0.1
Motor start
Motor current (Ie) 0.3:1.2*In 0.644 0.604 0.613 0.713 0.727 0.667 0.708
Start value (Is) 1:20 *Ie 6 6 6 6 6 6 6
Time(s) 0.07:300 10 10 10 10 10 10 10
Motor start 0.6:0.8*Is 0.6 0.6 0.6 0.6 0.6 0.6 0.6
Blocked rotor
Motor current Ie 0.3:1.2*In 0.644 0.604 0.613 0.713 0.727 0.667 0.708
Start value 1:20*Ie 6 6 6 6 6 6 6
Time(s) 0.07:0.3 3 3 3 3 3 3 3
No. of starts
No. of warm starts 1-10 6 3 2 2 2 2 2
No. of cold starts 1-10 10 4 3 3 3 3 3
Time(s) 1.02:7200 3600 3600 3600 3600 3600 3600 3600
Temp of warm... 20:200 C 80 80 80 80 80 80 80
Thermal over load
T nominal 50:400 C 130 130 130 130 130 130 130
I nominal 1:10000A 51.5 60.4 49 57 109 100 177
Initial temp… 50:120% T 50 50 50 50 50 50 50
Time constant I< 0.1Ie 10:2000S 3645.1 1931.2 4290.9 590.7 3549.8 5427.6 8976.4
Time constant normal 10:2000S 729 386.2 858.2 118.1 710 1085.5 1795.3
Time constant I> 2Ie 10:2000S 729 386.2 858.2 118.1 710 1085.5 1795.3
Maximum temp 20:400C 130 130 130 130 130 130 130
Warning temp 20:400C 120 120 120 120 120 120 120
Environmental temp 20 tno*tin 40 40 40 40 40 40 40
Operating time 0:1000 S 0 0 0 0 0 0 0
Under voltage
Start value 0.1:3*Un 0.75 0.75 0.75 0.75 0.75 0.75 0.75
Time(s) 0.07:0.3 0.5 0.5 0.5 0.5 0.5 1 1

N.I – Normal inverse

L.I – Long time inverse

Train2 REF settings:

1421/1511/1521/1611/1621And2TC-1411-M-10
2PK-3502B-CM-01BAnd2PK-3502 A-CM-01A
2P-1601B - M-01BAnd2P-1601A - M-01A
2P-1202B -M-01BAnd2P-1202A -M-01A
2C-1301 -M-01

Equipment No. Range 2C-2401-M-01

CT ratio 80/1 100/1 80/1 80/1 150/1 250/1

GCT ratio 50/1 50/1 50/1 50/1 50/1 50/1
IDMT
Type N.I N.I N.I N.I L.I L.I
I/In 0.05:40 0.71 0.67 0.68 0.78 0.8 0.78
K 0.05:1.5 1 1.1 1 1.3 0.2 0.2
Earth fault
Start value*In 0.05:40 0.2 0.2 0.2 0.2 0.2 0.2
Time (s) 0.07:100 0.1 0.1 0.1 0.1 0.1 0.1
Motor start
Motor current (Ie) 0.3:1.2*In 0.644 0.604 0.613 0.713 0.727 0.708
Start value (Is) 1:20 *Ie 6 6 6 6 6 6
Time(s) 0.07:0.3 10 10 10 10 10 10
Motor start 0.6:0.8*Is 0.6 0.6 0.6 0.6 0.6 0.6
Blocked rotor
Motor current Ie 0.3:1.2*In 0.644 0.604 0.613 0.713 0.727 0.708
Start value 1:20*Ie 6 6 6 6 6 6
Time(s) 0.07:0.3 3 3 3 3 3 3
No. of starts
No. of warm starts 1-10 6 3 2 2 2 2
No. of cold starts 1-10 10 4 3 3 3 3
Time(s) 1.02:7200 3600 3600 3600 3600 3600 3600
Temp of warm... 20:200 C 80 80 80 80 80 80
Thermal over load
T nominal 50:400 C 130 130 130 130 130 130
I nominal 1:10000A 51.5 60.4 49 57 109 177
Initial temp… 50:120% T 50 50 50 50 50 50
Time constant I< 0.1Ie 10:2000S 3645.1 1931.2 4290.9 590.7 3549.8 8976.4
Time constant normal 10:2000S 729 386.2 858.2 118.1 710 1795.3
Time constant I> 2Ie 10:2000S 729 386.2 858.2 118.1 710 1795.3
Maximum temp 20:400C 130 130 130 130 130 130
Warning temp 20:400C 120 120 120 120 120 120
Environmental temp 20 tno*tin 40 40 40 40 40 40
Operating time 0:1000 S 0 0 0 0 0 0
Under voltage
Start value 0.1:3*Un 0.75 0.75 0.75 0.75 0.75 0.75
Time(s) 0.07:0.3 0.5 0.5 0.5 0.5 0.5 1

N.I – Normal inverse

L.I – Long time inverse

Inspection Frequency:
According to the manufacturer’s recommendations the relay should be submitted to
secondary testing at seven years’ intervals.

Inspection activities:

1) Visual inspection:
- Signs of mechanical damage on relay case and terminals.
- Dust accumulated inside the relay cover or case; remove carefully with compressed
Air blower or a soft brush.
- Signs of corrosion on terminals, case or components inside the relay

2) IDMT Over current test:

This test applied for all REF 542plus with the following procedure

1- Make sure that the load/feeder which its relay under test is electrically
isolated.
2- Make sure that all REF settings are the same settings in the above tables
(record any changes).
3- Make sure that the REF input signals from CT’s are connected to terminals
X6/216, X6/221, X6/226 and X6/251) and the relay output signals are
connected to terminals:
 Generator case:
1. Trip MAN C.B X5/63 and X5/62
2. To F86 X5/65 and X2/32
3. To differential protection X5/66 and X5/67
4. U/V of generator (X10/342, X10/343 and X10/344)
5. DCS common alarm X5/120 and X5/121
 Transformer feeder case:
1. To close C.B X3/40 and X1/4
2. Trip MAN C.B X5/63 and X5/62
3. To F86 X5/65 and X2/32
4. To differential protection X5/66 and X5/67
5. To block close X2/32 and X3/41
6. DCS common alarm X5/120 and X5/121
 11 KV feeder case:
1. Trip MAN C.B X5/63 and X5/62
2. To F86 X5/65 and X2/32
3. To differential protection X5/66 and X5/67
4. U/V of generator V.T X10/352 and X10/353
5. U/V of generator V.T X10/356 and X10/357
6. DCS common alarm X5/120 and X5/121
 3.3 KV feeder case:
1. To YC close X1/4 and X3/41
2. Trip MAN C.B X5/63 and X5/62
3. To F86 X5/67 and X2/32
4. U/V trip X2/32 and X5/66
5. Not start protection X10/360 and X10362
6. DCS common alarm X5/99 and X5/100
 Motor feeder case:
 1. Trip MAN C2 X2/32 and X5/95
2. To C3 trip protection X2/32 and X5/96
3. DCS common alarm X5/99 and X5/100
4- Disconnect all input and output terminals.
5- Cover the wires of input and output with isolating tape.
6- Connect tester current output signals to terminals of REF input.
7- Connect the REF output terminals to the tester proper terminals.
8- Set the test current Itest at a value slightly under the set start current of the over
current protection.
9- Apply test current on the REF by turned the tester on.
10- Take the reading of REF displays for I1, I2 and I3.
(Record any changes between tester displays and REF displays for the
Currents).
11- Increase the current of relay tester until trip state occurs.
12- Record the value of current and time at which the trip occurs.
13- Compare the tripping values with REF settings.
14- Repeat the test with tester current 2 Itest and 4 Itest.
15- Reconnect the input and output wires to the REF terminals (after removing the
isolating tape).
16- Make sure all settings, switches and wires are proper.

3) Instantaneous Over current test:

This test applied for all transformer feeders REF 542plus with the following
procedure

1- Make sure that the load/feeder which its REF under test is electrically isolated.
2- Make sure that all REF settings are the same settings in the above tables
(record any changes).
3- Make sure that the REF input signals from CT’s are connected to terminals
X6/216, X6/221, X6/226 and X6/251) and the REF output signals are
connected to terminals:
 Transformer feeder case:
1. To close C.B X3/40 and X1/4
2. Trip MAN C.B X5/63 and X5/62
 3. To F86 X5/65 and X2/32
4. To differential protection X5/66 and X5/67
5. To block close X2/32 and X3/41
6. DCS common alarm X5/120 and X5/121
4- Disconnect all input and output terminals.
5- Cover the wires of input and output with isolating tape.
6- Connect tester current output signals to terminals of REF input.
7- Connect the REF output terminals to the tester proper terminals.
8- Set the test current Itest at a value slightly under the set start current of the
instantaneous over current protection.
9- Apply test current on the REF by turned the tester on.
10- Take the reading of REF displays for I1, I2 and I3.
(Record any changes between tester readings and relay readings for the
Currents).
11- Increase the current of relay tester until trip state occurs.
12- Record the value of current and time at which the trip occurs.
13- Compare the tripping values with REF settings.
14- Reconnect the input and output wires to the REF terminals (after removing the
isolating tape).
15- Make sure all settings, switches and wires are proper.

4) Under voltage protection:

This test applied for all REF 542plus with the following procedure

1- Make sure that the load/feeder which its REF under test is electrically isolated.
2- Make sure that all REF settings are the same settings in the above tables
(record any changes).
3- Make sure that the REF input signals from PT’s are connected to terminals
X4/216, X4/221, X4/226 and X4/251) and the REF output signals are
connected to terminals:
 Generator case:
1. Trip MAN C.B X5/63 and X5/62
2. To F86 X5/65 and X2/32
 3. To differential protection X5/66 and X5/67
4. U/V of generator (X10/342, X10/343 and X10/344)
5. DCS common alarm X5/120 and X5/121
 Transformer feeder case:
1. To close C.B X3/40 and X1/4
2. Trip MAN C.B X5/63 and X5/62
3. To F86 X5/65 and X2/32
4. To differential protection X5/66 and X5/67
5. To block close X2/32 and X3/41
6. DCS common alarm X5/120 and X5/121
 11 KV feeder case:
1. Trip MAN C.B X5/63 and X5/62
2. To F86 X5/65 and X2/32
3. To differential protection X5/66 and X5/67
4. U/V of generator V.T X10/352 and X10/353
5. U/V of generator V.T X10/356 and X10/357
6. DCS common alarm X5/120 and X5/121
 3.3 KV feeder case:
1. To YC close X1/4 and X3/41
2. Trip MAN C.B X5/63 and X5/62
3. To F86 X5/67 and X2/32
4. U/V trip X2/32 and X5/66
5. Not start protection X10/360 and X10362
6. DCS common alarm X5/99 and X5/100
 Motor feeder case:
1. Trip MAN C2 X2/32 and X5/95
2. To C3 trip protection X2/32 and X5/96
3. DCS common alarm X5/99 and X5/100
4- Disconnect all input and output terminals.
5- Cover the wires of input and output with isolating tape.
6- Connect tester voltage output signals to terminals of REF input.
7- Connect the REF output terminals to the tester proper terminals.
 8- Set the test voltage at a value slightly above the set start voltage of the under
voltage protection.
9- Apply test voltage on the REF by turned the tester on.
10- Take the reading of REF displays for U1, U2 and U3.
(Record any changes between tester displays and REF displays for the
Currents).
11- Reduce the voltage of relay tester until trip state occurs.
12- Record the value of voltage and time at which the trip occurs.
13- Compare the tripping values with REF settings.
14- Reconnect the input and output wires to the REF terminals (after removing the
isolating tape).
15- Make sure all settings, switches and wires are proper.

5) Earth fault protection:

This test applied for all REF 542plus except (1ES-101 feeders and generators) with
the following procedure

1- Make sure that the load/feeder which its REF under test is electrically isolated.
2- Make sure that all REF settings are the same settings in the above tables
(record any changes).
3- Make sure that the REF input signals from Ring core are connected to
terminals:
 Transformer feeder case X6/236 and X6/237.
 3.3 KV feeders case X6/230 and X6/231.
 Motor feeder case X6/230 and X6/231.
And the REF output signals are connected to terminals:
 Transformer feeder case:
1. To close C.B X3/40 and X1/4
2. Trip MAN C.B X5/63 and X5/62
 3. To F86 X5/65 and X2/32
4. To differential protection X5/66 and X5/67
5. To block close X2/32 and X3/41
6. DCS common alarm X5/120 and X5/121
 11 KV feeder case:
1. Trip MAN C.B X5/63 and X5/62
2. To F86 X5/65 and X2/32
3. To differential protection X5/66 and X5/67
4. U/V of generator V.T X10/352 and X10/353
5. U/V of generator V.T X10/356 and X10/357
6. DCS common alarm X5/120 and X5/121
 3.3 KV feeder case:
1. To YC close X1/4 and X3/41
2. Trip MAN C.B X5/63 and X5/62
3. To F86 X5/67 and X2/32
4. U/V trip X2/32 and X5/66
5. Not start protection X10/360 and X10362
6. DCS common alarm X5/99 and X5/100
 Motor feeder case:
1. Trip MAN C2 X2/32 and X5/95
2. To C3 trip protection X2/32 and X5/96
3. DCS common alarm X5/99 and X5/100
4- Disconnect all input and output terminals.
5- Cover the wires of input and output with isolating tape.
6- Connect tester current output signals to terminals of REF input.
7- Connect the REF output terminals to the tester proper terminals.
8- Set the test current at a value slightly under the set start current of the earth
fault protection.
9- Apply test current on the REF by turned the tester on.
10- Take the reading of REF displays for I1, I2 and I3.
(Record any changes between tester displays and REF displays for the
Currents).
11- Increase the current of relay tester until trip state occurs.
 12- Record the value of current and time at which the trip occurs.
13- Compare the tripping values with REF settings.
14- Reconnect the input and output wires to the REF terminals (after removing the
isolating tape).
15- Make sure all settings, switches and wires are proper.

Required logistics:

- Manpower:
Electrical engineer
Electrician
- Tools:
- Air blower (cordless, variable speed blower – MAKITA)
- Relays tester

Inspection Report