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Electric Iron Repaired

By on August 12, 2014
electric iron repair








electric iron repair

I was told that this electric iron quietly stopped functioning, that is, it was not getting hot anymore when connected to the power. I opened the outer cover and see the circuit arrangement. See photo below.


electric iron repairing

The Bi – metallic strip is made of two metals of different temperature characteristics: one expand with heat more than the other. The principle of operation of a Bi – metallic strip is that as the iron heats up one of the two metals will expand more than the other. This makes the metallic to bend up (in this case) and break the electrical contact, thus breaking the current flow to the heating element.


There was no any visible symptom of failure of any part. I used my digital multimeter set on Ohmic range. I tested the heating element, it tested well.  I followed the circuit from the entry point of a power cable to the heating element.

Current ought to pass from pole 1, through thermostat, a component in white coloured sleeves to pole 2. From pole 2 it passes through the element back to pole 3.  To my surprise there was no continuity between thermostat and pole 2. I took out that part in white sleeves and measured its continuity separately. It was giving me infinity. This means it was open circuited.


Honestly, I didn’t have any idea of what this component is. The marking on its body is Tt 240°C D242 ZSXJ. It is pointed on one end and has a coloured band near the other end. It looks like a diode, I don’t think it is. When I searched on internet I found that it is a Thermal Cut-Offs (Organic Thermal Element Type). These devices are used to prevent fires caused by abnormal heat generation from circuits and other heat producing electrical products. (

I bought a new component marked Tt 240 °C 250V AC 10A. The new one measures 4 Ohms in both directions. The device finds its application, among others, in Electric home appliances and heating devices.


I replaced the faulty component with a new one. Note that I put the new device into the original sleeves. I tested the continuity of the complete circuit: from pole 1 through heat control devices to pole 2 via the Device, to heat element and back to pole 3, the result was satisfactory. I connected the power cable; I made sure that it was safe to power it up. It worked so well! At different temperature ranges the heat was controlled by the thermostat by the operation of the Bi – metallic strip as expected. Glory to God!



Luciano Francisco Thomas Khware (Malawian) studied Electrical and Electronics at Comboni Technical College and at Polytechnic (University of Malawi). Currently, he is a student at Tangaza University in Nairobi Kenya.

Please give a support by clicking  on the social buttons below. Your feedback on the post is welcome. Please leave it in the comments. By the way if you have any good repair article that you want me to publish in this blog please do contact me HERE.



  1. Robert

    August 12, 2014 at 10:16 pm

    Good job Luciano. I fixed my son's electric fan and all that was wrong with it was the thermal cut-off fuse on the motor. I didn't have a camera at that time to send in an article about the repair.

    • Luciano Khware

      August 14, 2014 at 4:23 am

      Hi Robert,
      Thanks so much for the comment! surely it was my first time to see this Thermal cut off fuse.

      • Robert

        August 14, 2014 at 8:52 pm

        You are welcome my friend. The manufacturer of the fan hid the thermal cut-off fuse well. I had to take the motor apart to find it! Most people would just throw the fan away and buy another one since it is cheap at Wal-Mart. So instead of my son spending $20 for a new fan, I fixed it for $1.

  2. Yogesh Panchal

    August 12, 2014 at 10:35 pm

    Clear photographs and point to point clarification well done my friend keep on sharing the article.

    • Luciano Khware

      August 14, 2014 at 4:42 am

      Hi Yogesh,
      You are welcome my friend!

  3. Ken Hart

    August 13, 2014 at 9:06 am

    Be careful when replacing thermal cutoffs by soldering. Sometimes the heat from soldering is enough to cause them to open. (Been there, done that!) Use an adequate heat sink, or use crimp-on connections. Themal cutoffs are available in different temperature ratings, and the lower temperature ones are sometimes sold with a pair of crimp-on collars.

    • Luciano Khware

      August 14, 2014 at 4:47 am

      Hi Ken,
      I totally agree with you. soldering heating elements is not a good option. in my case i used clamp on connectors. i clamped on both sides tightly.
      thanks for the comment

  4. Gerald

    August 13, 2014 at 11:21 am

    Well done Luciano. I came across a couple of those when I repaired my coffee machine. They were opened because the temperature sensor was faulty so the the heater did not turn off when the set temperature was reached. It avoided a meltdown of the machine...

    As Ken correctly wrote they were connected with crimp-on collars. I used the same system when replacing them.

    • Luciano Khware

      August 14, 2014 at 4:54 am

      Welcome Gerald. i appreciate your sharing too

      • Ndy

        June 19, 2018 at 11:19 pm

        Nice one,just finish repairing my iron now.thanks

  5. Venu gopal

    August 13, 2014 at 11:40 am

    Good article.Thank you.

    • Luciano Khware

      August 14, 2014 at 4:55 am

      Mr. Venu
      You are most welcome!

  6. Joshua oloo

    August 13, 2014 at 12:42 pm

    Hi Luciano.thanks for sharing the Article.sometimes geting thermal cut-off at our local elect-shops is a problem,i guess you got it locally?otherwise keep up the good work.God bless.

    • Robert

      August 13, 2014 at 5:42 pm

      When I buy things like that I usually buy 10 or more of them so I will have one the next time I need one. When I ordered the SMD bridge rectifier for the camera battery charger I repaired, I bought 10 of them because they are cheap. So I still have 9 of them and the next time I need one I don't have to order or drive somewhere to get one!
      When I ordered the thermal cut-off fuse for my son's fan, I ordered a bunch of them in different degrees C. ICAIW, yes my son's fan is still working great all last summer and this summer also!!

      • Luciano Khware

        August 14, 2014 at 5:03 am

        In fact i do the same. this time i got a good number of Thermal cut off fuses and i have new other components in stoke.

    • Luciano Khware

      August 14, 2014 at 4:59 am

      Mr Joshua
      Yeah i got them in one of the shops along Lithuli Avenue, Nairobi and at a reasonable price. It was nice meeting you face to face that day... i feel blessed and got some inspiration from you through our sharing. May God grant you all the blessings you need.

    • Bryan Sanders

      August 14, 2014 at 5:03 pm

      Thermal fuses I guess you have figured out are used in almost any heating appliance including air conditioning heat
      Strips. Local appliance stores usually stock thermal fuses also.

      Thx for the article !

  7. marwan

    August 13, 2014 at 7:47 pm


    • Luciano Khware

      August 14, 2014 at 5:04 am

      Welcome Marwan!

  8. Taring K Arioka

    August 14, 2014 at 1:04 am

    Thank you so much again for this very nice article.

    I found the same component in rice cookers but have no idea what it purpose while being there. The rice cooker remained untouched as I dont what to do with it. Now is the right time to chase and have it fixed. Thank you again.

  9. Andre Gopee

    August 14, 2014 at 1:07 am

    Good Job Luciano, I had repair a couple of item with those thermal cut-offs.. I also buy 10 or more components when I buy in order to have them readily available especially if I am working at nights. Thanks for sharing.

  10. shahid ahmad

    August 14, 2014 at 4:18 am

    very good once again as usual
    thank u sir

    • Luciano

      August 17, 2014 at 5:38 pm

      You are most welcome Shahid

  11. stanley

    August 17, 2014 at 2:10 pm

    Thank you very much for such a good and educative article. Keep the good work.

  12. Luciano

    August 18, 2014 at 10:02 pm

    Hi Stanley
    You are most welcome!!

  13. Humberto

    August 19, 2014 at 12:01 am

    Good repair Mr. Luciano. Congratulations

  14. Raymundo Saura

    August 27, 2014 at 4:25 pm

    great thanks sir

  15. Fermin

    August 29, 2014 at 6:07 pm

    those thermal fuses can also be found on some rice cooker and deep fryers pan it can`t be soldered but, can be connected through bolted connectors then protect it by asbestos tubes.

  16. salman

    November 6, 2016 at 4:42 pm

    Thanks a lot
    surprisingly, my problem was exactly your problem
    Thanks again.

  17. Mubashir Khan

    June 6, 2017 at 4:16 pm

    Very informative thanks a lot dear for sharing this clear information and for uploading hd images, please keep it up.

  18. Emmanuel

    March 27, 2018 at 2:41 pm

    does d thermal cut off fuse limit d current flowing into the heating element of the pressing iron?

  19. jeck

    May 21, 2018 at 4:48 am

    which side connect to thermostat? flat side or other?

  20. innocent sheleni

    December 22, 2018 at 9:03 pm

    dad is on my neck to look after every electrical appliance in the house as his junior engineer... Thanks for knowledge add!

  21. Maurice Ojowah

    May 2, 2019 at 1:51 am

    Thanks Luciano. Your article is a God send to me. One morning my I/ box went dead, and after going through all the wires everything was ok, except one small capacitor-like component neatly hidden inside a tube, which couldnt pass a continuity test, and I didn't even know what it was.

  22. Waqar Ali Shah

    May 29, 2019 at 2:15 am

    Great bro. I was ignoring that thermal wire thing... was thinking iron is broken permanently. Saved extra expenses!!


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