ABB REF542plus Installation And Commissioning Manual

ABB REF542plus Installation And Commissioning Manual

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REF542plus
Manual Part 3:
Installation and Commissioning
ABB Power Distribution

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Summary of Contents for ABB REF542plus

  • Page 1 REF542plus Manual Part 3: Installation and Commissioning ABB Power Distribution...
  • Page 2 WE CONSTANTLY SEEK TO ENSURE THAT OUR PRODUCTS ARE DEVELOPED TO THE LATEST TECHNOLOGICAL STANDARDS. AS A RESULT, IT IS POSSIBLE THAT THERE MAY BE SOME DIFFERENCES BE- TWEEN THE HARDWARE/SOFTWARE PRODUCT AND THIS INFORMATION PRODUCT. 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 2 / 80...
  • Page 3: Table Of Contents

    4.2.5 Grounding of the REF542plus ............21 4.2.6 Typical examples of analog and binary connections ....23 4.2.7 Connection Example of the REF542plus Analog Inputs....24 Commissioning......................34 5.1 Safety Information....................34 5.2 Switching on the feeder ...................34 5.3 Test Equipment......................34 5.4 Testing the interlock conditions, ................34 5.5 Determining the transformer direction ..............35...
  • Page 4 REF542plus optical cable.............41 6.2.5.3 RS 485 Cable................41 6.3 Self test of the Central Unit..................41 6.3.1 Behavior after cold start ..............42 6.3.2 Enter REF542plus self test ............43 6.3.2.1 RAM test ..................44 6.3.2.2 Program flash memory test............44 6.3.2.3 Configuration flash memory test ...........44 6.3.3...
  • Page 5 Immunity tests - functional earth port..........71 10.3 Insulation Resistance....................72 10.4 Mechanical Robustness...................72 10.5 Climatic Conditions ....................72 Connection Diagram....................73 11.1 REF542plus with mechanical binary I/O..............73 11.2 REF542plus with solid state binary I/O..............77 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 5 / 80...
  • Page 6: Introduction

    Manual Part 3: Installation and Commissioning 1 Introduction This part of the manual describes the installation and commissioning of the REF542plus switchbay protection and control unit. The following section and its sub- sections contain information on: Mounting and installation instructions...
  • Page 7: Abbreviations And Definitions

    A note indicates items that are significant in the specific context. A note may contain information on the interplay of various software components and appears as shown below. Example: Note Please read this section completely for information on the various formats for safety notes. 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 7 / 80...
  • Page 8 An example is shown below: Caution Do not make any changes to the FUPLA unless you are familiar with the REF542plus and the configuration software Hazard information level 2 Level 2 hazard information indicates hazards affecting life and limb. It must be ob- served to avoid injury to the operator or other personnel.
  • Page 9: Operation Of The Ref542Plus

    The operating personnel for the REF542plus must have the appropriate qualifications for work on the unit. Your operating personnel must be authorized to work with or on REF542plus. (E.g. switching authorization in substations) Changes to the application as delivered may be made only by ABB personnel...
  • Page 10: Safety Regulations

    ABB assumes no responsibility for damages resulting from improper use of REF542plus. In the event of a guarantee claim, please contact the ABB office that sold the unit. Safety Regulations The safety notes in the following chapters represent only a general selection of the points that must be observed.
  • Page 11: Specific Safety Information

    This specifically includes switching on and off, isolat- ing, grounding and signage. Trained in safety engineering standards and are familiar with the maintenance and use of safety equipment. Trained in first aid. 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 11 / 80...
  • Page 12: Mounting And Installation

    REF542plus the requirements for the installation location and the environmental conditions, how to set up the REF542plus and integrate it into the bay and how to check the wiring to run the commissioning process.
  • Page 13 Figure 1: Dimension of the HMI Control Unit 179 mm Figure 2: Dimension of the Central Unit case, standard version 223 mm Figure 3: Dimension of the Central Unit case, wide version 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 13 / 80...
  • Page 14: Set-Up Area And Required Environmental Conditions

    The set-up area must be free of excessive air contamination (dust, aggressive sub- stances…). The natural air circulation around the unit must be free. The set-up area must maintain the specified environmental conditions 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 14 / 80...
  • Page 15: Installation In Lv Panels

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 4.2.2 Installation in LV panels Figure 4: REF542plus installed in gas-insulated switchgears (GIS) Figure 5: REF542plus installed in air-insulated switchgears (AIS) 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning...
  • Page 16: Connection Diagrams

    Figure 6: Example of mounting of the Central Unit in the LV compartment and the HMI on the door 4.2.3 Connection diagrams Connector Plate Figure 1: REF542plus connector plate for the wide case mixed analog input version 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning...
  • Page 17 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Figure 2: REF542plus connector plate for the short case mixed analog input version Figure 3: REF542plus connector plate for analog input with transformers or with sensors 1VTA100004-en...
  • Page 18 Snap in HP HFBR 4501 (gray) RX (optical interface) Snap in HP HFBR 4511 (blue) Caution The cable length for SPABUS connection with plastic fiber optical cable should not exceed 30 m 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 18 / 80...
  • Page 19 TX channel 2 (optical interface) ST plug HP type HFBR *XS* Caution The maximum baud rate is 115000 bit/s with glass fiber optical cable. Its length should not exceed 2000 m 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 19 / 80...
  • Page 20: Wiring The Ref542Plus

    Polarity check The polarity check (as close as possible to the REF542plus) is used to check the cur- rent circuit and also the installation position and the polarity of the transducer. The po- larity of the transducers to one another can also be checked with load current.
  • Page 21: Check The Voltage Transformer Circuits

    Check the polarity and the voltage value of the binary inputs on the REF542 in accor- dance with the technical data of the binary inputs. 4.2.5 Grounding of the REF542plus As can be seen in the following figure, the power supply board at connector X10 must be grounded to the housing.
  • Page 22 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Figure 4: Grounding of the REF542plus Central Unit housing To ensure the EMC (Electro Magnetic Compatibility) the housing must be grounded by a low impedance galvanic connection to the grounding system. As it is shown in the figure, an appropriate cable connection, which is fixed from a specific screw on the housing to the grounding system in the LV compartment, must be foreseen.
  • Page 23: Typical Examples Of Analog And Binary Connections

    4.2.6 Typical examples of analog and binary connections The following pages show examples for wiring analog inputs (measuring inputs) on the REF542plus with sensors or transducers, binary I/Os and analog output boards. Typical examples of usage in practice will be shown here. The following symbols are...
  • Page 24: Connection Example Of The Ref542Plus Analog Inputs

    Sensing element Three-phase transformer Current sensing element Voltage transformer Optical fibre cable 4.2.7 Connection Example of the REF542plus Analog Inputs Figure 6: Example of connection diagram for incoming or outgoing bays with transformers 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 24 / 80...
  • Page 25 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Figure 7: Example of connection diagram for incoming or outgoing bays with sensors 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 25 / 80...
  • Page 26 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Example of connection diagram for bus-tie and measuring bays with transformers Figure 8: 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 26 / 80...
  • Page 27 Example of connection diagram for bus-tie and measuring bays with sensors Figure 9: Caution Due to accuracy requirements the length of the cable connection to the sen- sors in other bay respectively panels should be less than 7 m 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 27 / 80...
  • Page 28 Example of connection diagram for the transformer differential protection with transformers Figure 10: Caution Due to accuracy requirements the length of the cable connection to the sen- sors in other bay respectively panels should be less than 7 m 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 28 / 80...
  • Page 29 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Example of connection diagram for the transformer differential protection with sensors Figure 11: 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 29 / 80...
  • Page 30 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Example of connection diagram for the synchronism check with transformers Figure 12: 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 30 / 80...
  • Page 31 Example of connection diagram for the synchronism check with sensors Figure 13: Caution Due to accuracy requirements the length of the cable connection to the sen- sors in other bay respectively panels should be less than 7 m 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 31 / 80...
  • Page 32 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Example of connection diagram for the synchronism check with transformers Figure 14: 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 32 / 80...
  • Page 33 Example of connection diagram for the synchronism check with sensors Figure 15: Caution Due to accuracy requirements the length of the cable connection to the sen- sors in other bay respectively panels should be less than 7 m 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 33 / 80...
  • Page 34: Commissioning

    Switching on the feeder Caution Before switching on the feeder check that the REF542plus is fully functional in the corresponding bay. Pay particular attention to the protective functions and the interlocking!
  • Page 35: Determining The Transformer Direction

    The feed device is primarily connected to the current transformer and the secondary value is measured at the secondary terminals of the transformer or at the protective cabinet with an ampere meter. 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 35 / 80...
  • Page 36: Voltage Transformer

    REF542 protection and control unit can also be checked at the same time. It is not necessary to record a magnetizing characteristic with the Rogowski coil, because it is an air-core coil with no saturation characteristics. 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 36 / 80...
  • Page 37: Voltage Sensor

    5.6 Testing the measured value recording Proper functioning of the transformers and sensors is important for proper functioning of the REF542plus. The measured-value processing of the unit and the set rated val- ues must be tested for this reason. The phase currents and phase voltages must be taken as measured input quantities.
  • Page 38: Testing The Protective Functions

    5.7 Testing the protective functions To ensure that no damage has been caused by transport or setup and installation of the protection equipment and systems, secondary tests are run on the REF542plus protection and control unit with the configured protective functions.
  • Page 39: Troubleshooting

    Self test of the Central unit Self test of the HMI By means of the self test the proper function of the REF542plus can be checked. It is to be recommended that the self test is done in uninstall condition of the REF542plus.
  • Page 40: Connection Cables

    The above figure shows the setting for the communication to the HMI Local Control Unit and can be stored e.g. as RHMITERM.INI. 6.2.5 Connection cables The next figure show the set up for trouble shooting. There are several cables needed to link the PC and the REF542plus: 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning...
  • Page 41: Rs232 Cable

    PC and the Central Unit. The connector on the central unit for this purpose is X72. 6.2.5.2 REF542plus optical cable. The HMI must be interfaced to a PC through the ABB RS232 optical cable. The opti- cal converter must be plugged in the connector situated on the front side of the HMI.
  • Page 42: Behavior After Cold Start

    Figure 10: Correct start up sequence of Central Unit displayed by Tera Term Pro software The REF542plus is after the indication “system running” in operation again. If the HMI Local Control Unit is connected, then on the LCD screen the single line diagram and the menu will be displayed.
  • Page 43: Enter Ref542Plus Self Test

    Figure 23: Tera Term Pro display for entering the self test of the Central Unit Type the proper password and press ‘enter’. Ask for the password from the author- ized personnel in your local ABB representative. After typing the correct password, the following sub-menu will be shown:...
  • Page 44: Ram Test

    Test result is shown on the terminal 6.3.3 Calibration of the Analog Input The calibration of the REF542plus is normally not necessary, because the related calibration data are stored in the memory of the analog input board itself. But if e.g.
  • Page 45: Transformer Input Board

    In this mode the offset errors of the signal conditioning chain for the fur- ther processing of the analog input signals in the REF542plus unit can be compen- sated. Moreover the connections to the connector X80 can be defined. Afterwards the calibration data are stored on the EEPROM on the Analog Input Board.
  • Page 46: Mixed Input Board

    In case of wrong connections to the input a phase error will be reported. The following figure shows the returned messages of the calibration procedure in case of phase er- ror. 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 46 / 80...
  • Page 47: Remote Hmi Self Test

    Connect the power supply to the connector X10. Take care of the voltage level of the HMI. Switch on the power supply of the HMI Local Control Unit. The connection to the Central Unit shall be removed. 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 47 / 80...
  • Page 48 In this case the e-key with the ABB code must be inserted in its plug and loop back cable must be inserted in X20 and in the optical interface in advance.
  • Page 49: Lcd Test

    2 seconds delay. After the delay time is expired the following next test will be started automatically: 6.4.1.2 Graphic writing test The LCD page is displayed 1 second delay The LCD page is cleared 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 49 / 80...
  • Page 50: Back-Light Test

    T h e L C D b a c k l i g h t w i l l b e t u r n e d O F F a n d t h e n O N a g a i n 1VTA100004-en DMS,2001-10-04 REF542plus: Installation and Commissioning 50 / 80...
  • Page 51: Lcd Contrast Test

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Figure 13: Back-light Test Page 2 seconds delay Back light off 1 second delay Back light on 2 seconds delay. After the delay time is expired the following next test will be started automatically: 6.4.1.4 LCD contrast test The following LCD page is shown...
  • Page 52: Leds Test

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 6.4.2 LEDs test This test consists of the following steps: The LCD page for for the LED Test is displayed 1 second delay Then the test carried out, in which the LED’s will be switched on and the colors will be cyclic changed After finishing the test, the HMI test page will be displayed again automatically.
  • Page 53: E-Key Test

    5 s e c Figure 16: E-Key Test Page The so called ABB-key must be inserted within 5 seconds. Afterwards the test will end with OK result. Otherwise, the result is FAIL. 6.4.5 Serial ports test...
  • Page 54 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Figure 18: Loop-back cable for the RHMI serial ports test The test will consist in the following steps: The LCD page for the serial ports test is displayed according to next figure: ↵...
  • Page 55 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning RS232 to RS485 communication test 10 messages are sent to the RS 485 port. Test result shown in the page (“TEST OK” or “TEST FAIL”) 2 seconds delay. After finishing the test, the HMI test page will be displayed again automatically.
  • Page 56: Firmware Upgrade

    7 Firmware upgrade In the following the upgrade of the firmware is described. The possibility of upgrading the firmware is to be asked to the authorized personnel to your local ABB representa- tive. Upgrade the Firmware of the Central Unit Use the RS232 port X72 on the Central Unit of the REF542plus.
  • Page 57: Decommissioning And Storage

    Please observe the following directions when decommissioning the unit: Isolate the bay Transfer the configuration from the REF542plus to the PC and save it on data media Switch off the REF542plus auxiliary supply voltage Switch off the remaining miniature circuit breakers as well...
  • Page 58: Technical Data

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 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 1A or 5A Rated voltage U...
  • Page 59: Binary Inputs And Outputs

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Binary inputs and outputs Each binary I/O board has the following number of inputs and outputs: 9.2.1 With mechanical relays (1 BIO version 3) 14 inputs (BI 1 to 14) For auxiliary voltage range: 20 to 90 V DC (threshold 14 V DC) or for auxiliary voltage range:...
  • Page 60: Interface

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Interface 9.3.1 HMI Control Unit: Optical/electrical standard interface RS 232 to the Notebook PC (at the front) Electrical isolated standard interface RS 485 to the Central Unit (at the rear) 9.3.2 Central Unit: Electrical isolated standard interface RS 485 to the HMI...
  • Page 61: Temperature Range

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Temperature range Operation -5 ..+ 55°C Transport and storing -20..+70°C Degree of protection 9.8.1 Central Unit Housing IP20 9.8.2 RHMI Control Unit Front IP 54 Rear IP 22 1VTA100004-en DMS,2001-10-04 REF542 plus : Installation and Commissioning...
  • Page 62: Type Test

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 10 Type Test 10.1 Protection Function All relevant tests according to the standard IEC 60255. ANSI Code Protection Function and the Setting Parameters Test Procedure Inrush stabilization (Only in connection with I>> and I>) IEC 60255-3 N = 2.0 …...
  • Page 63 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning ANSI Code Protection Function and the Setting Parameters Test Procedure Earth fault directional sensitive IEC 60255-12 IE> = 0,05 ... 2 In t = 120 ... 100.000 ms, for- / backward Slope angle α...
  • Page 64 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning ANSI Code Protection Function and the Setting Parameters Test Procedure Motor start protection (adiabatic characteristic) IEC 60255-3 Ie = 0,3 ... 1,2 In (motor current) Is = 1,00 ... 20 Ie (start value) t = 70 ...
  • Page 65 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning ANSI Code Protection Function and the Setting Parameters Test Procedure Unbalance load IEC 60255-3 Is = 0,05 ... 0,3 In (start value of the negative phase sequence) K = 2 ...
  • Page 66: Electro Magnetic Compatibility

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 10.2 Electro Magnetic Compatibility All relevant tests according to the standard IEC 60255, EN 61000 respectively to the new product standard EN 50263 10.2.1 Emission test Port Frequency range Limits Basic Test proce-...
  • Page 67: Immunity Tests - Enclosure Port

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 10.2.2 Immunity tests - enclosure port Environmental Test Units Basic Test pro- Acceptance Remarks phenomena specification standard cedure criteria Radiated radio 80 – 1000 EN 61000- EN 61000- See 15.2 See note 2 frequency elec-...
  • Page 68: Immunity Tests - Power Supply Port

    10 m. NOTE 4 10 and 50 MHz is for GIS applications relevant NOTE 5 The guaranteed interruption time must be mentioned in the data sheet (REF542plus 50ms) 1VTA100004-en DMS,2001-10-04 REF542 plus : Installation and Commissioning...
  • Page 69: Immunity Tests - Communication Ports

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 10.2.4 Immunity tests - communication ports Environmental Test Units Basic Test pro- Acceptance Remarks phenomena specification standard cedure criteria Conducted dis- 0,15 – 80 EN 61000- EN 61000- See 15.2 See note 2 turbance induced...
  • Page 70: Immunity Tests - Input And Output Ports

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 10.2.4.1 Immunity tests - input and output ports Environmental Test Units Basic Test pro- Acceptance Remarks phenomena specification standard cedure criteria Conducted distur- 0.15 – 80 EN 61000- EN 61000- See 15.2 See note 2...
  • Page 71: Immunity Tests - Functional Earth Port

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 10.2.5 Immunity tests - functional earth port Environmental Test Units Basic Test pro- Acceptance Remarks phenomena specification standard cedure criteria Conducted distur- 0,15 – 80 EN 61000- EN 61000- See 15.2 See note 2...
  • Page 72: Insulation Resistance

    REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning 10.3 Insulation Resistance Insulation resistance >100MOhm 500V DC 10.4 Mechanical Robustness Vibration test per IEC 60255-21-1 Shock response and withstand test per IEC 60068-2-2 Seismic test per IEC 60068-2-30 10.5 Climatic Conditions Cold test per IEC 60068-2-1...
  • Page 73: Connection Diagram

    11 Connection Diagram 11.1 REF542plus with mechanical binary I/O Example of REF542plus base version with one mechanical binary I/O version 3. Extension up to two additional mechanical binary I/O version 3 possible. Other configurations of the analog input board available, e.g mixed configuration for transformer and sensor connection.
  • Page 74 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Note: Please connect the right polarity on BO02. -X10: -X80: AI 01 AI 02 REF542plus AI 03 Base version with 100/110V binary I/O version 3 AI 04 100/110V...
  • Page 75 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Extension with second additional mechanical binary I/O version 3 Note: Please connect the right polarity on BO 10 -X31: -X30: BI15 BO09 BI16 BI17 BO10 BI18 BO11 BI19 BI20 BO12...
  • Page 76 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Extension with third additional mechanical binary I/O version 3 Note: Please connect the right polarity on BO 18 -X41: -X40: BI29 BO17 BI30 BI31 BO18 BI32 BO19 BI33 BI34 BO20...
  • Page 77: Ref542Plus With Solid State Binary I/O

    11.2 REF542plus with solid state binary I/O Example of REF542plus 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.
  • Page 78 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Extension with secondsolid state binary I/O. Note: Please connect the right polarity -X31: -X30: BI15 BI16 BO10 BI17 BI18 BI19 BO11 BI20 BI21 BI22 BO16 BI23 BO12 BI24 BO14 BO13...
  • Page 79 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Extension with third additional solid state binary I/O Note: Please connect the right polarity -X41: -X40: BI29 BI30 BO20 BI31 BI32 BI33 BO20 BI34 BI35 BI36 BO25 BI37 BO21 BI38...
  • Page 80 REF 542plus switchbay protection and control unit Manual Part 3: Installation and Commissioning Product information: Technical Marketing ABB Calor Emag Mittelspannung GmbH Oberhausener Str. 33 D-40472 Ratingen Phone: +49 (0) 2102 12 1046 Fax: +49 (0) 2102 12 1808 1046 E-mail: hendro.rijanto@de.abb.com...

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