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Temperature
Controller
Basics
Handbook
The copyrights in this document are owned by Danaher Industrial Controls Group. All rights reserved.
Unauthorized reproduction of this handbook or the software in the controllers or recorders may result
in imprisonment of up to one year and fines of up to $10,000 (17 U.S.C. 506). Copyright violators may
be subject to civil liability.
There are two fundamental types of temperature control; open loop and
closed loop control. Open loop is the most basic form and applies continuous
heating/cooling with no regard for the actual temperature output. It is analo-
gous to the internal heating system in a car. On a cold day, you may need to turn
the heat on to full to warm the car to 75°. However, during warmer weather, the
same setting would leave the inside of the car much warmer than the desired 75°.
Closed loop control is far more sophisticated than open loop. In a closed
loop application, the output temperature is constantly measured and adjusted
to maintain a constant output at the desired temperature. Closed loop control
is always conscious of the output signal and will feed this back into the control
process. Closed loop control is analogous to a car with internal climate control.
If you set the car temperature to 75°, the climate control will automatically adjust
the heating (during cold days) or cooling (during warm days) as required to
maintain the target temperature of 75°.
Summing
Junction
Setpoint Error
Controller Amp Output
Sensor
Feedback
Temperature Controller Basics Handbook
Introduction
A temperature controller is a device used to hold a desired temperature at a
specified value.
Heat Treat/Oven
Temperature controllers are used in ovens and in heat-treating applications
within furnaces, ceramic kilns, boilers, and heat exchangers.
Controller Basics
Packaging
In the packaging world, machinery equipped with seal bars, glue applicators, hot
melt functions, shrink wrap tunnels or label applicators must operate at desig-
nated temperatures and process time lengths. Temperature controllers precisely
regulate these operations to ensure a high quality product output.
Plastics
Temperature control in the plastics industry is common on portable chill-
ers, hoppers and dryers and molding and extruding equipment. In extruding
equipment, temperature controllers are used to precisely monitor and control
temperatures at different critical points in the production of plastic.
Healthcare
Controllers are used in the healthcare industry to increase the accuracy of tem-
perature control. Common equipment using temperature controllers includes
laboratory and test equipment, autoclaves, incubators,
refrigeration equipment, and crystallization growing
chambers and test chambers where specimens must be
kept or tests must be run within specific temperature
parameters.
Inputs
Temperature controllers can have several types of inputs. The type of input
sensor and signal needed may vary depending on the type of controlled pro-
cess. Typical input sensors include thermocouples and resistive thermal devices
Temperature Controller Basics Handbook
(RTD’s), and linear inputs such as mV and mA. Typical standardized thermo-
couple types include J, K, T, R, S, B and L types among others.
Outputs
In addition to inputs, every controller also has an output. Each output can be
used to do several things including control a process (such as turning on a heat-
ing or cooling source), initiate an alarm, or to retransmit the process value to a
programmable logic controller (PLC) or recorder.
Another type of output is an SSR driver. SSR driver outputs are logic outputs
that turn a solid-state relay on or off. Most solid-state relays require 3 to 32VDC
to turn on. A typical SSR driver turn-on signal of 10V can drive three solid-state
relays.
Controller Basics
A triac provides the relay function without any moving parts. It is a solid-
state device that controls currents up to 1A. Triac outputs may allow some small
amount of bleed current, usually less than 50mA. This bleed current doesn’t
affect heating contactor circuits, but it may be a problem if the output is used to
connect to another solid-state circuit such as a PLC input. If this is a concern, a
standard relay contact would be a better choice. It provides absolute zero current
when the output is de-energized and the contacts are open.
Analog outputs are provided on some controllers which put out a 0–10V signal
or a 4–20mA signal. These signals are calibrated so that the signal changes as a
percentage of the output. For example, if a controller is sending a 0% signal, the
analog output will be 0V or 4mA. When the controller is sending a 50% signal,
the output will be 5V or 12mA. When the controller is sending a 100% signal, the
output will be 10V or 20mA.
Other Parameters
Temperature controllers have several other parameters, one of which is a set-
point. Basically, a setpoint is a target value set by an operator which the controller
aims at keeping steady. For instance, a setpoint temperature of 30° C means that
a controller will aim to keep the temperature at this value.
The controller can also test for a broken output device, such as an open heat-
ing element, by checking the amount of output signal and comparing it to the
amount of detected change in the input signal. For example, if the output signal
is 100% and the input sensor does not detect any change in temperature after a
certain time period, the controller will determine that the loop is broken. This
feature is known as Loop Alarm.
Temperature Controller Basics Handbook
Process Variable
Process Variable
DEVIATION
HIGH ALARM
Alarm Hysteresis Value
Setpoint
Process Variable
Controller Basics
For example, if the setpoint is 150° and the deviation alarms are set at ±10°,
the alarms would be activated when the temperature reached 160° at the high
end or 140° at the low end. If the setpoint is changed to 170°, the high alarm
would activate at 180° and the low alarm at 160°.
How it Works
All controllers, from the basic to the most complex, work pretty much the same
way. Controllers control, or hold, some variable or parameter at a set value. There
are two variables required by the controller; actual input signal and desired set-
point value. The input signal is also known as the process value. The input to the
controller is sampled many times per second, depending on the controller.
This input, or process, value is then compared with the setpoint value. If the
actual value doesn’t match the setpoint, the controller generates an output signal
change based on the difference between the setpoint and the process value and
whether or not the process value is approaching the setpoint or deviating farther
from the setpoint. This output signal then initiates some type of response to
correct the actual value so that it matches the setpoint. Usually, the control algo-
rithm updates the output power value which is then applied to the output.
The control action taken depends on the type of controller. For instance, if
the controller is an ON/OFF control, the controller decides if the output needs
to be turned on, turned off, or left in its present state.
Temperature Controller Basics Handbook
Unlike ON/OFF control, PID control determines the exact output value
required to maintain the desired temperature. The output power can range from
0 to 100%. When an analog output type is used, the output drive is proportional
to the output power value. However, if the output is a binary output type such as
a relay, SSR driver, or triac, then the output must be time proportioned to obtain
an analog representation.
A time proportioned system uses a cycle time to proportion the output value.
If the cycle time is set to 8 seconds, a system calling for 50% power will have the
output on for 4 seconds and off for 4 seconds. As long as the power value doesn’t
change, the time values wouldn’t change. Over time, the power is averaged to the
50% commanded value, half on and half off. If the output power needed to be
25%, then for the same 8 second cycle time, the output would be on for 2 seconds
and off for 6 seconds.
Off = 4s On = 4s
100% 100%
0% 0%
All things being equal, a shorter cycle time is desirable because the control-
ler can more quickly react and change the state of the output for given changes
on the process. Due to the mechanics of a relay, a shorter cycle time can shorten
the life of a relay, and is not recommend to be less than 8 seconds. For solid state
switching devices like an SSR driver or triac, faster switching times are better.
Longer switching times, no matter what output type, allow for more oscillation in
the process value. The general rule is that, ONLY if the process will allow it, when
a relay output is used, a longer cycle time is desired.
Additional Features
Controllers can also have a number of additional optional features. One of these
is communication capability. A communication link lets the controller communi-
cate with a PLC or a computer. This allows data exchange between the controller
Controller Basics
and the host. An example of typical data exchange would be the host computer
or PLC reading the process value.
Another common feature is a digital input. The digital input can work togeth-
er with a remote setpoint to select the local or remote setpoint for the controller.
It can also be used to select between setpoint 1 and setpoint 2 as programmed in
the controller. Digital inputs can also remotely reset a limit device if it has gone
into the limit condition.
Types of Controllers
Temperature controllers come in many different styles with a vast array of
features and capabilities. There are also plenty of ways to categorize controllers
according to their functional capabilities. In general, temperature controllers
are either single loop or multi-loop. Single loop controllers have one input and
one or more outputs to control a thermal system. On the other hand, multi-loop
controllers have multiple inputs and outputs, and are capable of controlling
several loops in a process. More control loops permit controlling more process
system functions.
Temperature Controller Basics Handbook
Reliable single loop controllers range from basic devices that require single
manual setpoint changes to sophisticated profilers that can automatically execute
up to eight setpoint changes over a given time period.
Analog
The simplest, most basic controller type is the analog
controller. Analog controllers are low cost, simple control-
lers that are versatile enough for rugged, reliable process
control in harsh industrial environments including those
with significant electrical noise. Controller display is typi-
cally a knob dial.
Limit
These controllers provide safety limit control over process temperature. They
have no ability to control temperature on their own. Put simply, limit control-
lers are independent safety devices to be used alongside an existing control
loop. They are capable of accepting thermocouple, RTD, or process inputs with
limits set for high or low temperature just like a regular controller. Limit control
is latching and part of redundant control circuitry to positively shut a thermal
system down in case of an over-limit condition. The latching limit output must
be reset by an operator; it will not reset by itself once the limit condition does not
exist. A typical example would be a safety shut off for a furnace. If the furnace ex-
ceeds some set temperature, the limit device would shut the system down. This is
to prevent damage to the furnace and possibly any product that may be damaged
by excessive temperatures.
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Controller Basics
outputs, and programmable output functions. These
controllers can also perform PID control for excel-
lent general control situations. They are traditionally
placed in the front panel with the display for easy
operator accessibility.
Profile
Profiling controllers, also called ramp-soak controllers, allow operators to pro-
gram a number of setpoints and the time to sit at each setpoint. Programming
a setpoint change is called ramp and the time to stay at each setpoint is called
soak or dwell. One ramp or one soak is considered to be one segment. A profiler
offers the ability to enter a number of segments to allow complex temperature
profiles. The profiles can be referred to as recipes by the operator. Most profilers
allow storage of multiple recipes for later use. Smaller profilers may allow for four
recipes with sixteen segments each with more advanced profilers allowing for
more recipes and segments.
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Temperature Controller Basics Handbook
Multi-Loop
Besides single-loop controllers which can
control only one process loop, multi-loop
controllers can control more than one
loop, meaning they can accept more than
one input variable.
12
Controller Basics
longer than 8˝. They also reduce wiring by having a common connection point
for power supply and communications interfaces.
Size
Controllers come in several standard sizes that are referred to by DIN numbers
such as 1/4 DIN, 1/8 DIN, 1/16 DIN and 1/32 DIN. DIN is an acronym for the
roughly translated “Deutsche Institut fur Normung,” a German standards and
measurements organization. For our purposes, DIN simply indicates that a device
complies with a generally accepted standard for panel dimensions.
92mm
+0.5 –0.0
92mm (45mm
+0.5 –0.0
for 45mm
indicator) +0.5 –0.0
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Temperature Controller Basics Handbook
The smallest size is the 1/32 DIN, which is 24mm × 48mm, with a correspond-
ing panel cutout of 22.5mm × 45mm. The next size up is the 1/16 DIN which
measures 48mm × 48mm with a panel cutout size of 45mm × 45mm. The 1/8
DIN is 48mm × 96mm with a 45mm × 92mm panel cutout. Lastly, the largest size
is the ¼ DIN measuring 96mm × 96mm with a 92mm × 92mm panel cutout.
It is important to note that the DIN standards do not determine how deep
a controller may be behind a panel. The standards only allow for front panel
dimensions and panel cut-out dimensions.
Agency Approvals
It is desirable for a temperature controller to have some sort of agency approval
to ensure that the controller meets a minimum set of safety standards. The type
of approval depends on the country in which the controller will be used. The
most common approval, UL and cUL registration, applies to all controllers used
in the U.S. and Canada. Usually, there is one certification required for each
country.
A third type of approval is FM. This applies only to limit devices and for con-
trollers in the U.S. and Canada.
14
Controller Basics
means they can be used in applications requiring water washdown only (not oils
or solvents). The ‘X’ in a NEMA 4X rating means that the front panel won’t cor-
rode. NEMA ratings are used primarily in the U.S. and Canada.
Controllers
For over 75 years, PMA has been active in developing
leading-edge digital and electronic process and multi-
function controllers and solutions for measurement
and control. Partlow offers an equally expansive line
of process controllers and circle chart temperature
recorders equipped with diverse state-of-the-art capa-
bilities. West offers the broadest line of versatile and
affordable temperature and process controllers for the
European and Asian marketplace. Compact Hengstler controllers are trusted
for their ease of operation, value and short lead times. All are reputable and rec-
ognized world brands that are part of an expanding family of Danaher process
automation controls available around the globe and locally supported.
Counters
No company offers a broader selection of counters, timers, and indicators. Our
Veeder-Root™ brand, the best-known name in counting, offers rugged and
economical mechanical and electric totalizing counters. Veeder-Root also offers
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Temperature Controller Basics Handbook
Encoders
DICG industrial encoders and resolvers span applica-
tions from heavy duty/mill-duty to light-duty office
and assembly line applications. From the strengths of
our Dynapar™, Hengstler™ and NorthStar™ brands,
we offer more than 45 types of encoders to provide
speed, linear movement and position measurement in
diverse applications. Our Harowe™ brand resolvers are
the first choice for feedback in adverse operating conditions involving extreme
temperature, high shock and vibration and dirty environments. Rugged, noise
resistant, and brushless, these resolvers are trusted for non-stop performance in
tough conditions.
Recorders
Reliable Partlow and Rustrak™ brand strip and circle
chart recorders provide rugged, reliable and versatile
control of your process applications. From quality vali-
dation, trend analysis and product safety applications,
DICG recorder products offer an excellent value while
providing the benefit of a paper document record of
process results for traceability.
16
Controller Basics
control timers, we offer a full range of panel mount, reset and repeat cycle timers
as well as time delay and general purpose relays.
17
Customer Service: +1 800.390.6405
Application Support: +1 800.866.6659
www.pma-online.de
www.partlow.com
www.westinstruments.com
© 2005 Danaher Industrial Controls Group
Controller Basics Handbook
P/N# CBH200 (7/05) 10M