NewCode MK1 Relay User Manual 02C
Contents
1. Current Unbalance Select Frequency Monitoring Select Ir Analog Input 1 Select Short Circuit Select Analog Input 2 Select Single Phasing Select een eee Analog Output 1 Select vervoltage Select Iv Run Stal Select Minimum Load Detection JT Analog Output 2 Select Undervoltage Select Vectorial Stall Select Undercurrent Select Voltage Symmetry Select Power Factor Select Voltage Phase Rotation Select BWR Y Phase Rotation Select t 1 Select Read settings from relay 25 _ Moving Average Filter Select Earth Leakage Select Dynamic TC Ast THold Adj Select RTD 3 Select Transmit settings to relay Iv Insulation Lockout Select T7 Starts per Hour Select 17 4 Select coM25 Connected NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 6 3 2 Control Logic Screen Page 22 of 41 NewCode Relay File Options Disconnect Test Actual Event History Settings Calculator Control Logic Spectrum Analyser Starter Configuration Info Real Time Clock External Modules Fault History Comms Statistics Control Logic Functions Timer A Z 0 Ld v Start input Zeot gt gt Reset input n m Time sec Bi stable output2. coms Connected NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 27 of 41 6 4 2 Test Screen Automatic NewCode Relay Frontend Rev 2b File Options Disconnect Actual Settings Control Logic Starter Configuration Real Time Clock Fault History Comms Statistics Recorder Test Event History Calculator Spectrum Analyser Into External Modules Simulated Injection Test Automatic Simulated Injection State Sequence Table Cut a cell Copy a cel Paste a cell Delete a cell Delete aine Insert a ine Commands to be used in the time coulomb Save simulation file J loop x Loop to state 1 99 end Terminate state sequence operation watz Wait until z starter output 1 9 set wait z Wait until z starter output 1 3 reset if dygox dig input 1 7 state 1 99 if sygox starter output 1 3 state 1 99 Close Start queing Simulation Mode Selector Digital Field Signals J Manual bea ipae Input ees W E Input 2 Input 5 p M Timer Alarm to Trip Time m tage Reset 0 9 Input 3 Input 6 Thermal D capacity 51 used Relay Cols 4 DF Input Mode Simulation Control ME aeai Real vide a quick test for some of the
3. to Relay FPR0410 65687 Connection Cable 100mm C T to Relay FPR0411 65688 External Memory Module FPR0407 65695 NewCode Expanded Module 8 In 4 Out FPR0412 65696 RTD Expansion Module FPR0413 65697 NewCode Insulation Lockout Module FPR0420 65698 NC MK1 420 02 02 2X40 20 mA Input Output FPR0414 00000 Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY
4. 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 appropriate 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
5. Mono stable output pulse Timer B Zero 0 gt Start input Zero 07 X gt Reset input fi si Time sec Bi stable output P Mono stable output pulse Counter Zeot gt Ent up input gt Ent dn input gt Reset input Actual count Trip cnt setting fi 4 Counter Zeot gt Ent up input Zeo 0 gt Cnt dn input gt Reset input Actual count Trip cnt setting 5 j Logic Function 1 t 2 FrozContact tf w gt 254 Output table in Logic Function 3 DigFldinput gt gt A 4 zjem 92 Dutput table Logic Function5 zt BQ Zeot zjem Outputtabe Logic Function 2 gt am fZeoro 82 Zee oct Cutput table Logic Function 4 PLC Input 7 eju DigFldinput_7 gt 82 Zeot zeem 252 Qutput table Logic Function6 Zeot gt AC Zeot zee Zeot zje cn o Output table ud 1 Real Time Clock Start Time StopTime Comparator Thermal Capacity Usage Warming Level T 85 External Trip Reset LogicFunc 4 X gt Relay Pulse Generator Zero 0 z gt Ctl Period E min Duty Cycle 50 a u Recorder Latch zero 0 gt Set Zero
6. PLC Input 2 wj Start lt lt PLC Input 4 1 Interlock v Start gt gt Zero 07 v Start gt Zero 0 Stat lt Stop Starter Direct Line Reversal Starter Starter Input Assignment Start Forward Start gt gt Start gt Start lt lt Statt Reverse Stat lt 2 Starter utput Starter OP 1 AE Main Starter OP 2 7 Forward Starter OP 3 8 Reverse Starter OP 4 M Starter DP 5 MM Activity Flags Pre Stat Waming Active OP 5 Bl DC Break Injection Active OP 7 i OP 8 Bill Backspin Active _9 Starter Trip Flags M Execution Faut Feedback Unautherised Current Fault Starter Timer Settings Pre Start Warning Time ExecutionT ime Feedback Time 2000 zl Backspin Time 10 RestatTime 0 Star Maximum Time 10 4 Transition Time 0 ms sec DC Braking Time 250 zi ms sec Unautherised current Time 2000 ms Relay Coils RLI Stateitup 2 v 7 R2 StarterOutp_3 PreStartwWamF LogicFunc_1 Factory default settings Read settings from relay Transmit settings to relay com25 Connected NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 Page 24 of 41 6 3 3 Statistics Screen NewCode Rela
7. 200 gt 200 gt 200 500 500 50 250 1500 AmD4 o 21 E 240 40 3 E z 3 He ues gt 30 30 1000 100 ls 100 100 2 e 20 2 20 Simulated 4 to 20m4 Signals 2 2 10 210 B z z 100 100 Analoglnputi 0 gt Cnts E 50 wo a o a o m 0 a o m i 0 Fiequency Power Earth AnalogInput2 0 Cnts Boe biG Hz Factor Leak m nalog Dutpi nts MM o v DH o d EE La d E Analog Output 2 0 a Cnts Link voltage slider controls Link current slider controls EE ITO I wil Simulation Mode Selector Digital Field Signals m Ame meae veis Input2 Inputs Input 9 Input 12 input15 M Timer Alarm to Trip Time m eM pem M am Reset 0 3 Input 3 Input amp Input 10 Input 13 Thermal z capacity 51 used Relay Coils Mode s Please note SNO En Shun Hehe nei 8 Relays The sole purpose of this simulation facility is to pro Reset Th Relay 2 Relay 6 vide quick test for some of the protection features _Reset Thema Capac a a o of the relay It is not suitable for calibration purposes SER relays Relay due to process speed variances the different per art Simulation Reset Relay Trip State ME Russ Relays Simulation sonal and laptop computers
8. lt 3 ZO ex 5VdcOu o gt INCh2 gt IN Ch2 id NC 420 02 02 0414 OUT Ch1 OUT Ch1 Com SCR 5 ex 4 TBUS NewCode OUT Ch2 Rack Expansion Connector Powered from NewCode relay Com SCR i di Etec MOTOR PROTECTION amp CONTROL TECHNOLOGY NewCode Relay Revision 2c 6 Dec 2012 NewCode Relay Page 41 of 41 7 Accessories NewElec NewCode Ordering Information Description Part No Bin No 110 230V NewCode Motor Protection Relay FPR0416 65660 NewCode Motor Protection Relay with Profibus FPR0400 65661 NewCode Motor Protection Relay with DeviceNet FPR0417 65662 NewCode Motor Protection Relay with Modbus FPR0418 65663 NewCode Motor Protection Relay with Canbus FPR0419 65664 30 300 Amp C T amp Core Balance with 110 550V Converter FPR0401 65670 10 100 Amp amp Core Balance with 110 550V Converter FPR0402 65671 0 1 1 Amp C T Block with 110 550V Converter FPR0403 65675 0 5 5 Amp Block with 110 550V Converter FPR0404 65676 0 25 25 Amp Block with 110 550V Converter FPR0405 65677 5 50 Amp Block with 110 550V Converter FPR0406 65678 Core Balance 100mm Dia Window BTX0010 65679 Connection Cable 1000mm to Relay FPR0408 65685 Connection Cable 500mm to Relay FPR0409 65686 Connection Cable 300mm
9. 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 etcetera used of the motor It is normally indicated as capacity used unless otherwise stated Thermal curve class It is the thermal curve derived from the unitary one second 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 Total Harmonic JH Hits Distortion Two standards are used JH H THD 100 Undercurrent Current level when motor run at 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 as full speed is approached If no power factor improvement is detected for longer then 3346 of the curve class time the motor is tripped to prevent thermal and mechanical damage Volatile memory Itis memory that will loose data during a power supply interruption see also non volatile memory NES V LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay 4 Page 14 of 41 Functional Description The NewCode relay is controlled by a micro controller The th
10. Spectrum Analyser Info External Modules Actual Settings Control Logic Starter Configuration Real Time Clock Fault History Comms Statistics Recorder Real Time Clock of Relay Brine fro sf 32 E Update RTC from PC hh mm Set the real time clock 20 mm dd Real Time Clock of PC Laptop 24 25 26 27 28 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 SD 28 29 30 31 1 2 3 4 5 B ZD Today 2013 03 27 COM25 Connected NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 Page 26 of 41 6 4 Front End Assistance Screens 6 4 1 Test Screen Manual Code Relay Frontend Rev 2b1 NewCode Relay File Options Disconnect Actual Settings Control Logic Starter Configuration Real Time Clock Fault History Comms Statistics Test Event History Calculator Spectrum Analyser Info External Modules Simulated Injection Test De 4 72 400 17 400 400 T4000 E 1000 E FUE 772 30001 Simulated RTD Temperatures 900 900 90 90 o 3 2 B gt 2500 5 300 300 gt 300 20 ST E 2 0 156 z 2 x 700 700 20 gt 70 gt 2000 gt 600 gt e00 boo
11. Status Actual simulated Date Year month date Time Hour minute Fault description Run hours Max trip current Minimum trip voltage Breaker fault clearance time 2 6 Event Recording 2 6 1 Database capacity 1400 last events 2 6 2 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 2 7 Physical dimensions e Size of foot print 45 mm x 110 mm DIN Rail mount screw fix mount e Length 110 mm e Mass 400 gram 2 8 Auxiliary power supply e Voltage requirements 110 Vac 10 or 230 Vac 10 e Power requirements 2 5 Watt NE tec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 Page 11 of 41 2 0 Operating environment Temperature 0 50 Celsius e Relative humidity lt 85 2 10 Networking Communication 2 10 1 Protocol e Profibus e ModBus e Canbus Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY NewCode Relay Revision 2c 6 Dec 2012 NewCode Relay Page 12 of 41 3 Definitions and Terminology Apparent power It is the amount of energy consumed The power factor is not taken into consumption account and is measured in kV A h Apparent power It is the product of voltage and current The power is excluded and it is dissipation measured in kV A Breaker clearance
12. The real time clock should be checked and adjusted to the correct time setting The fault history can also be erased to start afresh Firmware upgrade instructions The relay has a boot loader program on board The function of the boot loader is to facilitate the down load of new firmware revisions via the frontend and the USB bus onto the relay Newer firmware revisions will be come available when bug fixes were made and new functionality was added When the user wants to upgrade the following steps must be followed to ensure success Step 1 Ensure that a USB to mini b USB cable is plugged into the NewCode relay LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 18 of 41 Step 2 Power up the relay either 110V or 220V AC as per Electrical wiring diagram Step 3 Launch the NewCode boot loader software Ver 1A from the CD provided Step 4 Select the correct Communication Port from the drop down list Once selected click PORT Step 5 The COMPORT OPENED message will be displayed in the Session message box Click on SEARCH FOR DEVICE Tab Top Left RED Button The UNBALANCE OVERLOAD and INSULATION FAILURE LED s will light up Step 6 Looking for Device will be displayed in the Session Message Box Device Found will be displayed in the Session Message Box Version will be displayed in the Session Message Box Produ
13. amp Class 15 e Class 10 Class 5 Class 3 i Class 1 10 1 1 3 4 5 6 7 8 10 Muiltipiles of Full Load Current Setting Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 36 of 41 6 6 Mechanical Outline of the Relay 143 16 mm TBUS Fie MI U wEw EM Rack Expansion INESSE MIS Connector O Healthy Relay Output Field Input 4 20 Module Temperature O In Service m O Int High High Ini Ons Lock Voltage Olng O Int Low OT Low z PhRotation E O Overload In2 High O T2 High du RESO In2 Low T2Low 3 2 E O Min Load E Data Earth O In12 Out1 High O T3 High zo E Exchange o Leakage oa USB O Oint3 Out Low OT3 Low 2 Een High O T4 High ra O ia O Out2 Low Q T4 Low NewCode NewCode NewCode NewCode 10 Expansion Module 4 20 mA RTD Module Motor Protection Relay 8 x Input 4 x Output 2x In 2x Ou 4 x Input 0400 FPR MO A FPR 0414 FPR 0413 13 00 mm 45 00 mm 22 5
14. 0 X gt Reset i Latch B Zero 0 gt Set Zero o gt Reset i T LogicFunc 3 E gt E Stop 0 O 0 Transmit settings to relay Read settings from relay Digital Field Inputs Hu 5 E A 3H 7 4 NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 6 3 3 Starter Logic Screen File Starter Configuration Page 23 of 41 NewCode Relay Options Disconnect Test Actual Event History Settings Calculator Control Logic Spectrum Analyser Info Starter Configuration Real Time Clock External Modules Fault History Comms Statistics Field Input Location Selector v Input msb Zero 0 Y Input Isb Local field 00 Remote field 01 Auto PLC 10 Operator panel 11 gt Operator Panel gt uto PLC Remote Field Local Field InService Feedback Signal from Switchgear Local DigFldinput 1 v Start gt gt DigFidinput_2 bd Start lt lt DicFldinput 4 l Interlock Zero 07 Start gt Zero 0 X Start lt DigFldlnput 3 v Stop Remote Zero 0 Zero 0 vj Start lt lt Zero t X Interlock vj Start gt gt Zero 0 v Start gt Zero 0 v Start lt Zero 07 X l Stop Auto PLC Input 1
15. designed and manufactured three phase motor protection relay It is a micro controller based precision instrument with protection advanced control features and starter logic The relay is designed to cater for the low voltage motor protection market and is available in different current models The current transformers including the core balance current transformers are external The relay is fully configurable with the aid of front end software or a man machine interface unit MMI Event records can also be downloaded with the aid of the MMI onto a memory stick 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 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 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 relay in the form of simulation This function could be used for personnel
16. training or relay functionality testing Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay 2 2 1 Page 4 of 41 Specifications Measurements Current e Three phase current e Range 5 Amp to 400 Amps 5A to 400A with additional external CTs e Models 5 10 25 50 100 200 and 400 e Sensitivity range adjustment MLC 10 to 100 of full load current e Dynamic range 0 to 100096 e Resolution 500 steps 246 per step Voltage e Range 110V 400V 525V 550V 1050V 6k6V and 11 from 3k3V 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 Type Apparent power and Real power kWatt e Derived from line voltage phase current and power factor where applicable Earth Leakage Range 30mA to 3 Amps e Trip time delay Inverse Definite Minimum Time IDMT or Instantaneous Definite Time IDT Real Time Clock e 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 NE tec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 20
17. 0 mm __ 174 l 6 7 E Relays 6 Amp 250V AC 6 Amp 30 V DC W LEC NewCope MOTOR PROTECTION RELAY PART No FPR 0400 112 75 mm mE E MOTOR PROTECTION amp CONTROL TECHNOLOGY MOTOR PROTECTION amp CONTROL TECHNOLOGY Tel 27 0 12 327 1729 Toll 27 0 860 10 30 41 Email sales newelec co za www newelec co za 6 Amp 250V AC 6 Amp 30 V DC Revision 2c 6 Dec 2012 NewCode Relay Page 37 of 41 6 7 Electrical diagram of the Relay RED WHITE BLUE s 8 3 2 5 x E s 7 x FIELD INPUTS 24Vdc ac to 220Vdc ac 110 220 VAC 1 AUX POWER S2 CBCT SUPPLY INS LOCKOUT EARTH TBUS NewCode Rack Expansion Connector Supplies power to expansion modules FIELD BUS PROFIBUS NewCode EXTERNAL CT Cable CT PLUG 4 x RELAY OUTPUTS RELAY 1 RELAY 2 RELAY 3 RELAY 4 NewCode FPR 0400 5 eT VA 8T EST Bo ET TT 5 Te NewCode CT Module Block NC 300 CBCT 30 to 300 Amps 550 Vac EL CBCT FPR 0401 NC 100 CBCT 10 to 100 Amps 550 Vac EL CBCT 0402 NewCode NC 001 CBCT 0 1 to 1 Amps 550 Vac FPR 0403 Backup Memory NC 005 CBCT 0 5 to 5 Amps 550 Vac 0404 Module NC 025 CBCT 2 5 to 25 Amps 550 Vac FPR 0405 FPR 0407 NC 050 CBCT 5 to 50 Amps 550 Va
18. 12 NewCode Relay 2 1 8 2 2 2 1 2 2 2 2 2 3 2 24 225 Page 5 of 41 Insulation Resistance e Measurement range 1 to 199 kOhm e Resolution 1 kOhm steps Protection Features resets are subjected to sufficient thermal capacity gain Over Current Overload Detection e Curve class settings 3 seconds to 40 seconds IEC 60255 8 specification Motor full load setting MLC 10 to 10096 Reset Manual or three automatic resets per hour when selected Reset threshold setting Fixed at 7096 thermal capacity or dynamic threshold adjustment determined over 10 last restarts Undercurrent Minimum load Detection Trip level adjustment 1096 to 10096 Selection Current level or power factor 96 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 NE tec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay 2 2 6 2 2 7 2 2 8 2d 2 2 10
19. 2 2 11 2 2 12 Page 6 of 41 Vectorial Stall Detection e Static or decreasing power factor e Trip delay 33 of curve class setting Reset Manual e Feature selectable Starts per Hour Control e Starts setting 1 to 60 starts adjustable e Consecutive starts 1 to 3 starts per interval adjustable e Reset Automatic e Feature selectable Short Circuit Detection e Articulated detection If Ij oAp gt 950 and Power factor lt 85 or ILoap gt 300 and Power factor gt 85 Trip delay time 1 second fixed Reset Manual Feature selectable Voltage Symmetry Detection e delay time 10 seconds fixed e level adjustment 70 to 99 e Reset Manual e Feature selectable Over Voltage Detection Trip delay time 10 seconds fixed e Trip level Factory settings e Reset Manual e 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 NE tec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 7 of 41 2 2 13 Voltage Phase Rotation e No trip delay time e Auto reset once fault is fixed Feature selectable forward reverse none 2 2 14 Insulation Failure Detection e Detection Only in static state motor not running Trip de
20. C Sqaure wave sete Current Phase Selector Ried Phase Current x COMS Connected NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 6 4 5 Actual Screen T NewCode Relay Frontend Rev 2b1 Page 30 of 41 NewCode Relay File Options Disconnect Test Actual Calculator Control Logic Event History Settings Unique Drive ID fis Thermal Curve Class Setting Thermal Trip Time Remainder 40 90 gp 70 e 80 90 100 Ried Phase Current Level White Phase Current Level Thermal Blue Phase Current Level 2 Current Unbalance RTD Temperatures 1 58 2 62 C 92 C Ried Phase Voltage Level White Phase Voltage Level Blue Phase Voltage Level dell e 5 lt lt x Voltage Symmetry Spectrum Analyser Starter Configuration Zero 4 95 c Info 50 60 70 40 80 30 90 4 00 10 1 10 0 120 load Analog Signals Input 1 Input 2 Cnts 1 0 Cnts 0 Cnts RealTime Clock External Modules Fault History Drive Description B78 5P20 MC33 voma IIR v Phase Current Trends Comms Statistics In Service Motor Running Phase Voltages Present Recorder Line Voltage Selection Actual Line Voltage Actual Phase Curre
21. Revision 2c 6 Dec 2012 NewCode Relay Page 1 of 41 NE VV LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY NewCode Relay User Manual Revision 2c 6th December 2012 NewElec Pty Ltd Head Office c o Soutter amp Maltzan Street Pretoria West Gauteng South Africa MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 Page 2 of 41 CONTENT ABSTRACT SPECIFICATIONS DEFINITIONS AND TERMINOLOGY FUNCTIONAL DESCRIPTION INSTALLATION INSTRUCTIONS 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 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 Mechanical Outline of the Relay Electrical diagram of the Relay Expanded I O module of the Relay RTD Module Wiring Diagram 4mA to 20mA Module Wiring Diagram ACCESSORIES Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY NewCode Relay Page 11 13 16 38 Revision 2c 6 Dec 2012 NewCode Relay Page 3 of 41 Abstract The NewCode Relay is an ISO 9001 2000 compliant local
22. al Settings Control Logic Starter Configuration Real Time Clock Fault History Comms Statistics Recorder Parameter Settings and Feature Selection Unbalance Phase Current r Minimum Load gt Motor Full Load Setting Trip Delay 10 sec TripLevel 10 2 Restart Delay Manual x Motor Full Load Setting 86 gt Under Current Trip Level 35 zi Thermal Curve Class Selector 15 sec Voltage Power Factor Trip Level 5 zi Line Voltage Selector 525V High Limit 10 Low Limit 10 Startup Trip Delay 2 sec Runtime Trip Delay Voltage Symmetry Trip Level 60 Run Stall Thermal Capacity Used Start Count Trip Level 3003 Actual Level Adjust 70 Starts per hour allowed e zi Trip Delay fi 000 ms Number of consecutive starts Trip Holdoff Delay 0 sec L Earth Leakage Starter Type Selection UT 3 uae Uu z Digital Field Input Delays Instantanious Definite Time On Line Reversal Starter input1 100 Sims 100 ms Trip Delay 100 3 ms Trip Level 250 2 Extemal Modules Input 2 too ms Input amp ms Digital Expansion Module Connected input 3 ne Ws Relay model NC 50 v FLED Connected Analogue Expansion Module Connected amp 4 100 ims Interposing CT EE si Reset Threshold Level 70 gt
23. ated 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 The fault indications are displayed on the front panel as follows Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 Page 15 of 41 NewCode Relay 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 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 rota
24. c FPR 0406 Backup for NewCode relay settings and control logic configuration TBUS NewCode NewCode CT Cable Core Balance Transformer Rack Expansion NC CT CAB 1000 1m FPR 0408 100mm Inside Diameter BTX 0010 Connector NC CT CAB 1000 500mm FPR 0409 Powered from NewCode relay NC CT CAB 1000 300mm FPR 0410 NC CT CAB 1000 100mm FPR 0411 NES V LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 38 of 41 6 8 Expanded IO module wiring diagram of the Relay 8 x DIFFERENTIAL FIELD INPUTS 24 to 220Vdc ac TBUS NewCode Rack Expansion NewCode Protection Connector EXPANDED I O FPR 0412 Powered from NewCode relay 4x RELAY OUTPUTS RELAY 5 RELAY 6 RELAY 7 RELAY 8 Etec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 Page 39 of 41 6 9 RTD Module Wiring Diagram EXCITATION 1 NewCode Protection IN 1 4 Channel RTD Module IN 1 SCREEN EXCITATION 2 e NC RTD 04 FPR 0413 EXCITATION 3 IN 3 IN 3 SCREEN EXCITATION 4 TBUS NewCode IN 4 Rack Expansion Connector N 4 Powered from NewCode relay SCREEN MOTOR PROTECTION amp CONTROL TECHNOLOGY NewCode Relay Revision 2c 6 Dec 2012 Page 40 of 41 6 10 4 to 20mA Module Wiring Diagram 5Vdc Out NewCode Protection IN Ch1 2x4to 20mA I O Module IN Ch2 z E A ComSCR 3 85 x
25. ct ID x will be displayed in the Session Message The UNBALANCE OVERLOAD and INSULATION FAILURE LED s will light up Step 7 Click on UPDATE FILE Second button from the left Select the latest NewCode enc file example NC ENC 1D 00 enc Click on OPEN The UNBALANCE OVERLOAD and INSULATION FAILURE LED s will light up Step 8 The Bootloader will now check the integrity of the selected file Status Busy Checking Open File xx will be displayed in the bottom left corner of the Bootloader This should take approximately 45 seconds PC dependant The UNBALANCE OVERLOAD and INSULATION FAILURE LED s will light up Step 9 Once the file has been checked and no faults found File Loaded File Location will be displayed in the Session Message Box The UPLOAD FILE TO RELAY Button will now be active Third button from the left Click on UPLOAD FILE TO RELAY Button Step 10 The Bootloader will erase the files currently stored in the Flash Memory on the relay and will automatically begin uploading the new firmware to the flash This step may take approximately 5 minutes to complete During the Erase Cycle the UNBALANCE OVERLOAD PHASE ROTATION and EARTH LEAKAGE LED s will light up During the Programme Cycle the MIN LOAD PHASE ROTATION and EARTH LEAKAGE LED s will light up During both cycles the p
26. dInput 2 PLC Input 8 Unbal af ShortCirc tf tf LogicFunc 1 DigFldInput 3 StarterOutp 1 Unbal af RunStall tf StartsPerHr tf 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 2 3 2 Timers e Timer A and Timer B e Time setting 0 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 2 3 3 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 2 3 4 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 2 3 5 Logic function blocks e Amount of function blocks 6 e Three fully configurable inputs per logic function block see 2 3 1 e Sum of product or product of sums operation NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 9 of 41 2 3 6 Starter Logic Starter
27. ec NES V LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 32 of 41 6 4 7 Fault Screen L lt Test Evera Hitoy Cacuia _ Spectrum Analyser Info ExemalModdes 5 Actual ConbuLoge Starter Coeiguaton Real Time Clock Recor _ lau records on hito cec a NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 33 of 41 6 4 8 Events Screen NES V LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 34 of 41 6 4 9 Recorder Screen 15 NewCode Relay Frontend Rev 2b1 Ele Options Disconnect Test Event History Calculator Spectrum Analyser Info ExternalModules Actual Settings Control Logic Starter Configuration Real Time Clock Fault History Comms Statistics Recorder aula lujt lt ala Cb e sjala 500 500 400 300 Parameters 100 Clear recorder screen 25 Connected NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 Page 35 of 41 NewCode Relay 6 5 Thermal Curves of the NewCode Relay NewCode Thermal Trip Curve 10000 1000 Class 40 Class 35 Class 30 Class 25 5 100 rn 20
28. l logic is realized with the aid of six logic function blocks Each of these blocks has three configurable inputs A 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 Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 16 of 41 The protection unit NewCode has an internal interchangeable communication module Three different protocols are available and to choose from namely Modbus Profibus and CANbus Etec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay 5 1 5 2 5 3 Page 17 of 41 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
29. lay time 1 second fixed Trip level Resistance 20 kOhm fixed Reset Manual Feature selectable pd Earth Leakage Detection Igi lt 2A 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 Igi 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 Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 8 of 41 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 17 UnderVolt af OverVolt tf RTClock LogicFunc 5 PLC Input 3 InService VoltSym af UnderVolt tf Counter A LogicFunc 5 PLC Input 4 VoltPresentF HiFreq_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 DigFl
30. nt Level 525 523 V 33 37 Supply Frequency Selection 50Hz Actual Frequency 50 Hz Actual Power Factor 78 Date 201 3 03 27 Time 10n26m1 3s Motor Total Running Hours 500 Apparent Power Dissipation 30 8 Real Power Dissipation 24 kwatt v Trip Reset Earth Leakage Current 17 m Firmware Rev 2c Serial Number 00000123 Model NC 50 tel Interposing CT Ratio Relay Coils gt MTR Alarm and Trip Flags Short Circuit Overvoltage Undervoltage Voltage Symmetry Insolation Lackout Earth Leakage Earth Fault Frozen Contactor Overcurrent Vectorial Stall Run Stall Current Unbalance Single Phasing Minimum Load Low Frequency High Frequency Voltage Phase Rotation Starts per Hour Limit System Failure Starter Fault ATD Fault Analog Signal Fault m PLC Inputs r Digital Field Inputs Input 1 i Input 2 Input 3 7 Input 4 7 Input 5 Input 6 7 Input 7 Mill L2 MEN NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 31 of 41 6 4 6 Calculator Screen File Options Disconnect Actual Settings Control Logic Starter Configuration Real Time Clock Fault History Comms Statistics Recorder Test Event History Calculator Spectrum Analyser Info Extemal Modules M Thermal Calculator C
31. nt of the relay current sensitivity This is where the current level measurement is adjusted to read just below 10096 when the motor operate at full load Non volatile It is memory that will maintain data even when power is switched off for memory long periods see also volatile memory Over current Current level above 100 of full load current Overload Phase rotation Normal phase rotation sequence is red white and blue Reverse rotation sequence is blue white and red Power factor It is die relationship between real power and apparent power Power factor V x Ix CosQ V x D x 100 Power factor Cos Real power It is the amount of energy consumed The power factor is taken into consumption account and is measured in kWatt h Real power It is the product of voltage and current The power factor is included and dissipation it is measured kWatt Run Stall The motor went through the normal start procedure and the current level NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 13 of 41 return to normal full level If the rotor jam and the current rise above the stall setting 110 to 300 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
32. protection features i Relay 2 Relay B Basel Thoma a if a peo of the relay It is not suitable for calibration purposes Start Simulati 7 B Relay 3 E Relay due to process speed variances of the different per art Simulation Reset Relay Trip State Relay 4 a Relay 8 Simulation sonal and laptop computers Please note The sole purpose of this simulation facility is to pro 25 Connected NES V LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 28 of 41 6 4 3 Spectrum Analyzer Screen 1 in NewCode Relay Frontend Rev 2b1 Control Logic Starter Configuration Real Time Clock FaukHistey Comms Statistics Calculator nalys External Modules Phase Current Harmonic Spectrum Display S idi Current Phase Selector Ried Phase Current x Total Harmonie Distortion 569 COMS Disconnected NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 29 of 41 6 4 4 Spectrum Analyser Screen 2 in NewCode Relay Frontend Rev 2b1 File Options Disconnect Actual Settings ConttolLogic Starter Configuration RealTime Clock Comms Statistics Test EventHistoy 7 Analyser Info Extemal Modules Fundamental frequency f1 502 Signal ype Sine wave
33. ree 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 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 port 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 gener
34. rogress is displayed as a in the bottom left of the Bootloader Step 11 Once the Programming is complete the relay should automatically be returned to its normal mode and the GREEN LED indicating RELAY HEALTHY will light up The Bootloader can now be closed and the NewCode Frontend must be re opened NESW LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 19 of 41 6 Diagrams 6 1 Picture of the Relay Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 20 of 41 6 2 Block Diagram of the Relay Core Balance Current Voltage Signal Current Transformers Transformer Conditioning Circuits Y Current Signal Conditioning Circuits Analogue to Digital Converters Reset Real Time Clock Switch Fault amp Status Indication LEDs Data Processor Relays Relay 1 4 Volatile Memory Temporary data Non Volatile Memory Relay settings Fault Records Event Records Boot loader Serial Port RS232 Communication Program code t Module Etec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 21 of 41 6 3 Front End Setup Screens 6 3 1 Settings screen File Options Disconnect Test Event History Calculator Spectrum Analyser Info External Modules Actu
35. 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 phases 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 10 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 Adjustme
36. tion 3 sec on 1 sec off Under voltage Phase rotation sec on 3 sec off Voltage symmetry Phase rotation 1 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 super 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 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 contro
37. types 2 3 7 2 3 8 2 4 Relays DA ON DA eq M9 OO n4 QN eR UX R3 Direct On Line Starter Reversible Direct On Line Starter Star Delta Starter Reversible Star Delta Starter Dahlander Starter Reversible Dahlander Starter Soft Starter Reversible Soft Starter Pulsed Output Direct On Line Starter imers Star Maximum Timer 1 to 50sec Pre Start Warning Timer 1 to 1200 sec 20 min Execution Timer 1 to 10 sec Start executing Feedback Timer 50ms to 2000ms Power dips Unautherised Current Timer 50ms to 2000ms Backspin Timer 1 to 600 sec Transition Timer 50ms to 5000ms Change over from high speed to low speed Selectable control sites Local remote automatic PLC control and operator pannel Amount of Relays 4 Input Configurable and level triggered see 2 3 1 Slow relay 1 Fast main trip relay selectable Single set of potential free switch over contacts Pulse Generator Period 1 to 250 min Duty cycle 1 to 99 Control Reset input Statistical Data Capturing Running hours Adjustable 0 to 65535 hours Startup counter Adjustable 0 to 65535 Trip counter Adjustable 0 to 65535 Apparent power consumption metering kV A h Real power consumption metering kWatt h Ec MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 10 of 41 2 5 Trip Fault Recording 2 5 1 Database capacity 35 last faults 2 5 2 Trip fault record content
38. urrent Calculation Delta connection Trip Time Calculation Cooling Time Calculation Full load power rating 30 kwatt Volt Motor load current Li ltage 525 f 5 Initial thermal capacity used ine voltage k 85 X Thermal time constant 5 Required thermal capacity Power factor y Thermal capacity used fra Thermal time constant Effieciency so Forced cooling Calculate trip time 339 sec Calculate cooling time 310 sec Calculate load current 431 L RMS Load Patern Calculation Motor Full Load Setting Load 1 0 gt Load2 600 Full load line current Time1 100 sec Time 2 sec Relay model 50 Interposing CT Ratio 241 Load 3 feo Load 4 n Power dissipation of motor 30 Time 3 15 sec Time 4 15 E He Calculate RMS Load 55 4 X gt Phase voltage 525 V Earth Leakage IDMT Calculator Power factor actual jo 2 lag Power Factor Correction Inductive load 2 Thermal Curve Class Setting Actual leak current p Power factor target so flag curent level flock rotor 600 Leak current trip setting 250 m Calculate capacitance required 5 6575 uF Max lock rotor time damage 15 sec Time multipier 01 Calculate curve class setting 5 Calculate trip time 00 s
39. y Options Disconnect Unique Drive ID PumpSum Description of drive unit 78 5 20 33 Start Date and Time 2013 03 27 09 10 User Defined Data Statistical Data Test Event History Calculator Spectrum Analyser Info Actual Settings Control Logic Starter Configuration Real Time Clock Extemal Modules Fault History Comms Statistics Recorder Startup Counter Trip Counter Total Motor Running Hours Motor Running Hours Load Drive Available Hours Apparent Power Consumption Real Power Consumption Online Change relay settings 3008 2005 Thermal Capacity required to start Drive Communication Network Communication Settings 1 Performance Statistics Protocol Profibus v Address 12 2 Read settings from relay Cyclic Time 002 msec Baud Rate Auto kbps Cyclic Time Positive Deviation 044 z GSD Supported NEWEF880 Cyclic Time Negative Deviation 155 x VPC Stack Revision 02 04 Transmit settings to relay Comms Software Revision 03 00 Baud Rate VPC Revision DP State Watchdog State 15 Reve COM25 Connected Ww LEC MOTOR PROTECTION amp CONTROL TECHNOLOGY Revision 2c 6 Dec 2012 NewCode Relay Page 25 of 41 6 3 5 Real Time Clock Screen File Options Disconnect Test Event History Calculator
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