Issued: 12/11

Supersedes: 3/09

Motor Thermal Protection

GENERAL
Overheating is the most common cause of electrical motor failure. Adequate protection
against overheating is necessary for all electrical motors, and adequate protection against
motor overloading (which causes overheating and mechanical strain) is required by the
National Electrical Code - Art. 430, Part C.
Motor protection against overloading can be done indirectly, controlling the cause - i.e.
high running current for a prolonged period of time. or directly controlling the effect - high
motor stator temperature, The second type of protection is provided for almost all
Flygt pumps by inserting temperature sensors into the motor stator windings.
THERMAL SWITCHES
Flygt pump motors, with a few exceptions, are provided with two (2) or three (3)
thermal switches embedded in the stator windings. The exceptions are:
- some big pumps and hydroturbines;
- warm liquid pumps (high temperature thermal switches are optional).
DESCRIPTION
Thermal switches installed into the pump motor stator windings are bimetallic, normally closed contact
type. The device consists of a strip made of two dissimilar metals. The two metals have different
temperature coefficient of expansion, so the heat causes the strip to bend. At a preset temperature the
switch contact will open. As the stator cools down, the metallic strip returns to its original shape and
the switch will reclose its contact.
For different pumps/motors. Flygt uses a few different thermal switches, rated for different openclose
temperatures. (See Technical Data.)
INSTALLATION
There are usually two (2) or three (3) switches inserted into the stator end turns during its
production. The thermal switches are wired in series and connected by two (2) leads to the pump
terminal board, (Terminals T1 and T2.) For small pumps, such as the 3085, the thermal switch connection
to the cable is made with wire nuts. The closed/open status of the thermal switches is supervised by a relay
or other device and the opening of one of the thermal switches shall trip the pump branch circuit breaker, or
deenergize the motor starter, interrupting the power to the pump motor. The thermal switches in the stator
will reset automatically, as described above, but to restart the motor a manual reset might be required,
depending on the type of operation. If a leakage detector is also installed in the pump in conjunction with a
Mini CAS supervision relay, the thermal switches are wired in series with the leakage sensor. (See Mini CAS
manual-wiring diagram.)
TECHNICAL DATA:
Rated Voltage: 250 VAC
Maximum Operating Voltage: 600 VAC
Rated Current: 6.3 Amps @ 250 VAC, PF 0.60
Thermal Class F (+155C) insulation
CSA/UL Approved
Operating Temperature: Opens at 110C through 155C, depending on pump type. Check the pump
manual for the specific thermal switch temperature rating.

Issued: 3/09

Supersedes:

Motor Thermal Protection

TESTING
The thermal switches have normally closed contacts and are wired in series. For a cold motor, between
the leads connecting the thermal switch, the resistance measured with a regular ohm meter should be
under 1 ohm. If the thermal switch resistance is measured at the end of the cable, cable leads
resistance should be considered in series with the switches when reading the meter. An open circuit or
high ohms reading for the cold motor indicates a defective thermal switch or a loose connection.
PTC THERMISTORS
Older Flygt pumps and some FM-Approved, explosion-proof pumps can use PTC (positive temperature
coefficient) thermistors for stator over temperature protection, instead of thermal switches.
DESCRIPTION
A PTC thermistor increases its internal resistance when temperature is increased. The thermistors used
in above-mentioned pumps are non-linear type, which means that for a preset temperature. thermistor
resistance will suddenly begin to increase rapidly. (See attached Resistance/Temperature curve.)

Non-Linear PTC Thermistor Curve

3K

Point of
activation

2K

1K
700

Resistance - Ohms

500

250

100

Switch-over
Point

50

20

68

104

140

20

40

60

176 201
80

94

248

284

120

140

Temperature

INSTALLATION
Stator thermistor circuits use three thermistors connected in series. The same type of thermistors are
also used for measuring the bearing temperature. For temperature supervision, the thermistors are
wired in the control panel to special thermistor relays - one for stator temperature and one for bearing
temperature. The relay will react to the sudden change in thermistor temperature and trip the pump
circuit breaker or de-energize pump motor starter.
TECHNICAL DATA
Stator temperature PTC thermistors - three (3) thermistors connected in series. Total
resistance at 25C (77F) - 150-300 ohms not to exceed 750 ohms.
Bearing temperature PTC thermistor - one (1) each - Resistance 50 - 100 ohms at 25C (77F) - not
to exceed 250 ohms.

Issued: 3/09

Supersedes:

Motor Thermal Protection

TESTING
CAUTION: MAXIMUM TEST VOLTAGE FOR PTC THERMISTORS IS 2.5 VOLTS D.C.
Application of more than 2.5 volts will destroy the thermistors. At room temperature, PTC
thermistor resistance should be within the above limits.
PT 100 SENSOR FOR BEARING TEMPERATURE SUPERVISION
DESCRIPTION
PT 100 sensors are Resistance Temperature Detectors (RTD) made of platinum. The resistance of
platinum is linear with temperature over a wide range and they are thus capable of a great temperature
accuracy.
100 refers to the sensor resistance at 0C (32F), which is 100 ohms. Used together with the Flygt
MAS 711 pump monitoring system, the PT 100 sensor provides an accurate indication and permanent
monitoring of the bearing temperature.

Linear PT 100 Lower Bearing Sensor Curve

160

150

Resistance - Ohms

140

130

120

110

100

68

104

140

176

212

248

284

20

40

60

80

100

120

140

Temperature

Issued: 3/09

Supersedes:

Motor Thermal Protection

INSTALLATION
One PT 100 sensor is installed into the bearing housing of the big pumps and hydroturbines.
Standard connection to the MAS 711 is made with two (2) wires. As the wires resistance adds to
sensor resistance, a long cable run from the pump terminal board to the supervision relay will change
the temperature reading. Example: At 90C (194F), PT 100 resistance is 134.7 ohms. A two-wire connection
with AWG #14 cable, 1,000 ft. Long, will add: 2 x 3.07 x 1.0 = 6.14 ohms. Total resistance is now 140.84 ohms,
which corresponds to 105C temperature for PT 100 itself. If the MAS 711 unit is set for l00C, the pump will be
tripped even if the bearing temperature is still acceptable.
To avoid having this happen, the MAS 711 must be programmed with a resistance offset to compensate for
lead resistance.
If the PT100 has three leads, connect red lead(s) to one measuring terminal point and blue lead(s) to the other
measuring terminal point. Terminal points can be found in the MAS 711 Installation Manual.
TECHNICAL DATA
Maximum measuring voltage: 2.5V

Issued: 3/09

Supersedes:

Motor Thermal Protection

Temperature/Resistance Table for Platinum PT 100 Sensors
C
-200
-195
-190
-185
-180
-175
-170
-165
-160
-155
-150
-145
-140
-135
-130
-125
-120
-115
-110
-105
-100
-95
-90
-85
-80
-75
-70
-65
-60
-55
-50
-45
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15

18.52
20.68
22.83
24.97
27.10
29.22
31.33
33.44
35.54
37.64
39.72
41.80
43.88
45.94
48.00
50.06
52.11
54.15
56.19
58.23
60.26
62.28
64.30
66.31
68.33
70.33
72.33
74.33
76.33
78.32
80.31
82.29
84.27
86.25
88.22
90.19
92.16
94.12
96.09
98.04
100.00
101.95
103.90
105.85

C
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235

107.79
109.73
111.67
113.61
115.54
117.47
119.40
121.32
123.24
125.16
127.08
128.99
130.90
132.80
134.71
136.61
138.51
140.40
142.29
144.18
146.07
147.95
149.83
151.71
153.58
155.46
157.33
159.19
161.05
162.91
164.77
166.63
168.48
170.33
172.17
174.02
175.86
177.69
179.53
181.36
183.19
185.01
186.84
188.66

240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
405
410
415
420
425
430
435
440
445
450
455

190.47
192.29
194.10
195.91
197.71
199.51
201.31
203.11
204.90
206.70
208.48
210.27
212.05
213.83
215.61
217.38
219.15
220.92
222.69
224.45
226.21
227.96
229.72
231.47
233.21
234.96
236.70
238.44
240.18
241.91
243.64
245.37
247.09
248.81
250.53
252.25
253.96
255.67
257.38
259.08
260.78
262.48
264.18
265.87

C
460
465
470
475
480
485
490
495
500
505
510
515
520
525
530
535
540
545
550
555
560
565
570
575
580
585
590
595
600
605
610
615
620
625
630
635
640
645
650
655
660

TESTING:
CAUTION: MAXIMUM TEST VOLTAGE FOR PT 100 SENSOR IS 2.5 VDC.

267.56
269.25
270.93
272.61
274.29
275.97
277.64
279.31
280.98
282.64
284.30
285.96
287.62
289.27
290.92
292.56
294.21
295.85
297.49
299.12
300.75
302.38
304.01
305.63
307.25
308.87
310.49
312.10
313.71
315.31
316.92
318.52
320.12
321.71
323.30
324.89
326.48
328.06
329.64
331.22
332.79