MB Relay User Manual 01A (mb_relay_user_manual_01a)
Contents
1. pueri rr perenne eniena enn Frequency Power Earth Hz Factor 2 Leak m 67 ie 230 90 50 60 Thermal Capacity j F Used Link voltage slider controls Link current slider controls eo oa 0 e Timer Alarm to Trip Time m Simulation Mode Selector r Digital Field Signals c Reset Tesse Input Input Input 11 heit Input inservice zi Please note Simulation Control 8 Relay The sole purpose of this simulation facility isto pro CURE NECS Reset Thermal Capacity Relay 2 am Relay 6 vide a quick test for some of the protection features of the relay It is not suitable for calibration purposes Stop Simulation Reset Relay Trip State nes 8 due to process speed variances of the different per a Relay 4 i Relay 8 sonal and laptop computers 5 Connected Input 3 Relay Coils Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 25 of 35 6 4 2 Test Screen Automatic A NewCode Relay Frontend File Options Disconnect Actual Control Logic Starter Configuration Real Time Clack Fault History Comms Statistics Event History Calculator Spectrum Analyser Info Simulated Injection Test Automatic Simulated Injection State Sequence T able E Open sequence in2. Fail Safe Select Auto Thermal Reset Select Moving Average Filter Select Dynamic TCap Reset THold Adj Select IV Starts per Hour Select v RTD 3 Select Minimum Load Select T Minimum Load Detection Undercurrent Select Power Factor Select Read settings from relay Transmit frontend settings to relay COMS Connected Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY 6 3 2 Control Logic Screen MB Relay Frontend File Options Disconnect Comms Statistics Actual Recorder Settings Page 20 of 35 Test Event History Starter Configuration Control Logic Calculator Real Time Clack NewElec MB Relay Spectrum Analyser Info Calibration Fault History i Control Logic Functions Timer A DigFidlnput 7 gt Reset input af gt Start input Logic Function 1 Zero 0 X gt 4 Zero 0 B2 Logic Function 3 InService gt 4 RunStall_at gt 2 VotPreseriF z Logic zt gt Ata zoea zw 20 Zeot gt C t Cutput table e 3 Time Bi stable output ll Mono stable output pulse Bill 28 Dutputtable gy Outputtable HE Logic Function 6 Zeo gt Ata wt zora Zeot jo Output table r Logic Function 4 zt gt At eem job ze 2tt fo Duputabe
3. Temperature Sensors RTD1 18 RTD2 18 C 18 Current Apparent Power Dissipation 18 kVA Real Power Dissipation D Kwatt Supply Frequency Selection 50Hz Actual Frequency Hz Actual Power Factor 0 zx Date 2010 03 24 Time 15h28m07s Motor Total Running Hours 0 Earth Leakage Current m A Reset Trips Software Rev 1a Model MB5 01234567 r Relay Coils MTR RL1 Serial Number Alarm and Trip Flags Overcurrent Vectorial Stall Run Stall Current Unbalance Single Phasing Minimum Load Low Frequency High Frequency Phase Rotation Error Short Circuit vervoltage Undervoltage Voltage Symmetry Insolation Lockout Earth Leakage Earth Fault Frozen Contactor Starts per Hour Limit EH di 2 HE di Unautherised Current System Failure me gt Starter Faults Execution Fault Feedback Fault W o MN ALS MN PLC Inputs Digital Field Inputs Input Input 2 Input 3 Bil Input 4 MI Input 5 i Input 6 Input 7 a 5 Connected MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec MB Relay Page 29 of 35 6 4 6 Calculator Screen NewCode Relay Frontend Options ControlLogic Starter Configuration Real Time Clock Fault History Statistics Actual Event History Calculator Spectrum Anal
4. Bl Logic Function 2 Zeo gt Ata x gt B Zeo 0 tt p Output table 1 2 0 gt Stat input Zeot gt Reset input o s Time sec Bi stable output Mono stable output pulse Real Time Clock Start Time pesifr si hh mm Counter A Zeot x gt Ent up input Zeot gt Ent dn input zeot0 z gt Reset input Actual count Trip ent setting Counter B Zero to gt Ent up input Zero 0 gt Ent dn input Zero 0 z gt Reset input Actual count 0 Trip cnt setting f af Thermal Capacity 2 Usage Warning Level ps si zao m E e Zero 0 gt Set Zero 07 gt Reset Comparator 1 Flasher 2 StopTime DigFldinput 3 gt Relay Digital PLC Inputs 1334 Esteri Relay Coils ALI TipFlag LogicFunc m3 ze gt ill RL4 Zeo 0 ALS Ze0 0 Digital Field Inputs Us om Transmit settings to relay 2 sii 7 UH Read settings from relay 4 Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 21 of 35 6 3 3 Starter Logic Screen MB Relay Frontend DAR File Options Disconnect Comms Statistics Recorder Test Ev
5. NewElec MB Relay Page 1 of 35 N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY MB Relay User Manual Revision la 23rd March 2010 NewElec Pretoria Pty Ltd Head Office Cnr 298 Soutter street amp Maltzan street Pretoria West South Africa 0182 GPS 25 45 12 S 28 09 46 E http www newelec co za This user manual is a preliminary document NewElec Pretoria Pty Ltd reserves the right to change and to add features towards the final release of the product N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY 5 1 5 2 6 1 1 6 1 2 6 2 6 3 6 3 1 6 3 2 6 3 3 6 3 4 6 3 5 6 4 1 6 4 2 6 4 3 6 4 4 6 4 5 6 4 6 6 4 7 6 4 8 6 4 9 6 5 7 1 7 2 7 3 7 4 NewElec Relay Page 2 of 35 CONTENT Page ABSTRACT 3 SPECIFICATIONS 4 DEFINITIONS AND TERMINOLOGY 11 FUNCTIONAL DESCRIPTION 13 INSTALLATION INSTRUCTIONS 16 Front end requirements Setting up procedure DIAGRAMS Picture of the relay Physical layout of the relay Block diagram of the relay Front End Setup Screens Settings Screen Control Logic Screen Starter Logic Screen Statistics and Network Screen Real Time Clock Screen Front End Assistance Screens Test Screen Manual Test Screen Automatic Spectrum Analyzer Screen square wave Spectrum Analyzer Screen sine wave Actual Screen Calculator Screen Fault Screen Event Screen Recorder Screen Thermal Curves of the Relay ACCESSORIES 32 FLED IrDA interface MMI
6. RDU NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 3 of 35 Abstract The MB Relay is an ISO 9001 2000 compliant local designed and manufactured three phase motor protection relay It is a micro controller based precision instrument with protection and advanced control features The relay is designed to cater for the low voltage motor protection market and is available in different current models The current transformers and the core balance current transformer are internal The relay is fully configurable with the aid of front end software Event records can also be uploaded with for further analysis the settings are password protected The relay has an on board database where time and date stamped records are kept Two types of records are kept namely fault records 45 last faults and event records 1500 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 analyzer which could be used to analyze motor performance and supplied power quality respectively The spectrum analyzer can detect harmonics up to the 9 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 re
7. 0 Stop 3 Pre Start Warning Active ga Execution Fault lll DC Break Injection Active WB Feedback Fault Auto Bl Transition Active Unautherised Current Fault Zero 04 Start gt gt Zero 0 Start gt WB Backspin Active Read settings from relay Transmit settings to relay Zero 0 v Start lt lt Zero 0 Start lt Zero 0 v Interlock Zero 0 Stop Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY 6 3 4 Statistics Screen MB Relay Frontend File Options Disconnect Page 22 of 35 Actual Settings Control Logic Starter Configuration Real Time Clack Comms Statistics Recorder User Defined Data Unique Drive ID DCX12_54 Description of drive unit Pump station DCX12 Transmit data to relay Communication Network Communication Settings Protocol Profibus Address 7 Baud Rate Auto kbps Transmit comms settings to relay Performance Statistics Cyclic Time 0 msec Cyclic Time Positive Deviation 0 Cyclic Time Negative Deviation 0 Test Event History Calculator r Statistical Data Startup Counter Trip Counter Motor Total Running Hours Motor Full Load Running Hours Relay Running Hours Apparent Power Consumption Real Power Consumption OnLine Change relay data N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Spectrum Analyser NewElec MB Relay Fault History Info Thermal Capacity required to s
8. Starter 7 Extemal Modules Expansion Module Connected FLED Connected Restart Delay Manual Under Current Trip Level 4 Power Factor Trip Level 50 2 Startup Trip Delay fi sec Runtime Trip Delay 4 sec 1 0 ajoe RTD 2 0 eps 3 0 es pos Relay 1 Configuration Dedicated Main Trip Relay Select Configurable Relay 100ms Select v Overvoltage Select Iv Undervoltage Select IV Voltage Symmetry Select I Voltage Phase Rotation Select Reverse V phase Rotation BWR Select Earth Leakage Select I Insulation Lockout Select Run Stall Trip Level 1300 Trip Delay 100 z ms Trip Holdoff Delay 0 Motor Full Load Setting zi X Thermal Curve Class Selector 15 gt sec M Low Speed Motor Setting Motor Full Load Setting ra Thermal Curve Class Selector 40 sec Thermal Capacity Used Auctual Level Adjust r4 Reset Threshold Level 70 Digital Field Input Delays Inp1 100 gt Inp 3 100 Inp2 100 ms Inp4 100 2 impe 100 2 ms Inp 100 ms ms Sims Inp5 100 gt ms Earth Leakage Trip Level 250 Trip Delay 100 ms Instantanious Detinite Time Frequency Monitoring Select jv Current Unbalance Select Iv Short Circuit Select Single Phasing Select Iv Run Stall Select V Vectorial Stall Select
9. disc file Save sequence in disc file 64 Thermal Capacity Used Timer Alarm to Trip Time gt Simulation Mode Selector Digital Field Signals Reset 0 0 MR Input 1 Input 4 Input 7 Input 5 Reset Input amp Please note i Relay 5 The sole purpose of this simulation facility is to pro Simulatio ess Reset Thermal Capacity Relays vide a quick test for some of the protection features of the relay It is not suitable for calibration purposes Stop Simulati Fieset Trip Stale HE Reas due to process speed variances of the different per E 2 ness Relays sonal and laptop computers coms Connected 8 Relay Coils Simulation Control Bl Relay 1 Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec MB Relay Page 26 of 35 6 4 3 Spectrum Analyzer Screen 1 NewCode Relay Frontend File Options Disconnect Actual Settings Contollogc StaterLogic RealTime Clock Fault History Statistics Test EventHitey Calculator Spectrum Analyser Info Phase Current Harmonic Spectrum Display C Sine wave Sqaure wave frequency ji Harmonic Amplitudes j f4 Signal Attenuator Harmonic Frequencies h Times Total Harmonic Distortion w r t the fundamental harmonic 1 473 Phase E Total Harmonic Distortion w ct the sum of all the harmonics 427 2 Re
10. no load condition Minimum load Vectorial Stall It is detected during the startup procedure of the motor A motor normally startup with a bad power factor and gradually improve it Vectorial Stall as full speed is approached If no power factor improvement is continue detected for longer then 3346 of the curve class time the motor is tripped to prevent thermal and mechanical damage Volatile memory It is memory that will loose data during a power supply interrup tion see also non volatile memory N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 13 of 35 Functional Description The MB Relay is controlled by a micro controller The three phase currents voltages and earth leakage current are detected by current transformers attenuator circuits and a core balance current transformer respectively The current and voltage signals are conditioned by appropriate circuits and converted to 0 to 5 volt analogue signals The analogue signals are digitized to 10 bit resolution The micro controller has non volatile and volatile memory The non volatile memory contains a boot loader program which is used to upload the operating software program of the relay The uploading is done from a personal computer or laptop via the USB port This feature also enables the user to do future software upgrades without factory assistance Front end software is included that runs on MS Windows The USB p
11. selectable Starts per Hour Control NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY 2 2 8 2 2 9 2 2 10 2 2 11 2 2 12 2 213 2 2 14 NewElec MB Relay Page 6 of 35 Starts setting 1 to 60 starts adjustable Consecutive starts 1 to 3 starts per interval adjustable Reset Automatic Feature selectable Short Circuit Detection e Articulated detection If ILoap gt 950 and Power factor lt 85 or gt 300 and Power factor gt 85 e Trip delay time 1 second fixed e Reset Manual e Feature selectable Voltage Symmetry Detection e Trip delay time 10 seconds fixed e Trip level adjustment 70 to 99 e Reset Manual e Feature selectable Over Voltage Detection e Trip delay time 10 seconds fixed Trip level Factory settings Reset Manual Feature selectable Under Voltage Detection Trip delay time 10 seconds fixed Trip level Factory settings Feature selectable Reset Manual High or Low Frequency Detection Trip delay time 10 seconds fixed Trip level Factory settings 45Hz to 55Hz Reset Manual Feature selectable Voltage Phase Rotation e No trip delay time e Auto reset once fault is fixed e Feature selectable forward reverse none Insulation Failure Detection e Detection Only in static state motor not running e Trip delay time 1 second fixed e Trip level Resistance lt 20 kOhm fixed NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Ne
12. to the reset switch on the front panel The last fault switch when pressed will replace the current fault indication with the last fault display When the motor is static and no real current is flowing the test switch will simulate a phase current injection of 600 The relay will respond as if it is a true over current condition and calculate thermal capacity usage overload trip will result if all the thermal capacity is used IrDA interface Part number IRDA KD This an infra red link that can be used in an intrinsic safe environment where isolation is required between the relay and external devices like remote display units RDU man machine interface units MMI laptops etcetera Remote Display Unit RDU Part number KD RDU 420 It is a display unit with a 4 x 20 character LCD display and a simplified keyboard The RDU can perform about 80 of the setup and display functions of the front end software Man machine interface MMI Part number KD MMI 420 EP It is similar to the RDU The unit is packed into a plastic toolbox with battery power supply The unit is designed for mobility and to be functional in intrinsic safe environments NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY
13. A 0SS SZS 00v 0L1 NOIL2313S 193X310 Etec MOTOR PROTECTION amp CONTROL TECHNOLOGY Page 18 of 35 6 2 Block Diagram of the Relay Core Balance Current Current Transformers Transformer NewElec MB Relay Voltage Signal Conditioning Circuits Current Signal Conditioning Circuits Real Time Clock Reset Switch Analogue to Digital Converters Fault amp Status Data Processor Indication LEDs Relays Relay 1 4 Digital Field Inputs Volatile Memory Temporary data Communication Module Serial Port RS232 NESW Event Records Boot loader Program code LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec MB Relay Page 19 of 35 6 3 Front End Setup Screens 6 3 1 Settings screen 7 MB Relay Frontend File Options Disconnect Comms Statistics Actual Calculator RealTime Clock Event History Starter Configuration Recorder Spectrum Analyser Settings Calibration Fault History Test Control Logic Parameter Settings and Feature Selection Unbalance Phase Current Minimum Load RTD Trip Levels High Speed Motor Setting Trip Level za EJ Trip Delay ra zi sec Voltage Line Voltage Selector 380V High Limit fio zx Low Limit 10 Voltage Symmetry Trip Level 185 Start Count Starts per hour allowed 3 Number of consecutive starts Starter Type Selection Pole Changing
14. C MOTOR PROTECTION amp CONTROL TECHNOLOGY 2 1 2 2 1 2 2 2 2 2 3 2 2 4 2 2 5 2 2 6 2 2 NewElec Relay Page 5 of 35 e Resolution 1 kOhm steps Protection Features All resets are subjected to sufficient thermal capacity gain Over Current Overload Detection e Curve class settings 3 seconds to 40 seconds 60255 8 specification Motor full load setting MLC 10 to 100 Reset Manual or three automatic resets per hour when selected Reset threshold setting Fixed at 70 thermal capacity or dynamic threshold adjustment determined over 10 last restarts Undercurrent Minimum load Detection Trip level adjustment 10 to 100 Selection Current level or power factor Trip delay time 1 to 10 seconds Start up delay 1 to 200 seconds To facilitate pump priming Reset time Manual or 10 seconds to 6 hours 9 steps Feature selectable Unbalance Phase Currents Detection e Trip level adjustment 0 to 50 e Trip delay time 1 to 10 seconds e Reset Manual e Feature selectable Single Phasing Phase lost Detection e Trip delay time 1 second fixed e Feature selectable e Reset Manual Run Stall Detection e Stall current trip level adjustment 110 to 300 e Stall trip delay time 0 to 120 seconds adjustable e Feature selectable e Reset Manual Vectorial Stall Detection e Trip Static or decreasing power factor e Trip delay 33 of curve class setting e Reset Manual e Feature
15. Star Delta Starter Dahlander Starter Reversible Dahlander Starter Soft Starter Reversible Soft Starter Pulsed Output Direct On Line Starter e Timers Star Maximum Timer to 50sec Pre Start Warning Timer 1 to 1200 sec 20 min Execution Timer to 10 sec Start executing Feedback Timer 50ms to 2000ms Power dips Unautherised Current Timer 50ms to 2000ms Backspin Timer to 600 sec Transition Timer 50ms to 5000ms Change over from high speed to low speed e Selectable control sites Local remote automatic PLC control and operator pannel NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY 2 3 1 2 4 2 5 2 5 1 2 5 2 2 6 2 6 1 2 6 2 Page 9 of 35 Relays e Amount of Relays 4 Input Configurable and level triggered see 2 3 1 e Slow relay 1 Fast main trip Relay selectable e Single set of potential free switch over contacts Statistical Data Capturing Running hours Adjustable to 65535 hours e Startup counter Adjustable 0 to 65535 e Trip counter Adjustable 0 to 65535 e Apparent power consumption metering kV A h e Real power consumption metering kWatt h Trip Fault Recording Database capacity 45 last faults Trip fault record content Status Actual simulated Date Year month date Time Hour minute Fault description Run hours Max trip current Minimum trip voltage Breaker fault clearance time Event Recording Database capacity 1500
16. d Phase Curent x COM2 Connected PEELE N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec MB Relay Page 27 of 35 6 4 4 Spectrum Analyser Screen 2 NewElec NewCode Mk Relay Frontend Control Logic Starter Logie RealTimeClock Fault History Statistics EventHistoy Calculator Spectrum Analyser Info Simulation Signal type Sine wave Sqaure wave Phase Current Harmonic Spectrum Display COMI Connected N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY 6 4 5 Actual Screen MB Relay Frontend File Options Disconnect Comms Statistics Actual Recorder Settings Unique Drive ID Thermal Curve Class Setting Thermal Trip Time Remainder sec Red Phase Current Level White Phase Current Level Blue Phase Current Level Current Unbalance Red Phase Voltage Level White Phase Voltage Level 220 V 220 V Blue Phase Voltage Level 220 y Voltage Symmetry 100 z fis FR Page 28 of 35 Event History Control Logic Starter Configuration 50 60 70 40 looi 80 30 3 490 40 90 gg 10 0 TC Thermal Capacity NewElec MB Relay Calculator Real Time Clock Info Fault History Spectrum Analyser Calibration Drive Description In Service Motor Running Phase Voltages Present E 380v Actual Line Voltage max 381 V Actual Phase Current Level 475 Line Voltage Selection c Zero
17. e fault indications are displayed on the front panel as follows Name of Fault Indication LED used Display mode Over current Overload Solid on Short circuit Overload Solid on Minimum load Min Load Solid on Phase Rotation Phase Rotation Solid on Unbalance Phase Currents Unbalance Solid on Single Phasing Unbalance Solid on NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Page 14 of 35 NewElec MB Relay Insulation Failure Insulation failure Solid on Run Stall Overload Solid on Vectorial Stall Overload Solid on Earth leakage Earth leakage Solid on Earth fault Earth leakage Solid on Over voltage Phase rotation 3 sec on 1 sec off Under voltage Phase rotation sec on 3 sec off Voltage symmetry Phase rotation sec on 1 sec off Starts per hour Overload amp Healthy Both 1 sec on 1 sec off High frequency Unbalance 3 sec on 1 sec off Low frequency Unbalance sec on 3 sec off The reset button is used to acknowledge and reset trip faults A reset will only take affect if sufficient thermal capacity is regained during the cooling period and no phase current flows If the reset button is pressed during the cooling cycle the Overload LED will start flashing 1 second on 1 second off to signify cooling Once the required thermal capacity level is reached the relay will reset The real time clock is running from a sup
18. ent History Calculator Spectrum Analyser Info Actual Settings Control Logic Starter Configuration Real Time Clock Calibration Fault History Starter Configuration Field Input r Starter Type Starter Timer Settings Location Selector x Pole Changing Starter Pre Start Warning Time 2 5 Zero 0 v Input msb mu ExecutionTime Remote Field Feedback Time Zero 0 v Input fsb Local Field Starter Input Assignment Local Field 00 Remote Field 01 Auto 10 Operator Panel 11 Statt Start High speed DC Breaking Time Start gt Start Low speed Start lt lt InService Feedback Signal from Switchgear Start lt 8 5 8 4b 4h 2 8 4b o Backspin Time a2 4 3 a 5 o o Restart Time 4 o o Star Maximum Time Transition Time am e 4 3 lt 8 Local Unautherised current Time DigFldlnput 1 Start gt gt DigFldlnput 2 vf Start gt Starter Output Zero 0 v Start lt lt Zero 0 v Start lt 1 Starter OP_1 High Speed DigFidInput_3 Interlock DigFldInput_4 v Stop Starter OP 2 Low Speed Starter OP_3 Remote Starter OP 4 W Zero 0 vj Start gt gt Zero 0 Start gt Starter OP_5 MIB J gaam Start lt lt Zero 0 Stats Activity Flags p Starter Trip Flags Zero 07 Interlock Zero
19. er capacitor which is continuously charged by the auxiliary power supply The real time clock should be able to continue running for another 5 days in the event of auxiliary supply failure The real time clock provides time and date for record keeping fault and event records and also participates in the control functions The protection unit NewCode MK 1 relay is equipped with four electromechanical relays Relay 1 2 3 and 4 and seven opto isolated digital field inputs Digital Field Inputs 1 to 7 When Relay 1 is configured as the main trip relay it has a dedicated protection function Relay 2 3 and 4 are general purpose relays The relays are configurable and available to participate in any of the control functions The control logic is realized with the aid of six logic function blocks Each of these blocks has three configurable inputs configurable input can typically be connected to any one of seventy three different signals see specifications Starter functions are added to the control logic and three types are available to choose from namely Direct On Line DOL Star Delta and Forward Reverse Three different start control localities are also selectable namely local remote and automatic PLC control to start the motor from These start control sites are static or dynamically selectable The protection unit has an internal interchangeable communication module Three different protocols are available and to choose from namel
20. last events Event record content Status Actual Simulated Settings adjust Power up Calibration Date Year month date Alarm flags Trip flags Run hours Max trip current Min trip voltage Breaker fault clearance time Digital field input states NESW NewElec MB Relay LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 10 of 35 2 7 Physical dimensions 2 7 1 Size of foot prin 45 mm x 110 mm DIN Rail mount screw fix mount 2 7 2 Length 110 mm 2 7 3 Mass 400 gram 2 8 Auxiliary power supply e Voltage requirements 110 Vac 10 or 230 Vac 1096 e Power requirements 2 5 Watt 2 9 Operating environment e Temperature 0 50 Celsius e Relative humidity lt 85 2 10 Networking Communication 2 10 1 Protocol Profibus o ModBus o Canbus NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 11 of 35 3 Definitions and Terminology Breaker clearance time It is the time taken by the breaker to clear the fault by interrupting the supply current to the motor It can be seen as breaker response time and is useful information for breaker maintenance Consecutive starts The amount of starts allowed during a time interval created by the starts per hour setting See also starts per hour Core balance current transformer A current transformer used to detected possible current leakage to earth from one or more of the pha
21. lay in the form of simulation This function could be used for personnel training or relay functionality testing N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 4 of 35 Specifications Measurements Current e Three phase current e Range 5 Amp to 250 Amps e Models 5 10 50 100 and 250 e Sensitivity range adjustment MLC 10 to 100 of full load current e Dynamic range 0 to 1000 Resolution 500 steps 296 per step Voltage e Range 110V 400V 525V 550V 680V 950V 1050V 3k3V 6k6V and 11kV from 1K1V upwards a step down transformer is used to step the voltage down to 110V e Range selection Manual Frequency e Range 30Hz to 100Hz e Selectable during calibration 50Hz or 60Hz factory setting Power Factor e Range Oto 100 leading lagging Power Dissipation e Type Apparent power kVA and Real power kWatt e Derived from line voltage phase current and power factor where applicable Earth Leakage e Range 30mA to 3 Amps e Trip time delay Inverse Definite Minimum Time IDMT or Instantaneous Definite Time IDT Real Time Clock 24 hour clock Year month date hours and minutes e Battery backup 5 days with 1 Farad super capacitor e Time and date stamping Fault and event records Breaker Fault Clearance Time e Measurement range 10 ms to 1000ms e Resolution 10ms steps Insulation Resistance e Measurement range 1 to 199 kOhm NESW LE
22. n disk Clear fault eme fi Dt eet Sim 2009 09 18 13h56 Vectorial Stall 2 Sim 2009 09 18 1356 Runstal a pa 9 2 EI EI es Ex EN COM2 Connected Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY Page 31 of 35 6 4 8 Events Screen A NewElec NewCode Mk Relay Frontend File Options Disconnect Actual Settings Recorder Control Logic Starter Logic Event History Real Time Clock Calculator Event Records Down Load Control Event down load quantity 200 E iStart downloading of records Stop downloading of records Please note The event records are downloaded on request The data is saved in a file on your computer under the Drive ID c 4BC12345 xls The event record file can be viewed with MS Excel or equivalent software The data fields are separated by tab characters MS Excel is a trademark ftm of Micro Soft Inc USA COM2 Connected N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Spectrum Analyser NewElec Relay Fault History Statistics Info NewElec Relay Page 32 of 35 6 4 9 Recorder Screen v NewElec NewCode Mk Relay Frontend File Options Disconnect Actual Settings Control Logic Starter Logic RealTime Clock Fault History Statistics Event Histoty Calculator Spectrum A
23. nalyser Info E ce eae Actual Data Recorder ThermalCap PwrFactor 0 00 _white ET Parameters 0 00 00 00 00 0 00 0 00 4 00 00 04 00 00 05 00 00 06 00 COM2 Connected NewElec Relay Page 33 of 35 6 5 Thermal Curves of the Relay N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Page 34 of 35 NewElec Relay 10000 1000 100 Trip delay time seconds KD Relay Thermal Curves Class 1 N Em EN 4 Multipiles of Full Load Currer 6 8 10 Class 5 Class 10 Class 15 Class 20 Class 25 Class 30 Class 35 Class 40 7 Accessories NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY 7 1 7 2 7 3 74 NewElec Relay Page 35 of 35 FLED Part number KD I2C FLED It is a field door mount display unit connected to the relay This unit relies on power supply from the relay and communicates via the bus with the relay The FLED display all the fault conditions similar to the front panel of the relay thermal capacity used 30 to 100 and last fault The FLED has three switches and is allocated as follows Reset switch e Last fault Test switch The reset switch is similar
24. ort and infra red link IrDA are used as communication ports The purpose of the front end is to configure and select the required functionality of a specific application The setup adjustments required at the installation phase will be discussed in the next chapter dealing with installation instructions The relay will monitor the parameters of the motor for the duration of auxiliary power supply The auxiliary power supply is selectable 110Vac or 230Vac When a trip condition occurs the main trip relay will be activated It will be energized or de energized non fail save or fail save respectively depending on what mode of operation was selected A time and date stamped trip record is also generated and saved in non volatile memory for later retrieval Memory space for 60 trip records is allocated The layout of the trip record is discussed in chapter 2 that deals with specifications Event records are also time and date stamped It is more comprehensive and saved in non volatile memory Only read access is given to the user This information can be used for insurance claims and liability cases The layout of the event record is discussed in chapter 2 specifications Six fault indication light emitting diodes red are placed on the front panel The green light emitting diode will come on only if the relay is in a healthy state A healthy state signifies that the motor could be static or in operation within it s save operating parameters Th
25. ropriate in some cases To determine the full load current setting MLC the motor has to be started and allowed to run at full load capacity Press the reset button and use the front end settings screen to adjust the MLC till the overload indication just switches off Release now the reset button The front end can be used to confirm that the load current level indicated is between 90 and 99 Hint Use the calculator of the front end to confirm the setting The minimum load setting adjustment motor run with no load is done in a similar way with the aid if the reset button minimum load setting The real time clock should be checked and adjusted to the correct time setting The fault history can also be erased to start afresh NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec MB Relay Page 16 of 35 6 Diagrams 6 1 1 Picture of the Relay Ni W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 17 of 35 6 1 2 Physical Layout of the Relay side panels RDTME XCHATION a HE nii 5 4 444 4444 eae TERM 52 51 EXTERNAL CBCT TERMINALS 51 AND 50 2 P V RED V WHITE V BLUE an18 31HW Q38 NOLLVLON 501 LIOA OLL 01 01 01 A1dd IS 150A OOF 901 0 01 Add S LOA SZS 01 01 9601 AIddNS 110A 095 123130 QHYONVLS AHOL12VJ AOLL VIA 99 OV
26. ses Earth leakage detection Digital field input A signal generated by an external switch that could have an effect on the relay operation depending on the logic configuration Earth fault It is leakage current above 2 amps and a severe form of an earth leakage condition See also core balance current transformer Earth leakage fault It is leakage current up to 2 amps exceeding a trip level setting See also core balance current transformer Full load current Current drawn by the motor at full load operation 9096 to 10096 Fundamental har monic frequency 50Hz in South Africa and 60Hz elsewhere In Service state Phase current above 1046 of full load current Isolation lockout Insulation failure The insulation resistance of the motor is measured while in a static not in service condition If the resistance drops below 20 kOhm the relay will trip and will prevent a start Motor full load setting MLC Adjustment of the relay current sensitivity This is where the current level measurement is adjusted to read just below 100 when the motor operate at full load Non volatile It is memory that will maintain data even when power is switched memory off for long periods see also volatile memory Over current Current level above 10096 of full load current Overload Phase rotation Normal phase rotation sequence is red white and blue Reverse rotation sequence is blue whi
27. tart Drive NewElec Relay Page 23 of 35 6 3 5 Real Time Clock Screen 4 NewElec NewCode Mk Relay Frontend DER File Options Disconnect Recorder Test Event History Calculator Spectrum Analyser Info Actual Settings Control Logic Starter Lagic Real Time Clock Fault History Statistics Real Time Clock of Relay Gn tine s zi 18 13 zi 55 zl Update RTC from PC hh mm Set the real time clock 20yy mm Real Time Clock of 7 Laptop Sun Mon Tue Wed Thu Sat 1 d ud 4 5 7 8 9 10 11 12 13 14 15 16 17 E 19 20 21 22 23 24 25 26 27 28 29 30 Today 2009 09 18 N W LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 24 of 35 6 4 Front End Assistance Screens 6 4 1 Test Screen Manual 7 NewCode Relay Frontend File Options Disconnect Actual i Control Logic Starter Configuration Real Time Clock Fault History Comms Statistics Recorder Event History Calculator Spectrum Analyser Info Simulated Injection Test 1000 900 800 8 8 000 S e e 1 3 w 8 N ti 8 t E s MN e 8 88 75 al B preperine gorong vapeon penaa ieee 8 Pepe eee 204 PORE Ey LO EL OC EE OY 8 quos eeneerqeeiqeenqneqeeipenpenipien ocowNgsggassmsSzs e Os Re
28. te and red Power factor It is die relationship between real power and apparent power Power factor V x Ix Cos V x D x 100 Power factor Run Stall The motor went through the normal start procedure and the current level return to normal full level If the rotor jam and the current rise above the stall setting 11096 to 30096 it is recognized as a Run Stall fault condition Running hours The amount of time the motor was in an in service state Starts per hour Starts per hour define the time interval in which a restricted amount of starts are allowed See also consecutive starts Thermal capacity It is a temperature related quantity expressed in percentage which also takes in consideration the physical size mass construction type of material used etcetera of the motor It is normally indicated NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec Relay Page 12 of 35 as capacity used unless otherwise stated Thermal curve It is the thermal curve derived from the unitary one second class thermal curve It is also the curve that goes through the points where maximum lock rotor current and maximum lock rotor time of the particular motor is specified 2 2 2 Total Harmonic n YHi Hit H x 100 Distortion Two standards are used H Hit Ht Undercurrent Current level when motor run at
29. tp 1 Unbal af RunStall tf StartsPerHr LogicFunc 2 DigFldInput 4 StarterOutp 2 SinglePhs af Unbal tf Timer A LogicFunc 2 DigFldInput 5 StarterOutp 3 EarthFault_af SinglePhase_tf Timer A LogicFunc 3 DigFldInput 6 Restart EarthLeak af EarthFault tf Timer B LogicFunc 3 DigFldInput 7 FrozenContact MinLoad af EarthLeak tf Timer B LogicFunc 4 PLC Input 1 TripFlag NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY 2 3 2 2 3 3 2 3 4 2 3 6 NewElec MB Relay Page 8 of 35 Timers e Timer A and Timer B e Time setting to 50 minutes e Start input Configurable and level triggered see 2 3 1 e Reset Inhibit input Configurable and level triggered see 2 3 1 Real Time Clock 24 Hour e Start time Hours and minutes configurable see 2 3 1 e Stop time Hours and minutes configurable see 2 3 1 Counters Counter A and Counter B Count range 0 to 250 Count up input Configurable and positive edge triggered see 2 3 1 Count down input Configurable and positive edge triggered see 2 3 2 Reset Inhibit input Configurable and level triggered see 2 3 1 Trip level setting 1 to 250 counts Logic function blocks e Amount of function blocks 6 Three fully configurable inputs per logic function block see 2 3 1 e Sum of product or product of sums operation Starter Logic e Starter types Direct On Line Starter Reversible Direct On Line Starter Star Delta Starter Reversible
30. wElec Relay Page 7 of 35 e Reset Manual e Feature selectable 2 2 15 Earth Leakage Detection lt 2A e Selection between Instantaneous Definite Time or Inverse Definite Minimum Time Instantaneous Definite Time 100 ms gt t gt 1000 ms 50 ms steps Inverse Define Minimum Time t gt 130 ms Harmonic filtering suitable for variable speed drives and soft starters Trip level Adjustable Reset Manual Feature selectable 2 2 16 Earth Fault Detection Ig 22A e Harmonic filtering suitable for variable speed drives and soft starters Trip delay time 1 second fixed Trip level 2A fixed Reset Manual Feature selectable 2 2 17 RTD PT100 Overtemperature Detection 2 3 Control logic 2 3 1 Table of control outputs which can be mapped to any configurable input Input Input Input Input Input Input Zero 0 OverVolt af MinLoad tf RTClock LogicFunc 4 PLC Input 2 One 1 UnderVolt af OverVolt_tf RTClock LogicFunc_5 PLC Input 3 InService VoltSym af UnderVolt_tf Counter_A LogicFunc_5 PLC Input 4 VoltPresentF HiFreg af VoltSym tf Counter A LogicFunc 6 PLC Input 5 OverCrnt_af LoFreq_af HiFreq_tf Counter_B LogicFunc_6 PLC Input 6 ShortCirc af IsoLockOut af LoFreq tf Counter B DigFldInput 1 PLC Input 7 RunStall af OverCrnt tf IsoLockOut tf LogicFunc 1 DigFldInput 2 PLC Input 8 Unbal af ShortCirc tf PhaseRot tf LogicFunc 1 DigFldInput 3 StarterOu
31. y Modbus Profibus and CANbus NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY 5 1 5 2 NewElec Relay Page 15 of 35 Installation Instructions Front end requirements A Pentium personal computer or laptop is required to setup the NewCode MK 1 relay The computer must be equipped with USB ports The operating system software requirement is MS Windows 2000 MS Windows XP or later versions The front end software is free of charge but remains the property of NewElec Pretoria Pty Ltd It is available from NewElec s website and also supplied with the purchase of new relays Setting up the relay Once the wiring is being done and checked by qualified personnel the relay is ready to be configured The four most important front end screens are the settings diagram 6 4 control logic starter and statistics screens These four screens enable the user to adjust parameters select protection features determine control strategy select a starter configuration and setup the communications network The control and starter screens are linked together when settings are saved or retrieved from disk When setting changes were made it has to be transmitted to the relay to become effective Changes on the control logic and starter screens can only be made when off line is selected When on line is selected again the settings are transmitted to the relay Relays are shipped to the user with a set of default settings and may be app
32. yser Info Recorder Current Calculator Delta Connection r Thermal Calculator TT Full load power rating 200 kwatt Trip Time Calculation p Cooling Time Calculation _____ Line voltage 400 Volt Motor load current Initial thermal capacity used Power factor 8 750 Ex Thermal time constant f 5 sec Required thermal capacity A Thermal capacity used o Thermal time constant Forced cocina Calculate current Calculate trip time 95 sec Calculate cooling time 1286 3 Phase curent 217 9 3773 A Line current Earth Leakage IDMT Calculator Motor Full Load Setting Thermal Curve Class Setting Max current level lock rotor 560 time lock rotor no damage 12 sec Actualleak curent 500 m Leak ttrip setting 50 Full load phase current 217 Time multipier Relay model 400 Calculate trip time 1 0 sec Calculate MLC setting 54 Calculate curve class setting 10 Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY NewElec MB Relay Page 30 of 35 647 Fault Screen 7 NewElec NewCode Relay Frontend File Options Disconnect Recorder Test EventHistoy Calculator SpectrumAnalyser Info Actual Settings ContolLoge StatterLogie RealTimeClock FaukHistey Statistics Update faults from relay Sa Save fault records o
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