Xiamen SET Electronics Co., Ltd.

The Direct Current Thermal-Link (Alloy Type) is defined as a non-resettable protective device functioning only once. It is widely used for over-temperature protection of electrical equipment and electric vehicles. The DC-ATCO primarily consists of a low melting point Thermal Element, Flux Resin, Case, Sealant, and Lead Wires. Normally, the Thermal Element is joined to the two lead wires. When the temperature reaches the fusing temperature of the Direct Current Thermal-Link (Alloy Type), the Thermal Element melts and quickly retracts to the two lead wire ends with the aid of the flux resin, disconnecting the circuit completely.

The SETsafe | SETfuse Direct Current Thermal-Link (Alloy Type) is classified into Axial and Radial shapes, with a Rated Functioning Temperature ranging from 76 °C to 230 °C, Rated Current from 10 A to 200 A, Rated Voltage from 60 VDC to 850 VDC, and it holds CCC CB Approvals. It is also RoHS and REACH compliant.

TCO

Thermal-Link

A non-resettable device incorporating a THERMAL ELEMENT which will open a circuit once only when exposed for a sufficient length of time to a temperature in excess of that for which it has been designed.

ATCO

Alloy Thermal-Link

Alloy Type Thermal-Link, Alloy is the thermal element.

DC-ATCO

DC-Alloy Thermal-Link

Direct Current Alloy Thermal-Link.

T_f

Rated Functioning Temp.

The temperature of the Alloy Thermal-Link which causes it to change the state of conductivity with a detection current up to 10 mA as the only load.

Tolerance: T_f 0/-10 °C (GB/T 9816, EN 60691, K60691).

Tolerance: T_f ± 7 °C (J60691).

Fusing Temp.

The temperature of the Alloy Thermal-Link which causes it to change its state of conductivity is measured with silicone oil bath in which the temperature is increased at the rate of 0.5 °C to 1 °C / minute, with a detection

current up to 10 mA as the only load.

T_h

Holding Temp.

The Maximum temperature at which a Thermal-Link will not change its state of conductivity when conducting rated current for 168 hours.

T_m

Maximum Temp. Limit

The temperature of the Thermal-Link stated by the manufacturer, up to which the mechanical and electrical properties of the Thermal-Link having changed its state of conductivity, will not be impaired for a given time.

I_min

Minimum Breaking Current

The minimum current that Fuse requires after the Alloy of Thermal-Link opens in the circuit.

I_r

Rated Current

The current used to classify a Alloy Thermal-Link, which is the Maximum current that Alloy Thermal-Link allows to carry and is able to cut off the circuit safely.

U_r

Rated Voltage

The voltage used to classify a Alloy Thermal-Link, which is the Maximum voltage that Alloy Thermal-Link allows to carry and is able to cut off the circuit safely.

Stud, Soldering

Radial, Axial

● Battery Cooling Systems

● Pre-charged Resistors

● Automotive Air-Conditioners

● Heaters

● EV Battery Modules

● Power Supplies

● Automatic Electronics

● High Power Solid State Relays

SETsafe | SETfuse Quality Policy

Provide Industry-Leading Products

Raw-materials Supplier

Select critical raw materials: Must be from a manufacturer with quality management system (ISO9001, IATF16949) certification.

Annual or Quarterly Audits.

IQC (Incoming Quality Check)

AQL(MIL-STD-105E), Dimensions, Function, Visual Inspection, RoHS & REACH Test.

Document

Formulate corresponding incoming inspection specifications (01-QA-06 Incoming Inspection Management Procedure) for each key materials according to design data such as material technical specification.

Testing Equipment and Tools

Projector, Tool Microscope, Salt Spray Tester, Universal Material Testing Machine, Spectrum Analyzer, etc.

Manufacturing Process

Online Inspection and Testing.

Document

Process Flow Chart.

Failure Mode and Effects Analysis (FMEA).

Quality Control Flow Chart (QCFC).

Inspection Specification for Process, Inspection Specification for Finished Good (SIP).

Work Instruction (WI).

Online Testing and Inspection

Resistance test system (100%).

100% Visual inspection.

etc.

IPQC (In Process Quality Control) Inspection

AQL(MIL-STD-105E), Dimensions Inspection, Function Test, Visual Inspection.

FQC ( Final Quality Control)

AQL(MIL-STD-105E), Dimensions Inspection, Function Test, Visual Inspection, RoHS & REACH Test.

Reliability Test

Test Specification (01-TE-01-xxx).

Including 26 items of Appearance Requirements, Temperature Characteristics, Electrical Performance, Mechanical Performance, Soldering Performance, Environmental Test and Life Test. e.g.

Rated Functioning Temperature Test.

Holding Temperature Test.

Internal Resistance Test.

Insulation Resistance Test.

Interrupting Current Test.

etc.

OQC (Outgoing Quality Control)

AQL(MIL-STD-105E), Packaging, Labeling, Quantity Inspection.

Agency

Agency (IATF16949 TUV) Annual Audits.

Management System

IATF16949, ISO9001 (TUV approved and issued certificate).

ISO14001, ISO45001, etc.

Click to view the certificate

Environmental

RoHS & REACH Compliant.

SETsafe | SETfuse

Usage

1. When atmosphere pressure is from 80 kPa to 106 kPa, the related altitude shall be from +2000 m to - 500 m.

2. Operating voltage less than rated voltage of DC-ATCO, operating current less than rated current of DC-ATCO.

3. Do not touch the DC-ATCO body or lead wires directly when power is on, to avoid burn or electric shock.

Replacement

DC-ATCO is a non-repairable product. For safety sake, it shall be replaced by an equivalent DC-ATCO from the same

manufacturer, and mounted in the same way.

Storage

Do not store the DC-ATCO at the high temp., high humidity or corrosive gas environment. The product shall be stored at 25 ± 5 °C and ≤ 70% RH, avoid direct sunlight and shall use them up within 1 year after receiving the goods.

Installation

Make Sure the Temp. of Installation Position

1. It is recommended that a dummy DC-ATCO with inbuilt thermo-couple shall be used to determine the proper temp.

2. The terminal product should be tested to ensure that potential abnormal conditions do not cause ambient temp. to exceed the Tm of the DC-ATCO.

3. Mount the DC-ATCO at the location where Temp. rises evenly.

Installation position of mechanical performance requirements.

1. Ensure that the electrode lead is long enough, and avoid actions such as press, tensile or twist.

2. The seal or body of DC-ATCO must not be damaged, burned or over heated.

Mechanical Connection

Riveting

Suitable for the stranded conductor diameter (d) of DC-ATCO ≥1.2 mm.

1. Choose small resistivity riveting material and be riveted.

2. A flexible lead or lead with low resistance should be used to rivet the DC-ATCO.

3. Contact resistance should be minimal, Large contact resistance will lead to higher temp., DC-ATCO Functioning in advance.

Soldering

Hand-Soldering

1. Soldering should be carried out according to Table -1.

2. The thermal element of DC-ATCO is thermal element with low melting point, which is jointed with DC-ATCO electrode lead. Improper soldering operation (too high soldering temp., too long soldering time etc.) may transfer more heat  to the thermal element and DC-ATCO may open in advance.

3. When soldering conditions are more severe than those listed in Table -1, a heat sink fixture should be used between soldering point and DC-ATCO body.

4. When soldering, please do not pull / push or twist DC-ATCO body or stranded conductor.

5. After soldering, let it naturally cool for longer than 20 sec. During cooling, never move the DC-ATCO body or stranded conductor.

TABLE -1 Hand-Soldering Time

SETsafe | SETfuse

SET

Thermal-Link(DC-ATCO) Catalog

View PDF