ABB REF542PLUS Feeder Protection and Control Terminal

Description

Application Scenarios

In a medium-voltage primary distribution substation supplying a large industrial plant, each outgoing feeder to different factory sections requires precise overcurrent and earth fault protection, remote switching capability, and detailed energy metering. Traditionally, this required a protection relay, a separate RTU or PLC for control logic, and additional hardware for communication. The ABB REF542PLUS​ consolidates all these functions. For a critical feeder powering a compressor house, the REF542PLUS​ continuously monitors current and voltage. It executes complex protection schemes, like directional overcurrent with voltage restraint. Simultaneously, it processes interlocking logic locally, allowing safe remote opening/closing of the circuit breaker from the control room via IEC 61850. It also logs all events, records fault waveforms, and streams energy data to the plant’s SCADA system. This integration simplifies the entire substation design, reduces panel space by over 60%, cuts wiring, and provides operators with a unified, intelligent view of each feeder’s health and status, dramatically improving operational decision-making and maintenance planning.

Parameter

Annotation:​ The REF542PLUS​ is distinguished by its IEC 61850​ capability and integrated programmable logic (CFC), which allows it to act as a standalone bay controller without an external PLC. Its communication suite is a core feature for modern substation automation.

Technical Principles and Innovative Values

The ABB REF542PLUS​ is built on a powerful multiprocessor architecture that executes protection algorithms, control logic, and communication protocols concurrently and deterministically.

Innovation Point 1: True Integration of Protection and Control Logic.​ Unlike a standard relay that sends signals to an external PLC, the REF542PLUS​ contains a full-featured, IEC 61131-3 compliant Control Function Chart (CFC) editor. Engineers can program complex interlocking, sequence control, and automation schemes (like load shedding) directly within the relay. This eliminates hardware, reduces point-to-point wiring, increases speed, and enhances reliability by keeping critical logic localized and independent of the SCADA network.

Innovation Point 2: Native IEC 61850 and Object-Oriented Data Model.​ The device supports IEC 61850-8-1 (MMS) and GOOSE messaging natively. Its entire data set—measurements, statuses, events, and controls—is modeled as standard logical nodes. This allows seamless, tool-based engineering with other compliant devices in a substation, enabling features like horizontal GOOSE messaging for fast inter-bay interlocking (e.g., busbar protection) without hardwiring. It represents a foundational shift from vendor-specific protocols to an interoperable, future-proof standard.

Innovation Point 3: Comprehensive Condition Monitoring and Diagnostics.​ Beyond basic protection, the REF542PLUS​ functions as a data concentrator. It performs detailed power quality analysis (harmonics, flicker), records extensive event logs with oscillography, and monitors its own hardware and the health of connected equipment (e.g., circuit breaker operating time, number of operations). This transforms it from a protective device into a predictive maintenance tool, providing actionable intelligence to prevent failures.

Application Cases and Industry Value

Case Study: Digitalization of a Municipal Distribution Network

A city utility aimed to digitalize its aging ring-main units (RMUs) to improve reliability and enable fault location, isolation, and service restoration (FLISR) schemes. They deployed the ABB REF542PLUS​ in each RMU feeder compartment. The relay’s protection functions secured the network. Crucially, its IEC 61850 GOOSE​ capability was used to create a peer-to-peer communication network between the units. During a cable fault, the REF542PLUS​ units communicated directly with each other using GOOSE messages, autonomously identified the faulted section, and reconfigured the network by opening and closing switches to restore power to unaffected sections in under 60 seconds—all without SCADA intervention. This reduced the average annual outage time (SAIDI) by 35%. The utility’s engineers also used the built-in energy metering of each REF542PLUS​ for granular feeder-level billing and loss analysis, uncovering significant non-technical losses.

Case Study: Integrated Mill Power Management in a Paper Plant

A large paper mill with its own generation and a complex 11kV distribution network faced challenges with load shedding and interlocking between multiple incomers and tie-breakers. The old system used discrete relays and a central PLC, leading to complex wiring and slow response. The plant installed REF542PLUS​ units on all key feeders and incomers. The protection was configured as required. The advanced control logic capability was then utilized to program the entire mill’s load-shedding and interlocking scheme directly into the relays. The REF542PLUS​ units communicated via IEC 61850. making decisions based on local frequency, voltage, and status. This distributed intelligence resulted in a faster, more reliable response to grid disturbances, preventing a total plant blackout on three occasions in the first year, saving an estimated $2M in production losses and equipment damage.

Related Product Combination Solutions

ABB Relion® 615 Series:​ The next-generation protection relays from ABB, offering similar integrated functionality with newer hardware platforms. The REF542PLUS​ is a mature, field-proven predecessor in this integrated protection & control line.

ABB RTU560:​ A more powerful remote terminal unit for larger substations or complex applications where the REF542PLUS​ can act as an intelligent bay controller feeding data to the RTU560​ as a data concentrator.

ABB MicroSCADA Pro:​ The substation SCADA system that seamlessly integrates with the REF542PLUS, using its native IEC 61850 client/server model for efficient data acquisition, control, and visualization.

ABB CMU 2.0:​ The Condition Monitoring Unit that can be paired with the REF542PLUS​ for enhanced monitoring of switchgear assets like circuit breakers, complementing the relay’s internal monitoring features.

ABB REC670:​ A more advanced line differential and distance protection relay. In a substation, the REF542PLUS​ would manage feeder bays, while the REC670​ would protect the main transmission lines or transformers.

ABB Bushing Current Transformers (e.g., BOE):​ High-accuracy CTs that provide the measurement signals to the REF542PLUS, forming the foundational sensing layer for its protection and metering functions.

ABB SACE Emax 2 Air Circuit Breaker:​ A primary circuit breaker that can be equipped with a REF542PLUS​ as its integrated protection and control unit, creating a fully intelligent, communication-ready low-voltage switchgear solution.

Installation, Maintenance, and Full-Cycle Support

Installation of the ABB REF542PLUS​ is streamlined by its compact, all-in-one design. It mounts in a standard cutout on the switchgear panel. Wiring is simplified as a single device handles protection, measurement, and control connections, reducing terminal points. Commissioning is highly efficient using ABB’s PCM600 or similar engineering tools, which allow for offline configuration, setting management, and easy upload/download via USB or Ethernet. The intuitive local HMI with its navigation wheel facilitates on-site checks and troubleshooting.

Routine maintenance is primarily software-based, leveraging the unit’s extensive self-diagnostic and condition monitoring features. Event logs, disturbance records, and breaker wear indices can be downloaded and analyzed remotely. Firmware updates can be applied securely via the engineering tool. Should a hardware issue arise, the modular design allows for efficient replacement. Our full-cycle support for the REF542PLUS​ encompasses expert assistance with system design and IEC 61850 engineering, comprehensive training on its advanced features, and reliable access to spare parts and firmware. We provide the technical expertise to help you maximize the value of this integrated platform, from initial configuration to long-term system health monitoring and upgrades.

Ready to streamline your substation automation with an integrated protection and control solution? Contact us today for detailed technical specifications, application consulting, and support for your ABB REF542PLUS system.