NewCode Motor Protection and Control Relay with Communication · The NewCode Relay is an ISO...

A South African Company to be Proud of

NewCodeMotor Protection and

Control Relay with Communication

NewCode Motor Protection Control and Communication Relay


2

MODBUS RTU



3

PROFIBUS DP

MODBUS RTU

32 Unit MMIThe 32 Unit MMI offers an exceptional user friendly interface to up to NewCode relays. The system integrator or operator will have access to the NewCode actual and parameter data without the use of a laptop or PC

• Control motor Function

• Standard Amp Meter

• Easy Trip Navigation

• Fully Customisable

• Automation Capabilities

• Modbus, Profibus and Ethernet

NewCode Motor Protection Control and Communication Relay 4

• ThermalOverload• LockedRotor• RunningStall–Jam• VectorialStall-StartStall• UnbalancedCurrent• SinglePhasing• MinimumLoad–Underload-DryRun• EarthLeakage• EarthFault• Short-circuit• StartsperHourLimitation• Overvoltage–Undervoltage• PhaseRotation• OverFrequency–UnderFrequency• Main-CircuitInsulationFailureLock-Out

• PowerFactorMeasurement• PowerConsumptionMeasurement• StatisticalData• 1400EventRecordswithtimeanddatestamp• 35LastFaultRecordswithtimeanddatestamp

• Timers• RealTimeClock(24Hour)• StarterControllerLogic• LogicFunctionBlocks• 7FieldInputs• MotorParameterCalculator• 4ProgrammableOutputs• 3PhaseRecorder• On-boardSimulatorforTraining/Commissioning• MultipleCommunicationProtocols

The NewCode relay is fully configurable with the aid of frontend software or a man machine interface unit (MMI). Event records can also be downloaded with the aid of the laptop for further analysis. All the settings can be password protected. The relay has an onboard database where time and date stamped records are kept. Two types of records are kept namely fault records (35 last faults) and event records (1400 events). In the case of event records, the user has limited access rights (read only). The front-end also has a data recorder and a spectrum analyser which could be used to analyse motor performance and supplied power quality respectively. The spectrum analyser can detect harmonics up to the 9th harmonic on any of the three phase currents. The relay detects earth leakage currents with the aid of the external core balance current transformer and is configurable to operate in inverse definite minimum time (IDMT) or instantaneous definite time (IDT) mode. A unique feature is added to the relay in the form of simulation. This function could be used for personnel training or relay functionality testing.

Protection Features:

About

Management Features:

Configurable Automation Features:

TheNewCodeRelayisanISO9001:2008compliant,three-phasemotorprotectionrelay,designedandmanufacturedinSouthAfrica.Itisamicro-controllerbasedprecisioninstrumentforthree-phaseinductionmotorprotectionwithadvancedcontrollogicfeaturesaswellasmultiplemotorstartercontrolcircuitconfigurations.Therelayisdesignedforthelowvoltagemotorprotectionmarket.Thecurrenttransformers,includingthecorebalancecurrenttransformersareexternal.Certainmodelscaterforcombinedcurrentandcorebalancecurrenttransformers,maximumfexibilityismaintainedbyallowingseparateC.B.C.T’swithinterposingcurrenttransformerswithasoftwareselectable,1to10ampsecondarywinding,Class1,5VA.



5

NEWCODE PROFINETPROFINET Cyclic Message Structure:• 1to4CyclicOut(FromPLC)bytestoNewCode• 1to2bytesarebitconfigurableintheNewCode.• 2to4areusedtodrivethe4to20mAoutputs.• 4to21CyclicIn(ToPLC)wordsselectable.• 2Wordmessagesbitsareconfigurable.

PROFINET :• AcycliccommunicationsameasoldF880structure

toeasedatatableupgrade.• Canbeusedinstar,ringorlinenetworktopology.• NewCoderealtimeclocksynchronizationfor• EventandfaulttimestampinginNewCoderelay

FRAM.

PROFINET Configuration



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PROFINET Variable Table, PROFINET Test Tab and NewCode Setup

NewCodeMMI420-FPR0415



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Auxiliary Power SupplyVoltage requirements : 110 - 230 V AC/DCPower requirements : 2,5 Watt

Operating EnvironmentTemperature : -20°C - 65°CRelative humidity : < 85%

Communication ProtocolsProfibus DPV-1, Modbus, CanBus

Input Converter Class : Class 1 Rating : 0,1 VA Frequency Response : 40 to 66 Hz

Overload Trip Delay Curves Class 3 – 40 to IEC 60255-8 Specification

Unbalance / Single Phasing Setting Level Setting : 5 – 50% Ie (M.F.L.) Trip Delay : 1 to 10 seconds

Underload Detection Range : 10 to 100% of Max Load Setting Trip Delay : 1 to 10 seconds Priming Time Available : 1 to 200 seconds Power Factor Setting : 0.1 to 1 on Minimum Load Setting

Auto Reset Limiter Auto Reset limited to only 3 times per hour

Maximum Load Current SettingLevel Setting Accuracy : ± 2% Linearity : ± 2% Repeatability : ± 1% Detection Level : ± 2% Calibration : Amps

4X Output Relays : 5 Amps 220 V AC Configuration : Form C (Common, NC / NO) : Fully configurable Fault Indication Operation : Latch LED on Trip, record on event and fault records : Clear LED on Resetting Running Stall Protection Detection Level : 110 to 300% of Max LoadTrip Delay Adjustable : 0.100 - 1 second

Three phase current measurementRange : 1 – 400 AmpsDynamic range : 0% to 1000%

Voltage Range : 110 V, 380 V, 400 V, 525 V, 550 V, 680 V, 950 V, 1100 V, 3 K 3 V / 110 V, 6 K 6 V / 110 V, 11 KV / 110 VRange selection : manual or automatic selection at power up

Earth Leakage Range : 30 mA to 3 AmpsTrip Time : Inverse Definite Minimum Time (IDMT) and Instantaneous Definite Time (IDT)Real Time Clock24hr clock (year, month, day, hours and minutes)Battery back-up (5 days)Time & date stamping (fault and event records)Insulation ResistanceMeasurement range : 1 to 99 kOhmResolution : 1 kOhm

Power Factor Range : 0 to 100% (phase angle 0 to 90°)

Standards compliance and certifications

ISO 9001:2008 : Quality management

CISPR 22:1-15 : Radiated emissions

CISPR 22:1-15 : Conducted emissions (Power Leads)

IEC 61000-4-2 : Electrostatic discharge immunity test

IEC 61000-4-3 : Radiated, radio-frequency, electromagnetic field immunity test

IEC 61000-4-4 : Electrical fast transient / burst

IEC 61000-4-5 : Surge immunity test

IEC 61000-4-6 : Immunity to conducted disturbances, induced by radio-frequency fields

IEC 61000-4-11 : Voltage dips

IEC 61000-3-2 : Harmonic current emissions

IEC 61000-3-3: Voltage changes, voltage fluctuations and flicker

Technical Specifications



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Thermal Curves



9

Frontend Actual Readings Frontend Settings

Starter Configuration Statistical Screen

Test Screen Actual Data Recorder



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Electrical Connection Diagram for NewCode Relay

Connection Diagram for Expanded I/O Module



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Electrical Connection Diagrams for 4-20 mA and RTD Modules

NewCode Current module dimensions for 5, 10, 25 and 50 Amps

NewCode Current module dimensionsfor 100 and 300 Amps



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Dimensions WHY WAIT TO AUTOMATE?



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THE QUESTIONAre you waiting to replace your MCC to automate?You can automate your existing MCC...

TypicalexistingwiringdiagramofFWD/REVstarter

This is all done with your existing:• Switchgearandcontrolgearinventory

• Staff-whiletrainingandupskillinginuseofPLCandMMItechnology

• Maintenancebudgetwithimprovedplantavailability

...with minimal wiring changes• Useexistingmaintenancestaffforchanges

• ImprovesafetybyaddingaseparateMMI/PLC

• CheckstatusofallstartersonMCCfromsafelocationwithinsubstation

• Start/Stopdrivefromasafelocationinsubstation

No need to open panel door to measure• Statusofinterlock,supplyvoltageorcurrent-all

fromMMIdisplay

• SetupNewCodeprotectionrelaywiththroughdoorIrDAcommunications

1

1

2

2

3

3

4

4

D D

C C

B B

A A

5

NewElec Pretoria (Pty) Ltd298 Souter StreetPretoria00486

Why wait to automate SchematicCAP-DOL-WTA-01 00C

2015/07/30 02:37:43 PMNC_WWTA_DOL Reversal_P05.1_00_14_C.SchDoc

Title

Size: Number:Date:File:

Revision:Sheet ofTime:

A4Disconnect Wire ST = Shunt Trip Coil

MC = Motor Contactor

POWER CIRCUIT

L1

L2

L3

Neutral

380/525VAC

380/525VAC

380/525VAC

Overload

Circuit Breaker

220VAC

Control CB

Fuse

CONTROL CIRCUIT

FWD

Motor

REV

FWD

U WV

EM 3 ~

Overload

18

ST

FWD

16

17

8

9

14

10

16

17

12

17

Neutral

REV

REV

REV13

12

FWD

FWDStart

REVStart

Stop

15

15

17

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ORIGINAL CONTROL AND POWER CIRUITS

Part 1 of 2

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WHY WAIT TO AUTOMATE?



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THE SOLUTIONNewElec is willing to assist your maintenance staff on site, every step of the way.• FromyourexistingMCCschematicdiagrams,identifythedifferentstartercomponents

• Suggestmodificationswhileconsultingwithyourelectricalmaintenancestaff

• FinalisationofcircuitconnectionstoprovidePLCControl/SCADAinterface

• AssistmaintenancestaffinreplacingexistingprotectionrelaywithintelligentNewCodeMotorProtectionRelayofyourchoice

THE RESULT• Existingplantcontrolwithoptionalautomatedcontrolwhichcan

nowbelinkedtoLocalcontrolHMIor

• CentralisedcontrolSCADA

• Improvedpersonnelsafety

• NoneedtoopenMCCcubicleduringfaultfinding

• Comprehensiveprotection,earthleakageaswellasfrozencontactor

• IRDAthroughdoorcommunicationNewCodeconfiguration

• NewCodememorymoduleretainsrelayconfigurationsettings

• StandardHMI/PLCmoduleextractscustomizedshiftreports

• Directlinktoengineering/foreman/productionsupervisor/desktop

• Maintenancestaffdirectlyinvolvedincommissioning

• Maintenancestaffabletotakeownershipandcontinuewithproductionoptimization

1

1

2

2

3

3

4

4

D D

C C

B B

A A

4

NewElec Pretoria (Pty) Ltd298 Souter StreetPretoria00486

Why wait to automate SchematicCAP-DOL-WTA-01 00C

2015/07/30 02:30:17 PMNC_WWTA_DOL Reversal_P04_00_14_C.SchDoc

Title

Size: Number:Date:File:

Revision:Sheet ofTime:

A4

Newcode

U WV

EM 3 ~

Earth

Motor

17181920

30

31

32

Core Balance CT

NTL

Input 1

Input 2

Input 3

Input 4

Input 5

25

3

2

7 12

Relay 1

Relay 3

Relay 2

Relay 4

4 8

6

11

10

1615

14

29

110-220V

AC

Earth

Network

DB9

Profibus

Profibus RS485

17

MTR

NTL

262728

Input 6

Input 7

Com

mon

2122S1

S2

CT Ribbon Cable

23

Insulatio

n Lo

ckout

TBUS Rack Connector

RTD

1RTD

2

Pin 67 & 68To RTD Module

Earth

POWER CIRCUITL1

L2

L3

Neutral

380/525VAC

380/525VAC

380/525VAC

Overload

Circuit Breaker

18

ST

FWD16

17

17

REV15

17

Voltage Converter

CT Block

NC 50 33

34

35

Module(1000 to 525 V)

CONTROL CIRCUIT

REV

FWD14

12

REV13

12

FWD

FWDStart

REVStart

Stop

FWD

16

17Neutral

REV

15

220VAC

Control CB

Fuse

8

9

11

10

1516

ST

18

17 17

24

Earth

S1S2Ins L

ock

Relay



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AccessoriesExternal Memory Module (Part number: FPR0407)Theexternal,pluggablememorymodulestorestherelaysetting,logicfunctionsettingsandstarterconfigurations.Thememorymoduleisupdatedbytherelayeachtimeanyofthesesettingsarechangedviathefront-endsoftwareordoormountedMMI.Themodule isintendedtoaidfieldmaintenancepersonnelinthesetupofareplacementrelayshouldarelayneedtobechanged.

Insulation Lock-out Module (Part number: FPR0216)Theinsulationresistanceofthemotorismeasuredwhileinastatic(notinservice)condition.Iftheresistancedropsbelow20kiloohms,therelaywilltripandpreventastart-up.

Expanded I/O Module (Part number: FPR0412)Thisisanexpansionmodulewith4programmableoutputrelaysand8digitalinputs(allwithLEDstatusindication).TheunitconnectstotherelayviaaT-Busconnectorandderivespowerfromtherelay’sownpowersupply.

RTD Expansion Module (Part number: FPR0413)Thisisanexpansionmodulewith4RTDinputswhichcanacceptaNTC,PTC,PT100orPT1000input.TheunitconnectstotherelayviatheT-Busconnectorandderivespowerfromtherelay’sownpowersupply.

4-20 mA Module (Part number: FPR0414)Thisisanexpansionmodulewith2inputloopsand2outputloopsfor4-20mAsignals.Runningampsorthermalcapacity,oranyanalogsignal,canbesentoutthoughtheoutputloops.Similarly,anyanaloginputcanbesenttotheNewCoderelayforcontrolpurposes.

NewCode Motor Protection Relay Product Code

NewCode Motor Protection Relay FPR0400NewCode MK1 Motor Protection Relay FPR0400NewCode MK2 Motor Protection Relay FPR0650Current Module:

NC-300-CBCT-110/550 (30-300 Amp 110-550 Volt Converter) FPR0401

NC-100-CBCT-110/550 (10-100 Amp 110-550 Volt Converter) FPR0402

NC-01-110/550 (0.1-1 Amp 110-550 Volt Converter) FPR0403



NC-50-110/550 (5-50 Amp 110-550 Volt Converter) FPR0406

NC-Core Balance CT-43MM BTX0004





NC-MM-I2C-TBUS (External Settings Memory Model) FPR0407

NC-CT-CAB-1000-1m (Current Converter to NC Conn Cable) FPR0408

NC-CT-CAB-1000-500mm (Current Converter to NC Conn Cable) FPR0409



NC-Expanded-I/O (4 outputs relays and 8 differential inputs) FPR0412

NC-RTD-04 RTD/PTC Temp Module (PTC, NTC, PT100, PT1000) Selectable FPR0413

NC-Insulation Lockout Module (400 – 1100 Volt direct connection) FPR0216

NC-4-20mA-Module (2x 4-20 mA In loops , 2x 4-20 Out loops) FPR0414

NC-Volt-Converter (1100 Volt to 525 Volt) FPR0208

NC- MMI FPR0415

Ordering information


Physical Address:

298SoutterStreet,

PretoriaWest

Tel:+27123271729

Fax: +27(0)123271733

Toll Assist:0860103041

www.newelec.co.za

[email protected]

NewCodeMotor Protection and

Control Relay with Communication

NewCode Motor Protection and Control Relay with Communication · The NewCode Relay is an ISO...

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