Product Information: Motor and Machine Protection

Product Information
Motor and machine protection
Temperature monitoring with PTC-thermistors
- Basic information
PTC thermistors are ceramic semi-conductors which
PTC-thermistor because of the very high Positive Temperature
for windings control Coefficient lend themselves to a variety of applications.
- Applications
Specially constructed versions of these products are
available and this facility enables most applications to
be catered for. Most typical application for PTC
thermistors is to protect the windings of heavy duty
motors and transformers.
- General function
The PTC thermistor, for the thermal protection of
electrical machines, is a temperature dependent
component. The rated operating temperature (ROT)
corresponds to the curie point temperature of the
ceramic. The resistance, of the PTC thermistor, rises
very steeply with relatively small increases in
temperature, thus triggering the switching function.
- Advantages
 Precise repeatability of the response point.
 Long hysteresis free switch cycle life.
 Extremely cost effective.
 Steep temperature-resistance curve characteristic
allows for simple evaluation electronics.
 Current self-limiting.
 Light weight.
 Low thermal time constant.
 Extremely small designs are available.
PTC-screw-in-sensor and surface sensor
REISSMANN Sensortechnik GmbH · Westring 10 (under the water tower) · D-74538 Rosengarten-Uttenhofen
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Telephone 49 (0)791 950 15-0 · Telefax +49 (0)791 950 15-29 · E-Mail info@reissmann.com · Internet http://www.reissmann.com
Product Information
- Technical base data
Typical resistance-temperature characteristic

The advantage of PTC-thermistors is demonstrated by
the very steep curve as shown in the graph. This graph
shows the relationship between temperature and
resistance. The characteristic of the curve
demonstrates the accuracy of the PTC‘s. The increase in
the resistance from the switching point onwards is
exponential. The DIN-standards relevant to these
products cover the temperature range from +60°C to
+180°C and are DIN 44081 and 44082.
Resistance values (according to DIN 44081 and DIN

44082)
The resistance temperature characteristic of PTC-
thermistors for the thermic protection of machines is
defined by the following formula:
Temperature PTC-Resistance Measuring DC voltage

Range (TKL) (RKL) U (test voltage)
-20°C to TROT
RKL < 250 Ω U < 2,5 V
-20K
at TROT -5K RKL < 550 Ω U < 2,5 V
at TROT +5K RKL > 1330 Ω U < 2,5 V
at TROT +15K RKL > 4000 Ω U < 7,5 V
Load must not be applied to the thermistors as this

creates a self-heating effect.
At ambient temperature the resistance value of
thermistors is normally between 50 Ω and 100 Ω. It can
also be between 30 and 250 Ω. At ambient temperature
the resistance values have no relevance to the
serviceability (functionality) at the ROT (rated operating
temperature).
The ROT of PTC-thermistors in the range of +60°C to
+180°C progresses normally in steps of 10 K.
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Product Information
Application-example for electric motor- and machine

protection
The accurate sensitivity and small dimensions of PTC‘s
makes them ideal for all electrical machine protection
applications. For electric motor or transformer
protection the PTC must be placed within the windings.
The ROT (rated operating temperature) is chosen in
relation to the insulation class of the windings. Three-
phase motors will require 3 PTC-Thermistors, wired in
series. The terminal leads of the PTC must be
connected through a terminal block to a relay and cut-
off device (Schütz). When the temperature of the
motor exceeds ROT the relay is activated and triggers
the power cut-off. When the temperature of the
windings cools to below ROT the low resistance of the
PTC-thermistor will allow the motor (transformer) to be
re-started.
Control-relays suitable for use in conjunction with PTC‘s
are produced by several manufacturers including
SIEMENS 3UN6, REISSMANN TMS 100 and TMS 200.
But also all other standard control-relays can be used.
PTC-operational range for use with control relays for

temperature protection
Control relays trip normally between 1650Ω and 4000Ω
(according to DIN VDE 0660).
Switching points for 1, 3, 6 und 9 PTC-thermistors
connected in series is shown in the diagram:
 1 PTC switches no later than TROT +15 K,
no earlier than TROT +5 K.
 3 PTC switch no later than TROT +5 K,
no earlier than TROT -5 K.
 6 PTC switch no later than TROT, no earlier than
TROT -20 K.
 9 PTC at ambient temperature have a combined
resistance value which is automatically within the
switching boundaries of the control-relay.
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Product Information
Mechanical and electrical qualities
characteristics standard form miniature form

K155, KZ 255, KD 355,G 155, GO 155 K135, KZ 235, KD 335,G 135, GO 135
pellet diameter approx. 3-3,5 mm approx. 2-2,5 mm
shrink tube Kynar, ca. 15mm Kynar, ca. 11mm
leads stranded silvered copper wire insulated with Teflon (PTFE), AWG 24, or AWG
26 according to the manufactures choice.
length
single-sensor: 500 ± 10 mm
twin-sensor: 500/180/500 ± 10 mm
triple-sensor: 500/180-180/500 ± 10 mm
colour code colour coding is to DIN 44081 and 44082 see table on page 6
endconnections half plucked
insulation strength U > 600 VAC
lead resistance at +20°C: AWG26= 133 Ω/km; AWG24= 82,7 Ω/km
admissable working temperature up to +200°C
maximum working voltage
model Siemens: Umax = 30V DC
model Philips: Umax = 25V DC
DC measuring voltage U = 2,5V DC
testing of insulation: Ueff = 2500V AC
wire against insulation
(insulation strength)
rated operating temperature TROT
in 10K steps: +60°C to +180°C
in 5K steps: +145°C, +155°C
Tolerance Δ TROT
ROT=+60°C to +160°C: ±5K ±5K
ROT=+170°C to +180°C: ±6K ±7K
operational cut-off time <5s <3s
Climatic categories as stated in DIN HFF:
40040 lower category temperature: H = -25°C
upper category temperature: F = +180°C
humidity class F: average relative humidity = 75%, 95% continuously on 30
days per year, 85% occasionally on the remaining days, dew precipitation
inadmissible
storage temperature minimum: -25°C
maximum: +65°C
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Product Information
Mechanical and electrical qualities
insulation class The insulation class of machines suitable for protection with PTC‘s is graded according to
VDE 0530 and this is demonstrated in the table below.
Insulating
material class Y A E B F H C
classified
temperature limit +90°C +105°C +120°C +130°C +155°C +180°C over +180°C
insulation test Before testing the leads of the sensors have to be connected electroconductively. The testing
voltage is connected to the leads and the motor winding according to DIN 44081 and DIN VDE
0530.
resistance test Because of the self-heating effect a method to measure PTC-thermistors must be used in which
of the installed the voltage drop per sensor is not greater than 2,5V DC. The measurement is to be done with a
thermistors measuring bridge, e.g. Wheatstone. A reading of ≤ 250 Ω per sensor indicates that the sensors
and leads are correctly installed. When more than 1 sensor is wired in series the allowable
resistance is in multiples of ≤ 250 Ω.
installation instruc- It is important that the sensors are inserted in the stator coils, nearest to the rotor before
tions for electric impregnating the windings. The sensors should be tested prior to the impregnation of the
motors rotor, winding temperatures must not exceed 175°C for sensors with ROT 160°C or 185°C for
sensors with ROT 170°C. If impregnating agents or impregnating varnishes are used, that are
not chemically neutral, the resistivity of the sensors has to be tested by the user. The sensor
must be inserted in the middle of the end coils, ensuring that they are completely surrounded
by the windings. Hollow space and trapped air influence the heat transmission. One sensor
must be inserted into each leg of the windings with the leads parallel to the coil conductors.
The mounting of several sensors has to be done in series. The leads must be connected to
a terminal block on the terminal board, to ensure that they are separate from the winding
terminals. Tension and other mechanical stresses must be avoided when installing sensors.
Please avoid loops in the leads to avoid possibly occurring interfering voltage.
Quality control
Unless requested otherwise, quality control is to DIN 40080, AQL (acceptable quality level) in accordance with MIL-
standard 105D and IEC 410 at the discretion of the manufacturer. Precise manufacturing and testing techniques
guarantee the accuracy of REISSMANN-PTC-thermistors. All manufacturing operations are designed to conform to DIN
44081 + 44082.
Special versions (e.g. longer leads) are quickly available on request.
Caution:
The lead ends of the PTC-thermistors must not be connected to a voltage larger than 2,5 V DC!
We recommend that a warning label be fixed to any apparatus where there is a possibility of more than 2,5 V DC
being connected to the sensor. These warning labels may be purchased from REISSMANN when required.
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Single-PTC Twin-PTC Triple-PTC
Thermistor Thermistor Thermistor
Product Information
Technical information, color coding of leads and ordering codes for PTC thermistors:
1) 1) 2)
Rated operating Resistance R [Ω] Resistence R [Ω] at PTC-thermistor temperature: color coding order reference
Temperature from -20°C to TROT -20K TROT - ΔTROT TROT + ΔTROT TROT + 15K leads-in
± Tolerance (UKL ≤ 2,5 V) (UKL ≤ 2,5 V) (UKL ≤ 7,5 V) single sensor twin sensor triple sensor screw-in-sensor surface sensor
TROT ± ΔTROT [°C]
60 ± 5 ≤ 100 ≤ 570 ≥ 570 - white grey 31-K1x5 31-KZ2x5 31-KD3x5 31-G1x5 31-GO1x5
70 ± 5 ≤ 570 ≥ 570 - white brown 41-K1x5 41-KZ2x5 41-KD3x5 41-G1x5 41-GO1x5
80 ± 5 ≤ 570 ≥ 570 - white white 51-K1x5 51-KZ2x5 51-KD3x5 51-G1x5 51-GO1x5
90 ± 5 ≤ 550 ≥ 1330 ≥ 4000 green green 61-K1x5 61-KZ2x5 61-KD3x5 61-G1x5 61-GO1x5
100 ± 5 ≤ 550 ≥ 1330 ≥ 4000 red red 71-K1x5 71-KZ2x5 71-KD3x5 71-G1x5 71-GO1x5
110 ± 5 ≤ 550 ≥ 1330 ≥ 4000 brown brown 81-K1x5 81-KZ2x5 81-KD3x5 81-G1x5 81-GO1x5
120 ± 5 ≤ 550 ≥ 1330 ≥ 4000 grey grey 91-K1x5 91-KZ2x5 91-KD3x5 91-G1x5 91-GO1x5
130 ± 5 ≤ 550 ≥ 1330 ≥ 4000 blue blue 101-K1x5 101-KZ2x5 101-KD3x5 101-G1x5 101-GO1x5
140 ± 5 ≤ 550 ≥ 1330 ≥ 4000 white blue 111-K1x5 111-KZ2x5 111-KD3x5 111-G1x5 111-GO1x5
145 ± 5 ≤ 550 ≥ 1330 ≥ 4000 white black 116-K1x5 116-KZ2x5 116-KD3x5 116-G1x5 116-GO1x5
150 ± 5 ≤ 550 ≥ 1330 ≥ 4000 black black 121-K1x5 121-KZ2x5 121-KD3x5 121-G1x5 121-GO1x5
155 ± 5 ≤ 550 ≥ 1330 ≥ 4000 blue black 126-K1x5 126-KZ2x5 126-KD3x5 126-G1x5 126-GO1x5
160 ± 5 ≤ 550 ≥ 1330 ≥ 4000 blue red 131-K1x5 131-KZ2x5 131-KD3x5 131-G1x5 131-GO1x5
170 ± 7 ≤ 570 ≥ 570 - white green 141-K1x5 141-KZ2x5 141-KD3x5 141-G1x5 141-GO1x5
180 ± 7 ≤ 570 ≥ 570 - white red 151-K1x5 151-KZ2x5 151-KD3x5 151-G1x5 151-GO1x5
3)
190 ± 7 ≤ 570 ≥ 570 - - - - - - - -
3)
200 ± 7 ≤ 570 ≥ 570 - - - - - - - -
3)
210 ± 7 ≤ 570 ≥ 570 - - - - - - - -
Legend:
1. Resistance value is given for single PTC-thermistors, the value is to be multiplied for twin, triple and multiple sets.
2. Please replace the „x“ in the order reference: for the standard-PTC-form by „5“, for the miniature-PTC-form by „3“.
3. The sensor types ROT 190°C, 200°C and 210°C did not meet the standard DIN 44081 and DIN 44082 and thus are not
subordinated to the standardized characteristic curves and the color coding.
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Product Information
Example models:
PTC-model dimensions: other design and change of length of leads (L4)

according to customer‘s requirements
L1 [mm] L2 [mm] / colour L3 [mm] L4 [mm] Ømax. [mm] ØL [mm] (according to choice of producer)
standard 15 180 / black 10 520 3,5 0,42 / 0,54
mini 11 180 / yellow 10 520 2,5 0,42 / 0,54
Electric motor- and machine protection PTC-thermistors for measurements and control 30V
to DIN 44081 und DIN 44082
Single-PTC Twin-PTC Triple-PTC PTC-screw-in sensor PTC-surface sensor
Thermistor Thermistor Thermistor
7-9
Product Information
- PTC-sensors
examples of PTC-thermistor-housings
shrink tube housing,

e.g. for monitoring windings
screw-in-sensors in alu housing:

AL-M3/SW8 and AL-M4/SW10
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Product Information
PTC-thermistor in cable shoe

surface sensor
PTC-thermistor in stainless steel housing
PTC-thermistor in ceramics
or brass housing
Responsibility:
No responsibility will be accepted for thermistors which have not been installed and tested according to the relevant
standards as previously listed in our data sheet.
Due to the ongoing research and development program, product specification may be subject to change, at the
manufacturers discretion.
For further advice and information contact:
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Product Information: Motor and Machine Protection

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Motor and machine protection

Temperature monitoring with PTC-thermistors

Temperature monitoring with PTC-thermistors

- Technical base data

Typical resistance-temperature characteristic

Resistance values (according to DIN 44081 and DIN

Temperature PTC-Resistance Measuring DC voltage

Load must not be applied to the thermistors as this

Temperature monitoring with PTC-thermistors

Application-example for electric motor- and machine

PTC-operational range for use with control relays for

Temperature monitoring with PTC-thermistors

Mechanical and electrical qualities

characteristics standard form miniature form

Temperature monitoring with PTC-thermistors

Mechanical and electrical qualities

Temperature monitoring with PTC-thermistors

Temperature monitoring with PTC-thermistors

PTC-model dimensions: other design and change of length of leads (L4)

Temperature monitoring with PTC-thermistors

shrink tube housing,

screw-in-sensors in alu housing:

Temperature monitoring with PTC-thermistors

PTC-thermistor in cable shoe

PTC-thermistor in stainless steel housing

For further advice and information contact:

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