From conveyors to crushers, find the best-fit motor protection path
Mining operations demand precision and reliability. This page helps you compare NewElec’s range of motor protection relays across key mining applications — conveyors, crushers, fans, screens, feeders, and more.
Scan the application fit, check core attributes, watch our explainer video, and download the full Comparison Guide (PDF) or use the Relay Selector to shortlist the right protection system for your site.
Table 1 – Application Fit (Mining)
Product | Conveyors | Crusher Motors | Compressors | Fans | Screens & Feeders | Hoists & Cranes | Earth Leakage Coordination |
MA Series | Best fit start supervision, stall/jam/ underload protection | Handles stall windows, thermal modelling | ◑ Suitable if frequent starts monitored | Ideal for ventilation motors | Manages cyclic loads | ◑ Verify interlocks | Advanced EL coordination |
NewCode | Adds logic/permissives for conveyors with sequencing | PLC-linked stall & unbalance logic | Anti-cycling control via logic | Communication with fans in PLC | Perfect for feeders needing permissives | ◑ Requires PLC interlock validation | Dual-Ethernet, VFD-safe |
NewFeed | ◑ Good for ancillary pump or booster circuits | Not for crushers | Designed for auxiliary compressors | Secondary ventilation fans | ◑ For light-duty feeders | - | ◑ Basic EL trip |
KD Series | ◑ Feeder-level PQ trends, upstream diagnostics | - | ◑ | Power quality monitoring | ◑ Condition-monitor only | ◑ | PQ data supports EL analysis |
KE Series | ◑ Basic conveyor protection | ◑ Suitable for small crusher drives | Basic overload/phase loss | Simple fan protection | ◑ Entry-level feeder circuits | - | ◑ Fixed EL thresholds |
GA Earth Leakage | For plant-wide EL | Used for MCC coordination | Suitable for all motor zones | Detects insulation degradation | Supports long-cable VFDs | Multi-zone EL selectivity | Main EL coordination relay |
Application Guides
Conveyors
Conveyors experience high inertia starts, jam risks, and mechanical strain. Look for relays offering start supervision, stall protection, and jam/underload detection. Earth Leakage must coordinate with long-cable VFD drives to prevent nuisance trips.
Crusher motors
Crushers demand accurate thermal modelling and stall window configuration to avoid costly downtime. Relays like MA Series and NewCode handle heavy-duty starting and detect unbalance or locked rotor conditions effectively.
Compressors
Frequent starts and pressure-based cycling can overheat motors. Use relays with anti-cycling logic, underload/overload bands, and temperature input monitoring.
Fans
Critical for mine ventilation and extraction. Balanced under/overload symmetry and phase loss protection are key. Ensure the chosen relay supports continuous duty and insulation leakage detection.
Screens & Feeders
Cyclic loads require protection that tolerates vibration and stop-start conditions. NewCode supports permissive logic and anti-cycling to minimize wear.
Hoists & Cranes
Require precise sequencing and interlocks to ensure safety. Select relays that accommodate brake control and verify interlocks for fail-safe operation.
Earth Leakage coordination
Proper EL coordination avoids false trips across MCC zones. Adjust thresholds and delays per motor class, verifying selectivity across the plant.
Need guidance on relay selection for your needs?
Protect Your Mining Equipment
Understanding mining motor protection: how to match relays by application and coordinate EL with VFD systems.
EL with VFDs & long cables, what to check
Start supervision vs stall, high inertia
PQ unbalance signals and next steps
Table 2 – Technical Attributes Fit (Mining)
Product | Key Protection Functions | Communications | Mounting & Retrofit | Environment & Ingress | Voltage Class / Motor kW Range | Certifications / Compliance | Notes / Assumptions |
MA Series | Comprehensive motor protection (stall, jam, earth fault, under/overload, start supervision). | RS-485 Modbus / Optional Ethernet | Panel mount / MCC bucket | IP54–IP65 (TBD by model) | LV / MV up to ~250 kW | SABS / IEC 60255 | Verify CT ratios on retrofit |
NewCode | Core motor protections + logic/permissives for sequencing and anti-cycling. | Dual-Ethernet + RS-485 Modbus | DIN-rail / Panel | IP65 industrial | LV/MV (application verified) | IEC / EMC compliant | Confirm PLC comms protocol |
NewFeed | Overload, phase loss, and voltage imbalance protection. | RS-485 | DIN-rail | IP40–IP54 | Up to 90 kW | IEC 60947 | Scope TBD on comms/IP |
KD Series | Quality analysis (voltage, current, harmonics, PF). | RS-485 / Modbus | Panel mount | IP54 | Feeder-level monitoring | IEC 61000 | For PQ trending; not for motor trip |
KE Series | Basic overload & phase loss relay. | None / optional RS-485 | DIN-rail | IIP40 | LV only | IEC 60947 | Use as secondary relay in small drives |
GA Earth Leakage | Earth leakage/residual current protection; adjustable trip levels. | RS-485 optional | DIN-rail / Panel | IP40–IP65 | LV–MV | IEC 60947-2 | Check mine spec for EL delays |
Need guidance on relay selection for your needs?
Download Now
Please complete the form below to gin access and download the Download full PDF.
Case Study: Coal Mine Washing Plant: Protection & PLC Integration
NewCode Dual-Ethernet relays were deployed across conveyors and screens at a coal washing plant in Mpumalanga. The result resilient PLC communication and repeatable protection behavior with zero setup friction.
View The Case Study Flipbook
Key Performance Indicators
Nuisance Trip Rate
PLC Network Uptime
Mean Time to Diagnose (MTTD)
Commissioning Time per MCC Bucket
Operational Continuity
Energy Efficiency Index
Testimonial/Case Study
FAQ
How do I coordinate EL with VFDs and long cable runs?
Use relays that allow adjustable thresholds and time delays. Verify selectivity by testing across zones — downstream EL must trip first. The GA Earth Leakage and MA Series relays both support these adjustments.
When should I tighten or loosen stall timers for high-inertia starts?
In high-inertia applications like conveyors, loosen timers slightly to avoid nuisance trips during startup. Always confirm acceleration times on-site before final settings.
What anti-cycling or permissive functions help on screens & feeders?
Use NewCode’s built-in permissive logic to prevent rapid restarts. Anti-cycling features protect mechanical components from repetitive stress and overheating.
How do I distinguish PQ unbalance from relay mis-settings?
Compare phase-current imbalance readings to voltage asymmetry data. If both exceed 2–3%, investigate supply quality before adjusting relay thresholds.
Which relays support Dual-Ethernet or PLC-friendly communications?
NewCode offers Dual-Ethernet, ensuring reliable PLC integration and data redundancy. MA Series provides RS-485 Modbus with optional Ethernet.
What should I check before retrofitting into existing MCCs?
Measure available space, confirm CT/VT ratios, and check ingress protection levels. Always verify wiring diagrams and auxiliary supply compatibility.
Can I mix EL thresholds across zones without nuisance trips?
Yes, if delays are coordinated. Use upstream relays with longer trip times. Avoid equal thresholds on adjacent circuits to maintain selectivity.
What’s the difference between MA vs KE in basic applications?
MA provides full motor protection, including start supervision; KE offers overload and phase loss only. Choose KE for small or secondary drives.
Where should feeder-level PQ monitoring live (KD)
Install KD upstream to monitor MCC health and unbalance trends. It’s not a tripping device but supports diagnostic insight.
How do I use the Relay Selector effectively?
Filter by application, voltage, and communication needs. The tool returns suitable relays with datasheet links and contact options.
Need Personalised Guidance?
Please complete the form below.
