Category: THERMOSTATS BY APPLICATION

Developed in our manufacturing facility in India, Model BPM thermostat is the best suited for battery pack over temperature protection.

Thermostat for Battery Packs – Model BPM

Description of Thermal Overload Protector

Model BPM has been developed after extensive research and development by our engineers for battery pack protection from over temperature and burnout. This thermal overload protector is the smallest thermostat in our complete range of thermal cutouts. This thermostat has sloping edges such that it can be fitted between two batteries. The lead wires termination in a nickel strip which is easily spot welded to the body of the battery cell. The outer body of this thermostat is made of engineering polymer which can withstand high temperature. All the internals are spot welded on a stainless steel plate and the contacts are made of solid silver. The body is sealed and resistant to dust, fumes, varnish, moisture, etc.

Unlike normal snap action disc thermostats, which have delayed restart and the trip temperature drifts after long usage, the operating principle of our thermostat is based on the over center mechanism with a snap action bimetal and a beryllium copper switching blade. This mechanism provides our thermal cutout with quick restart and stable trip temperature, even after continuous usage. This thermal cutout is available in Normally Closed (NC) or Normally Open (NO) contacts. The normally open contacts can be used to activate a fan or provide a signal or indication to a control circuit that the batteries are overheating.

Special Features:

• • Small Size fits easily between battery cells
  • Teflon lead wires joined to nickel strips for spot welding to battery body
  • Available in Normally Closed (NC) or Normally Open (NO) contacts
  • Solid silver contacts for long life of 1,00,000 operations
  • Snap action bimetal thermostat
  • No chattering or sparking, quick make and break switching
  • Available in any temperature from 50C to 160C
  • Application of Thermal Overload Protector

Thermostat fitted between Batteries

Model BPM thermal cutout has to be fitted between the batteries (as shown in picture) such that it can sense the heat buildup. The thermostat can be taped on to the battery pack with a high temperature resistant tape. As the batteries heat up, this thermal cut out will sense the heat rise and will trip off at the desired temperature, which is preset at the time of manufacturing and cannot be changed. The trip off temperature is provided by the customer and the thermal cutout is calibrated so that it always trips off at that temperature. For battery pack protection, this cut off is normally at 65C. Please consult us for complete technical guidance.

We are the leading manufacturers and suppliers of thermostats for gas pre-heaters and have been supplying thermostats to this industry for the last 25 years. Almost all manufacturers of various gas pre-heaters (especially Advani-Oerlikon type design) use our thermostat model ISQA due to its durability, strength and stable trip temperature over a long period of continuous usage.

Gas Pre-heater Thermostat – Model ISQA

Description of Thermostat/Thermal Overload Protector

Model ISQA thermal overload protector acts as a thermostat and heats the cold welding gas to the desired temperature. This thermostat model has a solid aluminum body for greater strength and better heat sensing capability. This thermostat has two holes by which it can be easily mounted on to the body of the gas pre-heater. The aluminum body is electrically insulated. So there is no chance of any electrical shock. The internal contacts of the thermostat are made of sold silver for long life. The internal mechanism is all spot welded on a stainless steel housing plate. The lead wires are Teflon insulated and can withstand high temperature. The body of the thermostat is double sealed with high temperature epoxy, so the operating characteristics is not affected by dust, moisture, varnish, etc.

Normal snap action disc thermostats have delayed restart and the trip temperature drifts downwards after long usage. Our thermostats have a snap action bimetal and a beryllium copper switching blade which operate on the over center mechanism. This provides the thermostat with quick restart characteristic and stable trip temperature, even after long usage of many years.

Special Features:

• Solid Aluminum body of strength
• Better heat sensing capability
• Solid silver contacts for long life of 1,00,000 operations
• Snap action bimetal thermostat
• Teflon insulated lead wires
• Available in any temperature from 50C to 160C

Application of Thermostat

This thermostat has to be mounted inside the gas pre-heater with two screws. It should be fitted close to the heating element so that it can sense the temperature rise quickly. This thermostat maintains the temperature of the welding gas in the desired temperature range. When the temperature of the heater rises, the thermostat senses this rise and trips off, thereby, switching off the heater and preventing overheating. Subsequently, when the heater cools down, the thermostat switches on and restarts the heater. After which it again switches off/on and maintains the desired temperature range. This temperature range is fixed at the time of manufacturing and cannot be changed. It is specified by the customer. Normally most customers are using 120C thermostat model ISQA. Please consult us for complete technical guidance.

For over temperature and burnout protection of Heat Sinks, the Thermal Overload Protector Model BPM is best suited.

Heat Sink Thermostat – Model BPM

Description of Thermal Overload Protector

To cater to the requirements of the electronics industry in India, our engineers have especially developed the Model BPM thermal cut-out for heat sink over-temperature protection. With our focus on quality and the extensive R&D and manufacturing facility in India, our engineers have developed the thermal cut-out Model BPM.

This marvel of precision engineering and miniaturization is the smallest thermal overload protector in our entire range of products. This thermostat has been specifically designed for over temperature protection of electronic equipment by sensing temperature rise of heat sinks. Since this thermal cutout has a thickness of only 3.3mm, it can be placed between the fins of a heat sink. Any adhesive such as silicone glue, epoxy, etc. can be applied over the thermal cutout so that it is permanently fixed in place. Our snap action bimetal thermostat operates on the over center mechanism, which gives it a quick restart characteristic and stable trip temperature, even after continuous usage. The normal snap action disc thermostats have a delayed restart and the trip temperature drifts downwards after continuous usage.

Due to small size, the response to heat rise is fast, and when the equipment overheats, the thermal cut-out trips off, thereby, ensuring complete protection to all electronic equipment against over heating. It is available with Normally Closed (NC) or Normally Open (NO) contacts. The internal mechanism is fully spot welded on a steel housing plate. Due to sophisticated materials used and intelligent design, the size has been reduced without affecting the operating characteristics of the thermal overload protector. The outer body is made of high temperature resistant engineering polymer. Lead wires are teflon insulated. The internal tripping contacts are solid silver alloy for long life. The body is sealed and resistant to moisture, gases, fumes and varnish. It is available for any trip temperature required from 50 degrees C to 160 degrees C.

Thermostat inside Heat Sink

Special Features of Thermal Overload Protector:

• Small size for easy fitting.
• Snap Action bimetal thermostat, precise operating temperature
• Quick make and break switching, no Sparking or contact chattering
• Solid silver contacts for long life of 1,00,000 operations
• Sealed body resistant to moisture, gases, fumes and varnish
• Lead wires are teflon insulated.
• Available with Normally Closed (NC) or Normally Open (NO) contacts
• Available for any trip temperature required from 50 degrees C to 160 degrees C

Heat Sink with Thermostat in a Circuit

Application

Use of Model BPM is recommended in applications where temperature of heat sinks need to be sensed for over heating and burnout protection. The thermal cut-out is connected in series with the main circuit or a control circuit. In case of over heating, the temperature of the heat sink will rise and the thermostat will sense this and trip off, thereby, switching off the main circuit and saving the equipment from burning out. This model is also available with Normally Open (NO) contacts, so that it can also be used to provide an indication or signal of over heat by connecting it to a fan or a control circuit, which is activated when the contacts close. The trip off temperature is specified by the customer and supplied factory preset. It cannot be changed or adjusted afterwards. Please consult us for complete technical guidance.

Thermal Overload Protector Model ISQB is the best suited thermostat for over temperature and burnout protection of Heater Moulds.

Heater Thermostat – Model ISQB

Description of Thermostat/Thermal Overload Protector

Our research and engineering team has developed Model ISQB Thermostat for over temperature protection of heater moulds. This thermal overload protector has a body made of solid machined aluminum, which provides the thermal overload protector with greater strength and better heat sensing capacity. This thermostat can be mounted on to the heater mould with two screws. This thermal overload protector contains a snap action bimetal strip and a beryllium copper switching blade which work on the principle of the over center mechanism. The normal snap action disc thermostats have delayed restart and the trip temperature drifts downwards, but due to the over center mechanism, our thermostats have quick restart characteristic and the trip temperature remains stable, even after long usage. The contacts are made of solid silver which give it a long life. All the internal components are spot welded and the lead wires are Teflon insulated which can withstand high temperature. The body of the thermostat is double sealed with high temperature resistant epoxy adhesive, so it is not affected by varnish, fumes, dust, etc. This thermal overload protector is available in Normally Open (N.O.) or Normally Closed (N.C.) contacts.

Special Features:

• Solid Machined Aluminum Body
• Better heat sensing capability and greater strength
• Easily mountable with two screws
• Solid silver contacts for long life of 1,00,000 operations
• Available in Normally Open (N.O.) or Normally Closed (N.C.) contacts
• Snap action bimetal thermostat
• Double sealed body with Teflon insulated lead wires
• Available in any temperature from 50C to 160C

Application of Thermostat/Thermal Overload Protector

Thermostat Model ISQB functions as a heater mould over heat protection device, in case, the main temperature controller fails. It has two grooves, one on each side, so that it can be screwed on to the heater mould with two M3 screws. This thermal overload protector needs to be screwed on to a flat surface near the heater so that it can sense the temperature. The thermostat is connected in series with the heater for low amperes (up to 500W heaters). For heavy loads, use a contactor or relay. If there are multiple heaters, then one thermostat needs to be connected with each heater. When the heat builds up, the thermostat will sense the temperature rise and trip off, thereby, disconnecting the heater from the mains. This trip temperature is not adjustable and is calibrated at the time of manufacturing. It is specified by the customer and it can be different for different types of heater moulds. Please consult us complete technical guidance.

Our Thermostat Model ITD is the best suited thermal overload protector for sensing temperature of liquids and for over temperature and burnout protection of Oil Transformers.

Thermostat for sensing temperature of Liquids – Model ITD

Description of Thermostat

Model ITD has been designed by our engineers after extensive R&D for sensing the temperature rise of liquids as well as for over temperature protection of Oil Transformers. It has a solid machined brass body with a 1/4″ BSP threading so that it can be screwed on to any liquid tank or oil tank. The brass body provides greater strength as well as better heat sensing capability. The operating principle is based on the over center mechanism which operates a snap action bimetal and a beryllium copper switching blade. The normal snap action disc thermostats have a delayed restart and the trip temperature drifts downwards, while in our thermostats, due to the over center mechanism, the restart is quick and the trip temperature remains stable, even after continuous usage. The bimetal strip inside senses the temperature rise and snap opens the contacts. The contacts are made of solid silver for long life. All the internal components are spot welded on a stainless steel housing. The brass body is electrically insulated, so there is no chance of any electrical shock. The body is double sealed, so it is not affected by dust, moisture, etc. This thermal overload protector is available in Normally Open (N.O.) or Normally Closed (N.C.) contacts.

Special Features:

• Solid brass body for strength
• Better heat sensing capability
• Available with Normally Open (N.O.) or Normally Closed (N.C.) contacts
• 1/4″ BSP threading for easy mounting
• Solid silver contacts for long life of 1,00,000 operations
• Snap action bimetal thermostat
• Teflon insulated lead wires
• Available in any temperature from 50C to 160C

Application of Thermal Overload Protector

Model ITD needs to be screwed in to the liquid filled tank or oil tank so that it can sense the temperature of the liquid or oil. This thermostat should be screwed in where the liquid becomes hot as this will enable it to accurately sense the temperature rise. When the liquid heats up, it will sense the temperature rise and the contacts will snap open, which will trip off the thermostat, thereby, disconnecting the equipment or transformer and saving it from burning out.

If the equipment has a low ampere load of up to 6 to 8 amps, the thermostat can be connected directly in series with the equipment. When it trips off, it will also switch off the equipment. Upon cooling, the thermostat will restart and will restore supply to the equipment.

In the case of oil filled transformers, the two Teflon lead wires should be connected to a relay or a contactor because the thermostat cannot be connected directly in series with an oil filled transformer as it cannot withstand the high ampere load. The relay or contactor can be used to provide an indication, such as a light or alarm, or switch on a cooling circuit or operate a control circuit when the liquid or oil overheats. Please consult us for proper technical guidance.

Motor Thermal Protector model BPM is the best suited thermostat for over-temperature and burnout protection of all types of AC and DC motors, electric motors, single and three phase motors, induction motors, and all pumps.

Motor Protector Thermostat

Description of Motor Thermal Overload Protector

Motor thermal protector model BPM has been developed by our engineering department after extensive R&D for over temperature and burn out protection of all electric motors and pumps. It is the smallest thermal overload protector in our entire range of thermostats. Due to its small size, this thermostat is very sensitive to temperature rise and current overload. This thermal overload protector has a snap acting bimetal strip and a beryllium copper blade. Due to this there is quick make and break switching and there is no sparking when the thermal cutout switches off the motor. The internal contacts are made of solid silver to ensure long life. The outer body of this thermal cutout is a high temperature resistant engineering polymer. The internal construction of this thermostat is all spot-welded on a stainless steel housing plate. The wires are Teflon lead wires, which can take high temperature. The body of this thermostat is sealed and resistant to dust, dirt, fumes, moisture, gases etc. Due to the small size the response to temperature rise is fast, thereby ensuring complete motor protection during rapid temperature increase.

Unlike imported snap action disc thermostats, which have a delayed restart and in which the trip temperature drifts after continuous usage, our thermostats operate on the over center mechanism which provides quick restarting characteristics in applications like pumps and motors when the customer prefers minimum down-time to ensure maximum utilization of his equipment.

Imported thermal cutouts consist of merely a bi-metallic strip inside a housing, but our thermostats are true thermal cutouts with a snap acting high temperature copper alloy switching blade and a separate bi-metallic actuating assembly. This sophisticated design ensures stable trip temperature, long life, high reliability and superior current carrying capability.

Special Features of Motor Thermal Protector:

• Snap Action bimetal thermostat for quick make and break switching.
• Small size for easy fitting and rapid response.
• Sparking free and precise operating temperature
• Solid silver contacts for long life of 1,00,000 operations.
• Sealed body resistant to moisture, gases, fumes and varnish.
• Lead wires are teflon insulated.
• Available for any trip temperature required from 50 degrees C to 160 degrees C.

Application of Motor Thermostat and Motor Thermal Overload Protector

Motor Thermostat inside Motor winding

Single Phase Motor Protection – Installation and Ordering Instructions

[a] Electrical Connections – For protection of motors up to 1H.P. the motor protector thermostat is located at the windings and connected in series with the line side of the mains. For larger motors the thermal overload protector is located at the windings and connected in series with the magnet coil of the starter, contactor or other control circuit, as shown below in the case of 3 phase motors.

[b] Installation – The thermostat can be embedded or tied to windings at a location where the start and running windings are preferably side by side. This thermal overload protector can even be tied to the overhang (with a high temperature tape) ensuring good heat transfer. The leads are brought out to the terminal box for making connections. For small motor protection, the connection can be made internally in series with the line side. Thus even existing motors can be provided with thermal protector, especially at the time they are opened for maintenance or rewinding. Avoid installing the thermal cutout near any cooling air flow. During the installation, while shaping the windings and fitting the end covers do not hammer or damage the thermal cut-out or subject it to excessive stress. Windings may be dipped in varnish and baked up to 150 C after installation of the thermal cut-outs.

[c] Ordering – When ordering the BPM motor protector thermostat, inform us of the H.P., insulation class (A, E, B or F) and normal full load current of the motor, so that we can provide the correct calibration based on running current.

Three Phase Motor Protection – Installation and Ordering Instructions

3 Phase Motor Protection Connection Diagram

[a] Electrical Connections – In three phase motors, the current in the three phases is not directly interrupted. Instead, the starter, contractor or other control circuit which switches on the three phases, is itself disconnected, stopping the motor. Hence, the thermostat located at the windings are wired in series with the magnet coil of the starter, contractor or other control circuit. Use 2 or preferably 3 thermal cut-outs (U.L. regulations of U.S.A. require 3 cutouts for a 3 phase motor), so that a thermostat is in touch with each phase winding to sense overheat in any phase individually. The thermal overload protectors are in, series with each other so that when any of them trips the circuit is interrupted. The leads of the thermal overload protector are guided individually or jointly to the motor terminal box to make the connections (See diagram). When temperature rises beyond the maximum permitted limit for the class of insulation of its windings (i.e, Class A, E, B or F), one of the thermostats will trip and the motor will stop. The smallest to the largest 3 phase motor can be protected this way and you only need to specify the insulation class of the motor. The thermostat rating is independent of the motor H.P. rating, because the thermostat handle only the light loads involved in operating the magnet coil of a starter, contactor or other control circuit. Hence, any size 3 phase motor can be protected.

[b] Installation – The thermal overload protector should be embedded in or tied to the phase windings so that one overload protector is located in each phase winding. The thermostats can even be tied to the overhang (with high temperature tape) so that there is good heat transfer from windings to the thermostats. Thus even existing motors can be provided protection, especially at the time they are opened for routine maintenance or rewinding. Avoid installing the motor thermal protector near any cooling air Flow. During the installation, while shaping the windings and fitting the end covers do not hammer or damage the protector or subject it to excessive stress.

Windings may be dipped in varnish and baked up to 150 degrees C after installation of the cut- outs.

[c] Ordering – When ordering Model BPM inform us of the H.P., insulation class (A, E, B or F).