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ABB REF542plus Manual

Multifunction protection and switchgear control unit
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Multifunction Protection and Switchgear Control Unit
REF542plus
Manual Motor Protection
with ATEX – Certification

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Summary of Contents for ABB REF542plus

  • Page 1 Multifunction Protection and Switchgear Control Unit REF542plus Manual Motor Protection with ATEX – Certification...
  • Page 2 CE Conformity Declaration The product „ Multifunctional Protection and Bay Control Unit REF542plus“ is de- signed and manufactured complying to the corresponding international standards of the series EN 50081, EN 50082 for EMC-Guidelines and EN 60255-6 for Low Voltage Directive of the European Parliament and Council 1VTA100114-Rev.

  • Page 3: Table Of Contents

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Table of Contents Introduction ......................6 Abbreviations and Definitions ................7 Abbreviations ....................7 Definitions ......................7 References:......................9 Motor protection functions ................10 Supervision of a blocking rotor................ 11 4.1.1...
  • Page 4 Grounding of the REF542plus ............46 7.2.5 Typical examples of analog and binary connections....48 7.2.6 Connection Example of the REF542plus Analog Inputs ....49 Commissioning ....................51 Safety Information ................... 51 Switching on the feeder................... 51 Test Equipment ....................51 Testing the interlock conditions,..............
  • Page 5 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Power supply....................58 9.7.1 Base Unit ..................58 9.7.2 HMI Control Unit ................58 Environmental conditions ................58 Degree of protection by enclosure ..............58 9.9.1 Central Unit................... 58 9.9.2...

  • Page 6: Introduction

    Manual: Motor Protection with ATEX-Certification 1 Introduction This part of the manual for the multifunctional protection and switchbay control unit REF542plus primarily focuses on the integrated motor protection functions. section and its subsections contain information on: The basic principle of functioning...

  • Page 7: Abbreviations And Definitions

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 2 Abbreviations and Definitions In the following the abbreviations and definitions used in thid manual are listed. 2.1 Abbreviations Air Isolated Switchgear Auto Reclosure Current Transformer Discrete Fourier Transformation...
  • Page 8 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Hazard information level 1 Level 1 hazard information indicates hazards affecting substations and devices. It should always be observed, because otherwise function interruptions or malfunctions may occur. An example is shown below:...

  • Page 9: References

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 3 References: [DIN1] DIN EN 60255 -8 / VDE0435 Part 3011: Electrical Relay, Thermal Elec- trical Relay (IEC60255-8:1990, modified), June 1998, VDE-Publisher GmbH, Berlin [DIN2] DIN EN 50014/ VDE 0170/171 Part 1: Electrical apparatus for potentially explosive atmospheres –...

  • Page 10: Motor Protection Functions

    Unbalanced load protection or optionally a simple positive sequence monitoring In all cases, the momentary motor temperature is crucial for the motor protection functions. The REF542plus therefore uses a common thermal replica of the first order for determining the motor temperature. Consequently, decisions can be taken by all applied protection functions, depending on the momentary value of the calculated mo- tor temperature.

  • Page 11: Supervision Of A Blocking Rotor

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 4.1 Supervision of a blocking rotor When the rotor is blocked, the current in the motor increases and is determined by the starting current which magnitude is a multiple of the rated motor current. In order to prevent a thermal overload, a fast tripping must be generated.

  • Page 12: Motor Start Protection

    Motor startup time starting The motor start protection function in the REF542plus can therefore supervised the motor startup behavior for temperature overload conditions using the calculation method based on equation (2). The current/time starting integral is calculated as soon as the preset response value of the starting current is exceeded within the first 100 ms during the motor starting process.
  • Page 13 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Figure 2: Setting parameters for motor start protection Where: nominal motor current Start value Is start current value, related to the nominal motor current, as a measure for the permissible temperature rise...

  • Page 14: Tripping Characteristic

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 4.2.2 Tripping characteristic The tripping characteristic for the motor start protection function can be approximated in a simplified approach through equation (3). The current of blocked motor can be assumed as the same for the starting current.

  • Page 15: Functional Check

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Table 1: Tripping time of the motor startup monitoring for t6IB=5s. Tripping time in s 1,00 180,00 1,50 80,00 2,00 45,00 2,50 28,80 3,00 20,00 4,00 11,25 5,00...

  • Page 16: Setting Parameters

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 4.3.1 Setting parameters For operation purposes, the parameters need to be set as shown below: Figure 4: Setting parameters for thermal protection Where: Permissible number of starts in warm condition...

  • Page 17: Functional Check

    For motor protection, the thermal overload protection based on the thermal replica is one of the major functions for supervising the motor for temperature violations on ac- count of overloads during operation. In the REF542plus, a thermal replica with a total memory function has been implemented in accordance with the applicable standard [DIN1].
  • Page 18 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification The heat losses is represented by resistor R During charging, a voltage is present at the capacitor. The capacitor voltage is again proportional to the motor temperature. The voltage characteristic can be determined based on the equation below: −...
  • Page 19 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification ϑ ϑ − ⎛ ⎞ ⎜ ⎜ ⎟ ⎟ − ϑ ϑ − ⎝ ⎠ τ (7.) ⎛ ⎞ ϑ ϑ − ⎜ ⎜ ⎟ ⎟ − ϑ...

  • Page 20: Setting Parameters

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification tor. The numerator is identical to the extended thermal capacity of the motor for trip- ping and only allowed for a very short time duration.. 4.4.1 Setting parameters...

  • Page 21: Setting The Time Constant

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Where: Nominal motor temperature (permissible operating temperature) Nominal motor current referred to the nominal current of the cur- rent transformer Tini Initial temperature of the thermal memory after switching on the auxiliary voltage .

  • Page 22: Setting The Temperature

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Thus, the value for TCOverheat (the time constant for motor operation at overload above 2 times the rated motor current) can be calculated on the basis of equation (11.1).
  • Page 23 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification With help of tables 2 and 3, the value for setting constant (k) or the root of the ex- tended memory contents can be calculated on the basis of equation (10) if the motor is to be run up to limit temperature.

  • Page 24: Setting The Temperature After Reset

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification sumed that the real-time clock in the REF542plus will continue to run for a period of at least 2 hours at the required accuracy. The initial temperature for continuing the thermal monitoring of the motor is calculated...
  • Page 25 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Thermal Overload Protection 1000,0 100,0 10,0 I/IB Time Constant 146s, 0% Time Constant 146s, 100% Figure 8: Tripping characteristic for thermal protection at τ = 146sec or t = 5sec If in contrary the blocking time in warm condition is stated, so the equation 11.2...

  • Page 26: Functional Check

    For calculating the memory contents, the REF542plus assumes that the root-mean-square value of the current in the individual phases is present.

  • Page 27: Unbalanced Load Protection

    When a tripping took place, it is usually advisable not to restart the motor immediately after the trip. The unbalanced load protection in the REF542plus has therefore been provided with the option to block motor reconnection by means of an output signal.

  • Page 28: Setting Parameters

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 4.5.1 Setting parameters For operation purposes, the parameters need to be set as shown below: Figure 9: Tripping characteristic for thermal protection at τ = 146sec or t...

  • Page 29: Tripping Characteristic

    ⎟ ⎥ 21.) ⎝ ⎠ ⎝ ⎠ ⎢ ⎥ ⎣ ⎦ The constant which is to be set at the REF542plus field control and protection device for the above example is: ⎡ ⎤ ⎛ ⎞ ⎛ ⎞ − ⎢ ⎥...
  • Page 30 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Unbalanced Load Protection 1000,0 100,0 10,0 I2/IMn Operation Time in s Figure 10: Tripping characteristic for thermal protection at τ = 146sec or t = 5sec The table below gives an overview of the times resulting for the tripping characteristic.

  • Page 31: Functional Check

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 4.5.3 Functional check For a functional check of the unbalanced load protection, we recommend to use three-phase testing equipment. By switching the phase sequence (e.g. L1, L3, L2) at the connections, a unbalanced load current can be simulated.

  • Page 32: Setting Example

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 5 Setting example The following paragraph presents an example for setting the motor protection func- tions which are used for thermal supervision. Special consideration is given to the set-...

  • Page 33: Rotor Block Protection

    Manual: Motor Protection with ATEX-Certification 5.1 Rotor block protection The rated motor current is known. Since the primary current transformer rated current is 100A, the rated motor current or the motor current Ie at the REF542plus has to be set to 0,91 100A For detecting a rotor blocking, only the overcurrent criterion is to be used.

  • Page 34: Number Of Starts Protection

    ° ° , 1 ( As a result, it is possible to define the temperature for tripping on the REF542plus ° With this setting the thermal memory contents can be expanded to 144%. A warning signal has to be generated, for instance, if the thermal memory contents of 120% is reached.

  • Page 35: Tripping Characteristic

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification and the setting of the number of starts from warm condition is Number Warmstart According to the selected setting, after each start the thermal memory will be filled up by 45%.

  • Page 36: Behavior After Recovering Of The Auxiliary Voltage

    Figure 13: Reducing the tripping time at a 100% preloading 5.6 Behavior after recovering of the auxiliary voltage When the auxiliary voltage of the REF542plus fails, the motor to be protected must also be switched off. The duration of the failure of the auxiliary voltage can be super- vised by the internal real time clock.
  • Page 37 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification After recovering of the auxiliary voltage the following temperature will be used for con- tinuing the operation of the motor protection: ⎛ ⎞ 600s ⎜ ⎟ ° °...

  • Page 38: 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 39: 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. 6.3 Safety Regulations The safety notes in the following chapters represent only a general selection of the points that must be observed.

  • Page 40: Risk Analysis And Safety Measures

    The risk analysis and the safety measures are mentioned in [DO1]. It can be con- cluded, that the motor protection function in the REF542plus can fulfil the requirement class 3 of DIN V 19250. By means of the watch-dog function all emergency situation can be detected in order to switch off the protected motor.

  • Page 41: 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 42 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification The figures below show the dimensions of the HMI Control Unit and Central Unit. Figure 15: Dimension of the HMI Control Unit Figure 16: Dimension of the Central Unit case, standard version 1VTA100114-Rev.

  • Page 43: Set-Up Area And Required Environmental Conditions

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Figure 17: Dimension of the Central Unit case, wide version 7.2.1 Set-up Area and Required Environmental Conditions Please note the following information regarding the set-up area: Allow sufficient space for access to the. The connections must be easily accessible.

  • Page 44: Installation In Lv Panels

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 7.2.2 Installation in LV panels Figure 18: REF542plus installed in gas-insulated switchgears (GIS) Figure 19: REF542plus installed in air-insulated switchgears (AIS) 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 44 / 66...

  • Page 45: 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 46: Check The Voltage Transformer Circuits

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification This enables weak ground faults currents that flow along the cable sheath to dissi- pate. In this way, they will not be incorrectly measured at their own relay feeder. The following shows another view of the cable current transformer grounding.
  • Page 47 HMI Local Control Unit to the grounding system in the LV compartment. Figure 23: Grounding of the REF542plus HMI Local Control Unit 1VTA100114-Rev. 04 en PTMV, 19.01.05...

  • Page 48: Typical Examples Of Analog And Binary Connections

    7.2.5 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 49: Connection Example Of The Ref542Plus Analog Inputs

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 7.2.6 Connection Example of the REF542plus Analog Inputs Figure 24: Example of connection diagram for incoming or outgoing bays with transformers 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 49 / 66...
  • Page 50 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification Figure 25: Example of connection diagram for incoming or outgoing bays with sensors Caution Due to accuracy requirements the length of the cable connection to the sensors in other bay respectively panels should be less than 7 m 1VTA100114-Rev.

  • Page 51: Commissioning

    8.2 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! 8.3 Test Equipment...

  • Page 52: Current Transformer

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 8.5.1 Current transformer The transformers must have a positive winding. This can be easily checked with a 9 V battery and an analog DC voltmeter. If the pri- mary coil of the current transformer is connected to the battery, the analog voltmeter connected on the secondary side must show positive.

  • Page 53: Current Sensor

    8.6 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. 1VTA100114-Rev. 04 en PTMV, 19.01.05...

  • Page 54: Testing The Protective Functions

    Disconnect the transducers or sensors from the REF542plus. The current transformers must be short-circuited, combination sensors disconnected. Connect the test set to the REF542plus. The relevant current and voltage signals are applied to the analog inputs. Set the required rated values on the test set...

  • Page 55: Technical Data

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 9 Technical data 9.1 Analog input channels Accuracy for measurement: Class 1 Accuracy for protection applications: Class 3 Accuracy of operation time: min ± 20 ms or Class 3 9.1.1 Current and voltage transformer input values...

  • Page 56: Binary Inputs And Outputs

    Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 9.2 Binary inputs and outputs Each Binary I/O module has the following number of inputs and outputs: 9.2.1 BIO module with mechanical output relays (version 3) 14 input channels Possible auxiliary voltage ranges: •...

  • Page 57: Bio Module With Static Outputs

    Six channel 4 to 20 mA 9.6 Communication (optional) SPABUS, optical interface, optional with SMA or ST connector, for plastic or glass fiber (multi mode) LON (according to ABB LAG1.4), optical interface with ST connector for glass fiber (multi mode) 1VTA100114-Rev. 04 en PTMV, 19.01.05...
  • Page 58 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification IEC 60870-5-103 with extension according to VDEW guidelines for controlling, optical interface with ST connector for glass fiber (multi mode) MODBUS RTU, electrical interface with two RS485 ports (twisted pair) or opti- cal interface with two standard ST connector for glass fiber (multi mode) 9.7 Power supply...
  • Page 59 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification 10 Appendix: The tripping characteristics for the thermal overload protection depending on the setting of the time constant with constant k and the preloading as parame- ter are summarized. According to [DIN1] the preloading is assumed to be 0% (cold start), 90% and 100% (nominal condition) each time.
  • Page 60 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification k = 1,05 with 100% preloading TC=20s TC=200s TC=2000s TC=20000s 100000 10000 1000 I/IB 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 60 / 66 Valid from Version V4D02...
  • Page 61 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification k = 1,1 with 0% preloading TC=20s TC=200s TC=2000s TC=20000s 100000 10000 1000 I/IB 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 61 / 66 Valid from Version V4D02...
  • Page 62 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification k = 1,1 with 100% preloading TC=20s TC=200s TC=2000s TC=20000s 100000 10000 1000 I/IB 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 62 / 66 Valid from Version V4D02...
  • Page 63 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification k = 1,15 with 0% preloading TC=20s TC=200s TC=2000s TC=20000s 100000 10000 1000 I/IB 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 63 / 66 Valid from Version V4D02...
  • Page 64 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification k = 1,15 with 100% preloading TC=20s TC=200s TC=2000s TC=20000s 100000 10000 1000 I/IB 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 64 / 66 Valid from Version V4D02...
  • Page 65 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification k = 1,2 with 0% preloading TC=20s TC=200s TC=2000s TC=20000s 100000 10000 1000 I/IB 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 65 / 66 Valid from Version V4D02...
  • Page 66 Multifunction Protection and Switchgear Control unit REF542plus Manual: Motor Protection with ATEX-Certification k = 1,2 with 100% preloading TC=20s TC=200s TC=2000s TC=20000s 100000 10000 1000 I/IB 1VTA100114-Rev. 04 en PTMV, 19.01.05 Motorprotection 66 / 66 Valid from Version V4D02...

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