High-temperature thermostats for foundries and other industrial environments

High-temperature thermostats are indispensable in various industries where employees encounter and handle extreme temperatures daily. From manufacturing facilities to research laboratories, high-temp thermostats have applications in diverse environments. Selecting the appropriate thermostat is crucial to ensure a safe and conducive work environment for all employees.

Industries That Rely on High-Temperature Thermostats

High-temperature thermostats play a pivotal role in industries that necessitate precise control over extreme temperatures. Sectors such as steel manufacturing, chemical processing, pottery making and material testing laboratories frequently utilize these devices. The ability of these thermostats to regulate temperatures ranging up to several hundred degrees Celsius makes them indispensable in applications involving extreme heat, like curing, drying, heat treatment, and material testing.

Benefits of High-Temperature Thermostats

Through the utilization of high-temperature thermostats, industrial companies can enjoy several indispensable advantages.

Precision and Accuracy

High-temperature thermostats excel in maintaining precise and consistent temperatures within extreme ranges. Their ability to regulate heat accurately ensures the reliability and quality of industrial processes, vital in sectors where temperature control is critical for product integrity.

Optimized Performance

Industries relying on high-temperature processes, such as chemical processing or material testing, benefit significantly from these thermostats. The precise control they offer helps optimize performance, resulting in better yields, improved efficiency, and consistent output quality.

Adaptability and Versatility

These thermostats come in various models catering to a wide range of temperature requirements, offering adaptability in different industrial settings. They are tailored to suit specific processes, providing flexibility in meeting diverse operational needs.

Improved Energy Efficiency

Since efficient temperature control directly impacts energy consumption, high-temperature thermostats that maintain precise temperatures help optimize energy usage, reducing overall operational costs in the long run.

Consistency in Research and Development

Laboratories and research facilities benefit from the consistent and precise temperature control these thermostats offer. This consistency is crucial for accurate experimentation, testing, and development of new materials or processes.

Considerations for Choosing the Right High-Temperature Thermostat

Selecting the appropriate high-temperature thermostat involves careful consideration of various factors to align with your specific industrial requirements, such as:
  • Temperature Range - Evaluate the temperature range needed for your processes. High-temperature thermostats vary in their maximum heat tolerance, so choose one that accommodates the upper limit required for your operations.
  • Precision and Accuracy - The ability of a thermostat to maintain a consistent temperature is critical. Look for devices with precise temperature control and minimal fluctuations, ensuring the reliability of your processes.
  • Durability and Build Quality - Industries operating in high-temperature environments demand robust and durable equipment. So, opt for thermostats built with high-quality materials capable of withstanding extreme heat without compromising functionality.
  • Safety Features - Prioritize safety features such as overheat protection, alarms, and fail-safes. These elements can prevent accidents and equipment damage, ensuring a secure working environment.
  • Compatibility and Integration - Ensure the thermostat seamlessly integrates into your existing systems or processes. Compatibility with your equipment and ease of integration are vital for efficient operations.
  • Cost and Long-Term Value - While considering the initial cost, also assess the thermostat’s long-term value. Investing in a durable, high-quality device might prove more cost-effective in the long run, considering reduced maintenance and replacement expenses.

Get Your High-Temperature Thermostat at Calco Electric

The selection of the right high-temperature thermostat for your industrial needs is a pivotal decision. If you rely heavily on precise temperature control, you must carefully assess your requirements and choose a thermostat that aligns with your operational demands. At Calco Electric, we understand the significance of high-temperature thermostats in various industries and offer reliable products to suit your needs, from our M2HA High Thermostat Sensor to our TK24HT High Temperature Disc Thermostat. Contact us today for expert guidance in selecting the ideal thermostat that meets your industrial requirements.



Temperature regulation is a critical aspect of various industries. From manufacturing to consumer appliances and beyond, precise and stable temperature control can impact processes and outcomes. One piece of equipment that excels in providing accurate temperature control is the creep action thermostat. In this article, we will explore what creep action thermostats are, how they function, and the wide array of applications where they excel.

The Advantages of Creep Action Thermostats

At Calco Electric, we are proud to offer creep action thermostats that live up to the highest of performance expectations. These thermostats are renowned for their exceptional accuracy in maintaining a set temperature in many different types of appliances. Two specific benefits of this type of thermostat are as follows:
  • Precision and Accuracy - Creep action thermostats are designed to meet tight precision tolerances. They contain two dissimilar metals that are bound together. As the thermostat works to regulate the temperature, one of these metals expands faster than the other, creating a gradual, rounded arc. This gradual bending of the metal components allows for precise temperature control. A creep action thermostat employs a coil form of the metals, effectively eliminating the range of temperature fluctuation and ensuring that the temperature remains at the setpoint.
  • Sustained Response - Creep action thermostats offer the consistency of a sustained response. They feature a slow cutout set at a specific trip point. Their slow make and slow break action are triggered around the setpoint, which further contributes to their accuracy and reliability.

Types of Creep Action Thermostats

Within the category of creep action thermostats, there are a few different types that can be selected depending on the task at hand. Calco Electric offers a great variety, including the two categories listed below. Also, remember that the team at Calco is always available to help you find the right part for your needs, so you are welcome to reach out at any time for assistance.
  • JRMC, JRMD, and JRMD-E Creep Action Thermostats - These thermostats use a bimetal slow break and slow make mechanism to regulate temperatures and limit thermal activity. They are also available with gold diffused contacts, adding another layer of durability and precision to their functionality.
  • WAA2 Creep Action Thermostats - Designed for use in certain appliances, these thermostats can be found in medical cushions, car seats, and heating pads, all environments where steady temperature control is necessary.

Applications Where Creep Action Thermostats Excel

It’s helpful to understand the basics of how these thermostats work, but it’s even better to know where they can be deployed effectively. We aren’t going to be able to cover all possible applications in the list below, but this is a good starting point.
  • Medical Devices - A range of different medical devices rely on the use of creep thermostats to keep patients safe while maintaining a precise temperature.
  • HVAC Systems - Managing the temperature within an indoor space is an important job and creep thermostats can play a role in this setting, as well. Not only will such a thermostat keep the space more comfortable, but it can also help to cut down on energy consumption.
  • Refrigeration Units - Like HVAC, refrigeration systems need to hold a steady temperature. Big fluctuations could lead to safety concerns and would use far more energy than is needed for the task.
  • Household Appliances - Many different components that help a house to run smoothly rely on creep thermostats to operate accurately and safely.
  • Lab Equipment - Perhaps nowhere is accuracy more important than within a lab setting, which is why creep thermostats are used in lab devices that have to be as precise as possible.

How Can Calco Electric Serve You?

Creep thermostats are one of the many items we offer to our valued customers. Whatever it is you need, our experienced and knowledgeable team is ready and waiting to serve you. Contact us with any questions, or to place an order, and we’ll jump into action.


PVC Insulated Heater Wire, with its versatility and reliability, finds a wide range of uses and applications in both domestic and commercial settings. Some of the most common include industrial heating systems, domestic heating appliances, and HVAC Industry.

Common Applications

Industrial Heating Systems

Industrial heating systems use PVC insulated heater wire for a variety of uses, but are commonly used in pipe heating, tank heating, and heat tracing for maintaining the desired temperature in industrial processes. These wires are designed to withstand high temperatures and provide efficient heat transfer.

Domestic Heating Appliances

PVC insulated heater wire is widely utilized in a variety of domestic heating appliances. Electric blankets, heating pads, and heated mattress pads all rely on PVC insulated heater wire to generate warmth and provide comfort. The flexible nature of PVC insulation allows for easy integration into these household items. Heating, ventilation, and air conditioning (HVAC) systems often incorporate PVC insulated heater wire for temperature control purposes. They are used in components such as duct heaters, electric baseboard heaters, and radiant heating systems to ensure efficient heat distribution and maintain comfortable indoor environments.

Commercial Appliances

Other uses include commercial appliances and freeze protection. Commercial appliances such as food warmers, coffee warmers, fryers, and industrial ovens all use PVC insulated heater wire to provide reliable and efficient heating. Freeze protection in pipes, tanks, and valves in cold climates or areas prone to freezing are also common by using heat generated by the wire to prevent water from freezing.

Refrigeration Systems

Finally, PVC insulated heater wire plays a crucial role in preventing condensation and maintaining optimal temperatures in industrial refrigeration systems. They are employed in applications such as refrigerated display cases, walk-in freezers, and cold storage facilities. It is important to note that PVC insulated heater wire should always be used in accordance with manufacturer guidelines and local electrical codes. Proper installation and regular maintenance are essential to ensure optimal performance, safety, and longevity in these diverse applications.

Maintenance and Troubleshooting

Proper maintenance of PVC insulated heater wire is essential to ensure its longevity and safe operation. For maintenance and troubleshooting practices, the best thing to start with is regular inspections. Periodic inspections of the wire for signs of wear, damage, or loose connections can ensure the insulation integrity and ensure it is not cracked or frayed. This will keep the wire from developing and issues by preventing further damage or safety hazards. The wire should also be kept clean and free of debris or contaminants that could affect its performance. Further troubleshooting practices can be used if any performance issues arise with the PVC insulated heater wire. First, check for loose connections, damaged insulation, or other potential causes. If necessary, consult with a qualified technician for assistance. It’s also advisable to have professional maintenance scheduled periodically, especially in commercial or high-demand applications. A professional can conduct thorough inspections, perform necessary repairs or replacements, and ensure compliance with safety standards.

Safety Considerations

When working with PVC insulated heater wire, safety should be a top priority. Proper installation and usage are essential to ensure the safe operation of the wire. Here are some key safety considerations to keep in mind:
  1. Installation by a Qualified Technician: A qualified technician should handle the installation of PVC insulated heater wire as they have the necessary knowledge and expertise to ensure a safe and reliable installation.
  2. Follow Manufacturer Guidelines: Always follow manufacturer's guidelines and instructions when installing and using PVC insulated heater wire. These guidelines help to provide important information including wire ratings, maximum temperatures, and other safety-related specifications.
  3. Local Electrical Codes: Familiarize yourself with the electrical codes and regulations specific to your location. These codes dictate the proper installation practices, grounding requirements, and safety protocols to be followed.
  4. Insulation Integrity: It is recommended to regularly look over the insulation of the PVC wire for any signs of damage or degradation. Compromised insulation can lead to electrical hazards or malfunctions, therefore, any damaged wire should be replaced.
  5. Overloading and Overheating: Avoid overloading the wire with excessive wattage or voltage beyond its rated capacity. Overloading can cause the wire to overheat, leading to insulation failure or even electrical fires. Always choose the appropriate wire gauge and rating for your specific application.

Selection Guide

Choosing the right PVC insulated heater wire for your application is crucial for optimal performance and safety. It is important to consider the following during the selection process:
  1. Wattage Requirements: Determine the wattage requirements of your heating system or device. This information will help you choose a wire with the appropriate resistance and power handling capacity.
  2. Voltage Rating: The voltage levels of your application should be considered. Make sure the PVC insulated heater wire chosen can handle the specific voltage rating without the risk of electrical breakdown or insulation failure.
  3. Wire Gauge: The wire gauge is recommended to be chosen that can accommodate the electrical load while minimizing the voltage drop and excessive heating. A wire gauge chart or seeking out a professional is recommended to choose the correct gauge for the application.
  4. Temperature Limits: Take into account the maximum temperatures the PVC insulated heater wire will be exposed to. Ensure that the wire's temperature rating is suitable for the intended application to prevent overheating or insulation melting.
  5. Certification and Compliance: Look for PVC insulated heater wire that complies with industry standards and certifications. These certifications make sure that the wire meets safety and performance standards.
Contact the experts at Calco Electric for assistance selecting the right PVC insulated heater wire for your specific application.

Current protection is important in a number of electrical applications. For both safety and the protection of expensive, important pieces of equipment, current protection is often required within electrical systems. 

While there are a number of ways to accomplish this goal, PTC thermistors are often used for the job. Let’s take a closer look at what these resistors can accomplish so you can determine if they are right for your project.

What is a PTC Thermistor?

The concept behind a PTC thermistor is quite simple. These resistors are designed to have a positive temperature coefficient, which is where the “PTC” name comes from. As temperature rises, the resistance that is offered by the thermistor increases, allowing circuit designers to tie the flow of current to the temperature that is being experienced. 

This type of resistor is popular because it can be used in a variety of applications. It can be used for current protection – which we will talk more about in a moment – but it can also be used as a time delay function within a circuit, it can be used in the motor starting process, and it can also be used to self-regulate heating components. If you’d like help understanding some of the various ways our PTC thermistors can be put to use, feel free to get in touch with our expert team today. 

Implementing a PTC Thermistor for Overcurrent Protection

Often, fuses are used as a form of current protection, as the fuse will blow if the current exceeds a set limit and the circuit will be broken. The problem with this arrangement is obvious – if the fuse is blown, it will need to be replaced. As a better solution, a PTC thermistor can be used to accomplish the same goal without the downside of ongoing, potentially frequent replacements being required. 

For current protection, you’ll typically be looking at a switched PTC thermistor. This is a type of resistor that maintains a steady level of resistance at a given temperature range, but the resistance will suddenly jump up (or “switch”) once a certain temperature is reached. That design allows the switched PTC thermistor to act effectively as a fuse, only it won’t need to be replaced after the overcurrent event. Once the additional flow of current has abated and the temperature in the thermistor returns to normal levels, the resistance will drop and the performance of the circuit will be allowed to continue once again. 

Protecting circuits from the inevitable, occasional rush of additional current is essential for countless businesses. At the same time, utilizing standard fuses for the job adds a layer of maintenance and ongoing upkeep that is not desirable. The PTC thermistor is an elegant solution to this problem, as it essentially automates the fuse management task. There is no fuse to blow, and the current can go up and down without doing any damage to the equipment that is downstream of the thermistor. 

Order from Calco Electric Today

In addition to our extensive selection of quality products, it’s the expertise of the staff at Calco Electric that allows us to stand apart from the competition. If you would like to learn more about the PTC thermistors we offer, or if you are ready to place an order, please reach out today and we will be happy to serve you. 

We all can appreciate the need for an accurate thermostat to regulate temperatures within a home or building. But for some industries, the accuracy of a thermostat is an absolute necessity for safety and to protect the equipment inside. Narrow differential thermostats are used in heat-treating ovens. Those industries include:

  • Heavy construction machinery
  • Aerospace
  • Mining
  • Metalworking
  • Tool and die sectors

Typical heat-treating applications include aging, annealing, baking, brazing, drying, hardening, normalizing, solution-treating, tempering, and more.

The temperature differential refers to the variance between the temperature outdoors and whatever it is indoors. If you’re trying to cool the building to 72°F and it is 100°F outside, the thermostat will work harder to catch up. And with heat-treating ovens and furnaces that reach temperatures as high as 1400°F, you need a thermostat with a narrow differential to ensure the building is kept cool enough inside without error.

This is where Calco Electric’s narrow differential thermostats excel.

Narrow Differential Thermostats Require Extreme Precision

Narrow differential thermostats need the ability to turn on and off at close tolerances. A narrow differential allows the heat to turn on and off rapidly. Calco Electric’s narrow differential thermostats provide the following benefits:

  • 100% regulated temperature
  • Snap action and creep action
  • Personalized wire length and type
  • 100% RoHS Compliant
  • 100,000 life cycles for long-term capacity
  • Personalized terminals located at the same or opposite ends
  • Use of a snap action with bimetal discs to open and close the contact
  • 17AME-H thermal switch
  • The lowest temperature is from 0°C to 180°C
  • High resistance to shock and vibration

Thermostats have adjustable temperature settings that determine how often the system cycles. A low differential setting is similar to a narrow differential setting. The tighter this setting, the more the system will cycle and the tighter the temperature will remain. A broad differential setting will result in longer cycle times. But where heat-treating ovens are used, that wide setting can be problematic.

Three Advantages of Narrow Differential Thermostats

Though a wide differential can increase efficiency and extend equipment life in most circumstances, it’s not ideal for personal comfort. It can be dangerous where heat-treating ovens are in use. For this reason, a narrow differential thermostat will provide the following advantages.

  • Ability to control the temperature of an application under a minimal range
  • More comfort for personnel working close to ovens that can reach temperatures as high as 1400°F
  • Heat-treating ovens do not have the same compressor minimum run-time constraints - rapid cycling from a wide differential would cause excessive wear, and tear - narrow differential thermostats are far more efficient and effective
  • Safer working conditions for employees in close proximity to heat treating ovens

Contact Calco Electric for More Information

For more details about narrow differential thermostats and the benefits they can provide for your application, contact the team at Calco Electric. Our experienced, trained staff will gladly answer any questions you have about these thermostats. 

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