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Basics of Built-in Motor Protection for Beginners
Basics of Built-in Motor Protection for Beginners (on photo: View of installed thermostat inside motor; credit: johndearmond.com)

Why is motor protection necessary?

In order to avoid unexpected breakdowns, costly repairs and subsequent losses due to motor downtime, it is important that the motor is fitted with some sort of protective device.

This article will deal with built-in motor protection with thermal overload protection to avoid damage and breakdown of motor. The built-in protector always require an external circuit breaker while some built-in motor protection types even require an overload relay.


Internal protection // Built into the motor

Why have built-in motor protection, when the motor is already fitted with overload relays and fuses? Sometimes the overload relay does not register a motor overload.

Here are a couple examples of this //

  1. If the motor is covered and is slowly warmed up to a high damaging temperature.
  2. In general, high ambient temperature.
  3. If the external motor protection is set at a too high trip current or is installed in a wrong way.
  4. If a motor, within a short period of time, is restarted several times, the locked rotor current warms up the motor and eventually damages it.

The degree of protection that an internal protection device provides is classified in the IEC 60034-11 standard.


TP designation

TP is the abbreviation for thermal protection. Different types of thermal protection exist and are identified by a TP-code (TPxxx) which indicates:

  • The type of thermal overload for which the thermal protection is designed (1 digit)
  • The numbers of levels and type of action (2 digit)
  • The category of the built-in thermal protection (3 digit)

When it comes to pump motors, the most common TP designations are:

  • TP 111 – Protection against slow overload
  • TP 211 – protection against both rapid and slow overload.
Internal protection built into windings
Internal protection built into windings

Indication of the permissible temperature level when the motor is exposed to thermal overload. Category 2 allows higher temperatures than category 1 does.

Symbol
(TP)
Technical overload with variation
(1 digit)
Number of levels and function area (2 digits)Category
(3 digits)
TP 111Only slow (i.e. constant overload)1 level at cutoff1
TP 1122
TP 1212 levels at emergency signal and cutoff1
TP 1222
TP 211Slow and fast (i.e. constant overload and blocked condition)1 level at cutoff1
TP 2122
TP 2212 levels at emergency signal and cutoff1
TP 2222
TP 311Only fast (i.e. blocked condition)1 level at cutoff1
TP 3122

Information about which type of protection has been applied to a motor can be found on the nameplate using a TP (thermal protection) designation according to IEC 60034-11.

In general, internal protection can be implemented using two types of protectors:

  1. Thermal protectors or
  2. Thermistors.

Thermal protectors – built into the terminal box

Thermal protectors or thermostats use a snapaction, bi-metallic, disc type switch to open or to close the circuit when it reaches a certain temperature. Thermal protectors are also referred to as Klixons, (trade name from Texas Instruments).

When the bi-metal disc reaches a predetermined temperature, it opens or closes a set of contacts in an energized control circuit. Thermostats are available with contacts for normally open or normally closed operation, but the same device cannot be used for both.

Thermostats are precalibrated by the manufacturer and cannot be adjusted. The discs are hermetically sealed and are placed on the terminal board.

Top nameplate: TP 211 in a MG 3.0 kW motor equipped with PTC; Bottom nameplate: TP 111 in a Grundfos MMG 18.5 kW motor equipped with PTC.
Top nameplate: TP 211 in a MG 3.0 kW motor equipped with PTC; Bottom nameplate: TP 111 in a Grundfos MMG 18.5 kW motor equipped with PTC.

Motor thermal switch symbols
Motor thermal switch symbols

Symbols (left to right):

  1. Thermal switch without heater
  2. Thermal switch with heater
  3. Thermal switch without heater for three-phase motors (star-point protector)
A thermostat can either energize an alarm circuit, if normally open, or de-energize the motor contactor, if normally closed and in series with the contactor.

Since thermostats are located on the outer surface of the coil ends, they sense the temperature at that location. In connection with three-phase motors, thermostats are considered unstable protection against stall or other rapidly changing temperature conditions.

In single phase motors thermostats do protect against locked-rotor conditions.

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Thermal switch – built into the windings

Thermal protectors can also be built into the windings, see the illustration below. They operate as a sensitive power cut-out for both single and three-phase motors. In single-phase motors, up to a given motor size around 1.1 kW it can be mounted directly in the main circuit to serve as an on-winding protector.

Thermal protection to be connected in series with the winding or to a control circuit in the motor
Thermal protection symbol

Thermal protection to be connected in series with the winding or to a control circuit in the motor.

Thermal protection built into the windings
Thermal protection built into the windings

Klixon and Thermik are examples of thermal switch These devices are also called PTO (Protection Thermique à Ouverture).


Current and temperature sensitive thermal switches
Current and temperature sensitive thermal switches: Top: Klixons; Bottom: Thermik – PTO

Internal fitting

In single-phase motors one single thermal switch is used. In three-phase motors 2 thermal switches connected in series are placed between the phases of the motor. In that way all three phases are in contact with a thermal switch.

Thermal switches can be retrofitted on the coil end, but the result is an increased reaction time. The switches have to be connected to an external monitoring system. In that way the motor is protected against a slow overload. The thermal switches do not require an amplifier relay.

Thermal switches CANNOT protect against locked- rotor conditions.

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How does a thermal switch function?

The curve on your right-hand side shows the resistance as a function of the temperature for a typical thermal switch. Depending on the thermal switch manufacturer, the curve changes.

TN is typically around 150 – 160°C.

Resistance as a function of the temperature for a typical thermal switch
Resistance as a function of the temperature for a typical thermal switch

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Connection

Connection of a three-phase motor with built-in thermal switch and overload relay.


TP designation for the diagram

Protection according to the IEC 60034-11 standard: TP 111 (slow overload). In order to handle a locked-rotor, the motor has to be fitted with an overload relay.

Automatic reclosing (left) and manual reclosing (right)
Automatic reclosing (left) and manual reclosing (right)

Where:

  • S1 – On/off switch
  • S2 – Off switch
  • K1 – Contactor
  • t – Thermal switch in motor
  • M – Motor
  • MV – Overload relay

Thermal switches can be loaded as followed:

Umax = 250 V AC
IN = 1.5 A

Imax = 5.0 A (cut-in and cut-out current)

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Thermistors – also built into the windings

The second type of internal protection is the thermistors or Positive Temperature Coefficient sensors (PTC). The thermistors are built into the motor windings and protect the motor against locked-rotor conditions, continuous overload and high ambient temperature.

Thermal protection is then achieved by monitoring the temperature of the motor windings with PTC sensors. If the windings exceed the rated trip temperature, the sensor undergoes a rapid change in resistance relative to the change in temperature.

As a result of this change, the internal relays de-energize the control coil of the external line break contactor. As the motor cools and an acceptable motor winding temperature has been restored, the sensor resistance decreases to the reset level.

At this point, the module resets itself automatically, unless it was set up for manual reset. When the thermistors are retrofitted on the coil ends, the thermistors can only be classified as TP 111. The reason is that the thermistors do not have complete contact with the coil ends, and therefore, it cannot react as quickly as it would if they were fitted into the winding originally.

Thermistor / PTC
Thermistor / PTC

The thermistor temperature sensing system consists of positive temperature coefficient sensors (PTC) embedded in series of three – one between each phase – and a matched solid-state electronic switch in an enclosed control module. A set of sensors consists of three sensors, one per phase.

PTC protection built into windings
PTC protection built into windings

Only temperature sensitive. The thermistor has to be connected to a control circuit, which can convert the resistance signal, which again has to disconnect the motor. Used in three-phase motors.

The resistance in the sensor remains relatively low and constant over a wide temperature band and increases abruptly at a pre-determined temperature or trip point.

When this occurs, the sensor acts as a solid-state thermal switch and de-energizes a pilot relay.

The relay opens the machine’s control circuit to shut down the protected equipment. When the winding temperature returns to a safe value, the module permits manual reset.

Go back to Index ↑

Reference // Grundfos – Motor Book (Download here)

About Author //

author-pic

Edvard Csanyi

Edvard - Electrical engineer, programmer and founder of EEP. Highly specialized for design of LV high power busbar trunking (<6300A) in power substations, buildings and industry fascilities. Designing of LV/MV switchgears.Professional in AutoCAD programming and web-design.Present on

8 Comments


  1. Raj
    Dec 21, 2015

    I am a bit confused. I am under the impression that a thermistor employs a resistor as the sensing element. Very similar to an RTD. What is the sensing element in a thermal protector? Would it be the difference in metals, per the bi-metal disc? This would be much like a thermocouple, but when I look at a Thermik spec sheet on a thermal protector, I do not see where the type of thermocouple is listed (K,N,T)? If we are talking about the sensing element only, would it be acceptable that a thermal protector employs a resistor as the sensing element, much like a thermistor or RTD?


  2. Sanjay
    May 21, 2015

    Mr. Edvard, very nice article. I want to make a ppoint

    We can use 2 PTC one for alarm & other for trip. PTC 110 can be for alarm & PTC130 for trip in same motor can be fitted & both purpose can be achieved.


  3. Sanjay
    May 21, 2015

    For 3 phase machines if we use 2 different PTC then both alarm & trip can be achieved. In single motor we can emplyPTC110 for alarm & PTC130 for Trip for class F insulated motor. Hence both protections can be achieved.


  4. Joe
    May 20, 2015

    Nice topic


  5. R.Shanmugasundaram
    May 16, 2015

    Dear Edward

    I am a regular reader of your articles. Thanks for your postings. This article is really informative


  6. pakt
    May 16, 2015

    Good lucky for you…..thanks


  7. dhaval
    May 15, 2015

    nice one


  8. vipul kapuria
    May 15, 2015

    Hello Mr.adward I m vipul an electrical engineer & a self employed in the field of motor winding since last 13 years. I would like to know how can we set winding data for different types of motors for both 1 ph -3 ph. I am also interested to know how different types of servomotor works.

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