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#60478 - 01/03/06 11:24 AM Thermal Protection Saga
wendel Offline

Registered: 08/07/04
Posts: 57
Life is stranger than fiction at times. It appears a simple thermal protection device made by Leviton ( as an OEM for Lightolier is next to impossible to buy. Even the few electrical supply houses I called don't carry thermal protection devices. And electrical contractors cannibalize old recessed lights for them. Now I can't believe it's so hard to buy a very simple and important safety device except in lots of 500. Anyone know of a cross to a Leviton 9454A10 (7.2K resistor, 110 degree C temp, 120 volts) thermal protector, or as Leviton calls them, "Self-heating Thermal Protectors"? Thanks again for all your help.

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#60479 - 01/03/06 12:02 PM Re: Thermal Protection Saga
Electricmanscott Offline

Registered: 01/12/02
Posts: 1478
Loc: Holden, MA USA
Wendel, I have been in business for 12 years and have only needed to replace a VERY small amount. 2 or 3 total so I am not surprised they are not widely available. I just buy a can and take it out. I'll keep the socket from the can for future use.
Check a local lighting store. They may have damaged cans that they will let you take a sensor from.

[This message has been edited by Electricmanscott (edited 01-03-2006).]

#60480 - 01/03/06 01:27 PM Re: Thermal Protection Saga
DougW Offline

Registered: 06/08/03
Posts: 1083
Loc: North Chicago, IL
Check your local HVAC supplier for similar items as well - they're called "Klixons", IIRC- they're used as cutouts for forced air furnaces, and open when a pre-set temp is reached.

Not sure if they'll be able to find an identical match, but since ther are several types and models, it's worth a call.

#60481 - 01/03/06 02:27 PM Re: Thermal Protection Saga
hbiss Offline

Registered: 12/16/03
Posts: 893
Loc: Hawthorne, NY USA
I have to caution you not to take DougW's advice. An exact replacement is necessary to maintain the safe operation and listing of the fixture. Jury rigging is going to get you in trouble.

This may be the reason these things are not available for replacement. I suspect that the thermal protector is tailored to the fixture according to the max lamp wattage, etc. I don't believe that they are supposed to be replaced, instead you are supposed to replace the whole can.


#60482 - 01/03/06 03:36 PM Re: Thermal Protection Saga
LK Offline


Registered: 01/21/03
Posts: 1721
Loc: New Jersey
Hal, is giving good advice, failure to use the manufacture part, may void the listing.

#60483 - 01/03/06 05:17 PM Re: Thermal Protection Saga
wendel Offline

Registered: 08/07/04
Posts: 57
Hal, I agree about finding the exact replacement. It is a very common part as shown in this Leviton catalog file
Unfortunately this is also an OEM part which means I need to get it from Lightolier who doesn't seem to want to sell individual parts (can't imagine why)or I need to buy 500 of them. Since this part is in the junction box, it's far more sensible, cost effective and easier to replace the thermal protector than the whole light. From a consumer safety point of view I find it hard to believe this important safety device is so hard to come by. Again, thanks for you help.

#60484 - 01/03/06 05:28 PM Re: Thermal Protection Saga
Lostazhell Offline

Registered: 02/21/04
Posts: 1248
Loc: Bakersfield, CA (Originally Or...
Im gonna have to stick with Les and Hal on this one... Monkeying around with that thermal cutout isn't something I'd do personally without an OEM part spec'd from the can mfr... It's much easier to knock the old can into the ceiling space and install a cut-in can in its place than to devote hours into seeking a part.

Just FYI, have you made sure your bulb wattage is at or below the can's specified max wattage?
Have you tried an edison base fluorescent lamp in place of an incandescent bulb? they typically generate a fraction of the heat

If you do replace the can, make sure you get an IC rated can if it's going to be surrounded by insulation.

#60485 - 01/03/06 06:27 PM Re: Thermal Protection Saga
renosteinke Offline
Cat Servant

Registered: 01/22/05
Posts: 5305
Loc: Blue Collar Country
As I mentioned before, the fixtures are cheap. If you're not willing to replace the entire fixture....what's to keep you from buying a fixture just to get the part you need?

#60486 - 01/03/06 08:52 PM Re: Thermal Protection Saga
frenchelectrican Offline


Registered: 02/06/03
Posts: 938
Loc: Wi/ Paris France { France for ...
as far the resseced cans i useally just buy the whole work and use what you need to replace it becase the time to replace the safety cutoff thermal switch it will take more time than just swap the can all you have to do is slide it down and get in the Jbox and remove the bad can and hook up new can and slide it back up.

belive me it take far less time than just try to replace the **** thermal switch and less fustrating too

Merci , Marc
Pas de problme,il marche n'est-ce pas?"(No problem, it works doesn't it?)

#60487 - 01/03/06 10:59 PM Re: Thermal Protection Saga
caselec Offline

Registered: 04/14/02
Posts: 557
Loc: San Jose, CA
Lightolier does sell replacement thermal protectors and some Juno cans use the same device.

Lightolier part number = 1970
Juno part number = S599

As others said it is probably best to just purchase a new housing/frame instead of spending the time to find the replacement part. You should be able to find a 1002P1 or 1102P1 housing for less than $15.

Curt Swartz

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