From Conveyors to Crushers – Choose the Right Motor Protection with Confidence
Mining environments are tough on equipment, and unplanned motor failures cost time, production, and revenue. This guide makes it easy to compare NewElec’s motor protection relays across critical mining applications, including conveyors, crushers, screens, fans, feeders, and pumping systems so you can select the most reliable solution for your site.
Review application fit, compare key technical features, watch the quick explainer video, and download the full Product Comparison Guide (PDF). You can also use our Relay Selector tool for fast, practical guidance to shortlist the best protection system for your operation.
Application Fit for Mining Industry
Applications in Mining
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 of Technical Attributes Fit for Mining Applications
Need guidance on relay selection for your needs?
Download Our Mining Relay Comparison Guide
Complete the form below to gain access to our complete Mining Relay Application Comparison Guide.
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.
Case Study: Coal Mine Washing Plant - Reliable Motor Protection
Key Performance Indicators
Nuisance Trip Rate
PLC Network Uptime
Mean Time to Diagnose (MTTD)
Commissioning Time per MCC Bucket
Operational Continuity
Energy Efficiency Index
Customer Testimonial
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.
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