Sensi Internal Component Overheating

Thermostat plastic housing feels unusually warm to the touch

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

High ambient temperature at wall cavity, Overloaded 24 V transformer feeding multiple devices, Internal short or failing component on Sensi PCB, Thermostat installed above heat‑producing equipment

How to Fix / Troubleshooting

Safety first: Turn off power to the HVAC system at the breaker before removing the thermostat from the wall. If you smell burning plastic, leave power off and contact a professional.

Steps to evaluate:

  • Check installation location: Ensure the thermostat is not mounted on a wall that backs up to a flue, hot water pipe, or other heat source.
  • Inspect wiring: Remove the thermostat and inspect for discolored or melted insulation on the low‑voltage wires.
  • Measure transformer load (advanced): If multiple devices share the 24 V transformer, an HVAC technician can verify that the VA rating is not exceeded.
  • Monitor temperature: After restoring power, lightly touch the thermostat after 30 minutes. Slight warmth can be normal, but hot to the touch is not.

When to replace: If the thermostat becomes hot or shows signs of melting or discoloration, discontinue use and replace it immediately. Have an HVAC technician verify the 24 V system.

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Repair Difficulty

Hard 4/5

Required Part

Sensi Smart Thermostat Main Control Assembly
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