is to go with a redundant system. All proportional and a lot of the non proportional thermostats have the output controlled by turning on and off a triac. This is a solid state component with no moving parts so the chance of failure is very low but with any electronic component the chance is there. If this component does fail it can fail in the on state. This is not something that can be controlled by the thermostat manufacture other than using the highest quality and overrated components to lessen the possibilities. Some on/off thermostat like the Rancos and Johnson Controls use a relay to turn on and off the voltage. The relay is a mechanical switch that can also fail under rare circumstances. Your best bet is to use a good proportional thermostat as your main and a relay based as a backup…
Here is a post from Dion at Spyderrobotics I found on the Bob Clark forum that discusses basically the same thing just better….
“One thing to watch out for in the small cheap thermostats is heat. We all know heat is the killer of electronics and the majority of the under $50 thermostats (the one in question, 500r units, ect) use what is called a Triac. All the wattage runs through this component and is the same component used in proportional thermostats. The difference is often the cheaper products use a component that is to spec but do not necessarily count for all the extra heat. Those have small packages with little room for circulation. When a Triac fails it has a high chance of failing in the on position. So keep an eye on the heat of the case and make sure the thermostat is mounted where it can get airflow. The cooler, the longer it will last. We take the other approach and assume the spec is not enough and overbuild everything to prevent this. Where a 5amp triac could be used we put in 15's. They take more heat and handle voltage spikes where others would fail. Its like having a Hemi in grocery wagon. You don't need it buts its nice to have just in case. Since the heart of the circuit is overbuilt we have the fuses there which should trip before something like this happens giving the much preferred "power off" failure. That being said I believe the ultimate setup is to have a relay based thermostat directly into the wall(think ranco or johnson controls, maybe us one day) and then a proportional thermostat plugged into it. This way should you ever have a lightning hit, voltage spike, or just a faulty component in the proportional (or any triac based thermostat) the old fashoned relay thermostat will take over and save the day.
Dion Brewington
Owner, Spyder Robotics”