Description
Detailed Parameter Table
| Parameter Name | Parameter Value |
| Product Model | ABB REF542PLUS |
| Manufacturer | ABB |
| Product Category | Feeder Protection Relay |
| Rated Voltage | 24-250 V DC / 100-240 V AC |
| Protection Functions | Overcurrent (50/51), Earth Fault (50N/51N), Directional OC (67), Arc Flash (AFD) |
| Arc Detection | <7 ms via external sensors (LIGHTARC) |
| Communication Protocols | IEC 61850, Modbus RTU/TCP, PROFIBUS DP, DNP3.0 |
| IEC 61850 Certification | Ed 2.0 (GOOSE, MMS, Sampled Values) |
| Measurement Accuracy | 0.5% (voltage/current), 0.2° (phase angle) |
| Operating Temperature | -40°C to +70°C |
| Fault Recording | 128 cycles (256 samples/cycle) |
| Control Outputs | 6x programmable relays (5A @ 250V AC) |
| Certifications | IEC 60255, UL 1053, DNV-GL, ATEX Zone 2 |
| Enclosure Rating | IP54 (front)/IP20 (terminals) |
ABB REF542PLUS
Product Introduction
The ABB REF542PLUS is a multifunctional feeder protection and control terminal designed for medium-voltage switchgear applications up to 40.5kV. Combining advanced protection algorithms with comprehensive control capabilities, this intelligent electronic device (IED) provides selective fault clearance, power quality monitoring, and arc flash mitigation in industrial and utility power distribution networks. As part of ABB’s Relion® product line, the ABB REF542PLUS integrates seamlessly with ABB Ability™ digital solutions for predictive maintenance and energy analytics.
Featuring dual Ethernet ports with PRP/HSR redundancy support, the ABB REF542PLUS enables high-availability communication in mission-critical infrastructures like data centers and process plants. Its modular design supports flexible hardware expansions including RTD input cards and communication gateways. The ABB REF542PLUS delivers unparalleled value by reducing installation space by 60% compared to conventional relays while providing integrated arc flash detection that reduces incident energy by up to 90%.
Core Advantages and Technical Highlights
Ultra-Rapid Arc Protection: Integrated Light Detection (LIGHTARC) triggers breaker tripping within 7 ms – 10x faster than conventional overcurrent protection. Fiber-optic sensor inputs cover switchgear compartments without EMI susceptibility.
Cyber Secure Architecture: Hardware-based secure boot with IEC 62443-4-2 compliance. Role-based access control with LDAP/Radius integration. Encrypted GOOSE messaging (AES-128) and event logging with cryptographic hashing.
Advanced Grid Intelligence: Synchrophasor measurement (μPMU) enables voltage stability monitoring. Harmonic analysis up to 25th order (THD, TDD). Directional power element prevents false tripping during network reconfiguration.
Dual Switching Capability: Unique “Switch-Disconnector” logic enables safe maintenance operations without protection bypass. Integrated interlocking via IEC 61850 GOOSE messaging.
Engineering Efficiency: PCM600 software enables drag-and-drop configuration with pre-certified protection templates. Automatic documentation generator creates wiring diagrams and setting reports.
Typical Application Scenarios
In steel mill melt shops, the ABB REF542PLUS protects 33kV furnace transformers from through-fault damage. Arc flash detection triggers before pressure waves develop, while harmonic monitoring prevents capacitor bank resonance. During electrode breaks, directional overcurrent elements discriminate between transformer inrush and actual faults.
For offshore wind farms, the relay’s DNV-GL certification ensures operation in salt spray environments. IEC 61850-9-2LE process bus integration reduces cabling by 80% across collector substations. The ABB REF542PLUS coordinates feeder protection with turbine controllers using <4ms GOOSE messaging.
In hospital campuses, the device’s <30ms fault clearance prevents voltage sags affecting MRI equipment. Load shedding schemes prioritize critical care units during generator transfer. The front-panel IP54 rating withstands washdown in central utility plants.
Related Model Recommendations
ABB REF615: Compact successor with enhanced cyber security
ABB CM-PSU: Power supply module for dual DC systems
ABB REX010: Voltage relay for REF542PLUS backup protection
ABB FCP-03: Fiber-optic sensor kit for arc detection
ABB SPAJ 110 C: Lockout relay interface
ABB COM600: Gateway for REF542PLUS SCADA integration
ABB SDCS-REL-4: Redundancy module for critical feeders
ABB ZSG 101: Test switch for maintenance operations
ABB REF542PLUS
Installation, Commissioning and Maintenance Instructions
Installation Preparation: Verify CT/VT burden compatibility (CT ≤ 0.5 VA). Use 600V shielded cables for binary inputs/outputs. Maintain 100mm clearance from high-voltage compartments. Ground shield at relay panel only. Pre-configure IEC 61850 ICD file in PCM600.
Maintenance Suggestions: Test arc protection annually using ABB FOT-01 test tool. Verify setting changes via digital signature audit trail. Monitor “Contact Wear” index for circuit breaker operations. Update firmware during planned outages:
Download signed firmware package
Disable protection functions
Update via USB or Ethernet
Verify checksum and re-enable
Replace cooling fans at 70,000 operational hours.
Service and Guarantee Commitment
ABB provides a 60-month warranty for the REF542PLUS, including performance guarantee for protection functions. Our global support includes:
24/7 technical hotline with remote relay diagnostics
Next-business-day replacement for critical failures
Complimentary cyber vulnerability assessments
Lifecycle commitment until 2030
On-site commissioning assistance
Calibration services with NIST-traceable reports
All units undergo 1000-operation endurance testing and complete type tests per IEC 60255-121. Cybersecurity validation includes Penetration Testing Certification by independent labs.
