TopChiller Temperature Controller Unit Manufacturer and Supplier

Temperature Controller Unit-An Ultimate Buying Guide by TopChiller.

Steelmaking, food, furniture, plastic, and polymer, etc. are some examples of industries that use temperature for production.

In these processes, a Temperature Controller Unit is a heating device that controls and regulates the temperature.

In case you want to increase the temperature of the process to a specific point, or vice versa.

In case you want to raise temperature to a specific point and make it stay there for some specific time.

It can increase, decrease, or keep temperature fixed at a set-point value.

The Temperature Controller Unit has a wide range of innovative features which make the process more accurate, easy, and safe.

This comprehensive article covers basic components, like types, features, safety measures, working mechanisms, and FAQs.

What is a Temperature Controller Unit?

In industries around the world, temperature control and regulation can be one of the most important parameters of success and it is achieved by using a proper Temperature Controller Unit.

Temperature Controller Unit is a heating device that is used to regulate the needed temperature and hold the temperature on a particular point

The most basic function of it is to regulate a heater or heating system or any other temperature-based equipment.

All you have to do is to set a point and changes before the process. The Temperature Controller Unit will regulate the whole heating according to your desired specifics.

There is a wide range of controllers are used in industries to regulate the various operational parameters.

The modern Temperature Controller Unit comes with several features that are very beneficial for your industry. These features may differ with different types of it.

When it comes to the selection of the most suitable one for your industry, these features act as the parameters of the selection.

The most common example is the heating thermostat used in houses.

You can keep your Temperature Controller Unit working at its maximum efficiency by following several maintenance strategies and techniques.

These techniques are easy and can be followed by anyone.

Let’s take an example of a simple water heater device. This device contains a small Temperature Controller Unit that holds your desired heating temperature and does your job.

What are the Different Types of Temperature Controller Unit?

Temperature Controller Unit comes in a wide range of designs and types. All the types differ from each other in some specific features.

Every Temperature Controller Unit uses an input signal.

To receiver and decode the signal sensors are used.

These input signals and their corresponding sensors may differ from each other depending upon the type of process in which these are being used.

Some of the most common sensors are; RTDs, thermocouple-based sensors, linear input sensors, etc.

The different Temperature Controller Unit is used to regulate a different range of voltages and currents. These ranges can be from millivolts to kilovolts or milliamp to amperes.

These features are added to make your desired job fulfilled. When grouped it can be classified into three different types.

These are the On-Off Unit, Proportional Unit, and Proportional Integral Derivatives (PID) Unit.

1. On-Off Unit:

This one is the simplest Temperature Controller Unit of all types. Its output is on or off.

When a particular point of temperature (set-point) is reached, it will give output as on or off.

This type is used where accuracy is not the problem. It is used in processes where a range of temperatures can be allowed.

2. Proportional Unit:

It is used where a stable set-point temperature is required. Unlike, On-Off Temperature Controller Unit, it does not operate on-off.

In this controller when a specific point of temperature is reached, it will hold that set-point for a specified time.

This type of controller is more accurate than the On-Off temperature controller unit.

3. Proportional Integral Derivatives (PID) Unit:

PID is the combination of a proportional Unit with two other features.

These features are integral control and derivative control. It is used where a high level of automation and is needed.

PID Unit automatically adjusts with the alterations in the system, hence giving out the highest range of accuracy.

What is the Importance of Temperature Controller Unit for your Industry?

A wide range of industrial processes needs temperature regulations on regular basis.

These processes are responsible for producing various vital products for the survival of human beings.

In these processes, temperature regulation is must be constant and precise. For example, you are producing some product that needs to be treated at a specific temperature for 3 days.

In case of slight variation in the temperature can jeopardize the whole production. Apart from the product, there are other losses too.

These losses include loss of capital, loss of time, and resources.

In these types of crucial situations, a Temperature Controller Unit is the only solution left for every industry.

It is the sole technology that can keep your process stable and efficient.

These can be used in several situations like, heating, cooling, keeping specific temperature (set-point), or a combination of these all.

The Temperature Controller Unit is the barrier that keeps your process at a particular temperature, coping with the variations in environmental temperature and conditions.

Keeping a particular temperature while coping with altering environmental conditions is crucial for many industrial processes.

Especially, for laboratories, and research facilities where a system is needed to be kept at controlled temperatures for a specific period.

What are the Main Features of a Temperature Controller Unit?

These features are desired by the concerned industry to complete their processes efficiently.

These days everything is getting innovative with advanced features day by day.

Temperature Controller Unit technology has some advanced features too that are very helpful for the users.

The Temperature Controller Unit is one of the controllers that is used to regulate the flow of temperature to achieve maximum efficiency for the process.

These features are made to make processes efficient, economic, and easy.

Some of the common features are a digital monitor, connectivity to PC, safety alarms, notification system, etc.

Following discussed are some of the most common features of the Temperature Controller Unit.

• Communication With Other Devices:

This feature is the most desired one. By having this feature, a Temperature Controller Unit will be able to connect to other devices, especially a computer or laptop.

This makes the designing of the process, much easier. It is connected to a laptop or PC, and you can govern all the operations.

Another advantage of this feature is the monitoring of the process. By using these features, you can monitor the process in deeper detail constantly.

You can easily transfer and store all the data time by time, using this feature.

These features also help you to keep entire process readings and records safe in your storage device, PC, etc.

• Long-distance Control:

This is one of the most advanced features.  This feature allows you to control and change the specific temperature (set-point) remotely from distance.

You can connect the Temperature Controller Unit to your PC and control the set-point. Control distance and range of signals may change with some different designs.

These features make control more easy and safe. Operating devices from distance will surely decrease unwanted accidents.

In case you are busy in another room or office, you can control the Temperature Controller Unit easily sitting relaxing on your chair.

• Configuration Control:

You can connect its internal setting and data to a PC.  By using particular design software on the PC, you can design, alter and control the process temperature.

By using this feature, one can design desired set of structures to achieve higher process efficiency.

• Display Feature:

Nowadays almost every Temperature Controller Unit is coming with an output screen display.

On this screen, you can monitor and in some cases, change temperature.  You can monitor alteration graphs of temperature and other details.

Different readings are colored differently so that one can identify and study the process in more detail.

• Notification Alarm System:

This feature notifies you when a specific process is completed or a particular state of the process is reached.

A most common way to notify is to make an alarm noise. It also contains colored lights. Every light indicates to specific code of the process.

When a particular state is reached, concerning light will notify you. One of the desirable things about this feature is safety.

In case of an accident or unfortunate situation, this alarm feature will notify you so that proper action can be taken.

• Voltage Supply:

This one is the most feature of every Temperature Controller Unit.  Either it is low voltage or high voltage. Low voltage means 24VAC/DC and high voltage refers to 110-230VAC.

• Size of Unit:

This one is the most basic and considered feature. The standard size of any Temperature Controller Unit is a very crucial factor in its performance.

The most common standard sizes come as DIN number codes. These are 1/4, 1/8, 1/16, and 1/32 DIN sizes. DIN refers to Deutsche Institute for Normung.

This is a German standard for evaluating the size of any Temperature Controller Unit.

DIS standard is compared to the panel measurements and its suitability for the process is evaluated.

• Legal Approvals from Agencies:

This feature is a unique one as it has nothing to do with the performance of the Temperature Controller Unit.

Although is vital for the industry to have standards for safety.

These approvals refer to the certifications and approval given to the company that is manufacturing a Temperature Controller Unit.

These approvals ensure that controller meets the standards for safety.

Agencies, approvals, and types of approvals differ from nation to nation.  In the USA UL approvals are used, and so on for different nations.

What are the Major Applications of Temperature Controller Unit?

It is used in almost every industry around the world.

This equipment has become a crucial part of the industry nowadays.

From food and health or academia and manufacturing, every industry relies on a Temperature Controller Unit for the efficiency of the process.

Following are some of the examples of industries, where it is used.

• Heat Treatment Industries:

All the industries where heat treatment is the basic part of the process use the Temperature Controller Unit as a vital part of their industry.

These include steel-making industries, furnaces, car, and vehicle manufacturing industries, boiler manufacturing, molding industries, etc.

In these industries, a Temperature Controller Unit is used to maintain a stable temperature for processes with high accuracy.

• Research Faculties Around the World:

Either it is a small level research laboratory or a big one, temperature control is very crucial.

Many research experiments needed to be conducted at a controlled range of temperatures. This job is efficiently done by any suitable Temperature Controller Unit.

• Packaging Industries:

The packing industry’s processes highly rely on temperature.

Sealing, applying glues, melting polymers, shaping caps and bottles, labeling, etc is the process completed under temperature control conditions.

• Polymer Industries:

Making different kinds of polymers and plastics is all above temperature and melting.

Shaping and molding of almost all plastic products require melting at a specific temperature.

Some of the common processes in plastic industries where a Temperature Controller Unit is used are; melting, molding, extrusion, chillers, and quenching, etc.

In packaging industries, it is highly crucial and the quality of a product depends upon its performance efficiency.

• Medical and Healthcare Industries:

A large number of medical treatment process depends upon temperature control.

Apart from treatment, the Temperature Controller Unit is also used in various medical instruments in a laboratory.

Autoclaving of waste and instruments, heat-based curing processes, heat chamber, etc are processes of heat control.

• Food Industries:

Food industries are the industries of cooking at suitable heat.

A food product’s taste and quality highly depend upon the cooking temperature control.

Processes like backing, heating, melting, drying, sterilization and autoclaving, etc are processes where a Temperature Controller Unit is used.

How to Select a Proper Temperature Controller Unit for your Industry?

The secret to its optimum performance highly depends upon the selection of the proper device.

Choosing the most suitable Temperature Controller Unit can be a tough job and requires enough homework.

One should know completely about the process in which it is going to be installed.

After the know-how of the process, you should proceed toward the selection of the Temperature Controller Unit.

The type and number of features desired in it may differ from industry to industry.

Following are some of the most common features desired by all industries.

A proper selection of the Temperature Controller Unit can be made based on the following features.

1. Input Sensor:

The type and range of the input sensor may change according to the different requirements.

You should know which type of input sensor is suitable for your process.

Either it is Thermocouple based sensor, or linear. It may be the combination of the former and the latter.

2. Temperature Range:

There is some Temperature Controller Unit for different temperature ranges.

Select the one which operates within your desired temperature range.

3. Accuracy:

Every type of Temperature Controller Unit differs inaccuracy from another.

A simple On-Off temperature controller is selected when low accuracy is needed.

The proportional Unit is more accurate in readings than the On-Off unit.

PID unit is the most accurate one among all the types.

One should know the range of accuracy needed for the process and then go for the selection of a Temperature Controller Unit.

4. Safety Standards:

Safety is a necessary factor while selecting any instrument. In this case, safety is a factor of selection.

One should select the temperature controller with standard safety approvals from concerned agencies.

It should possess safety measures and considerations established by international or national agencies.

For example, it should not produce noise above safe levels.

What is the Fundamental Working Principle of a Temperature Controller Unit?

The basic mechanism of work behind every Temperature Controller Unit is the same.

From the simplest of it like; On-Off to the most complicated one like; PID unit, all resembles the basic principle of work.

The most vital parameters required for the chilling performance are the input signal value and specific point of temperature.

Input signal value is very necessary for the process to proceed and is often called the “process parameter” or “process value”.

The basic mechanism is to compare the input signal value to the desired specific value of temperature and generate an output signal based on that comparison.

This output signal is the action that is to be taken by a Temperature Controller Unit to reach a specific point of the temperature.

After the basic mechanism is completed, it proceeds to the next level process.

The next process is to follow particular action after reaching a specific value of the temperature.

This action differs for each kind of Temperature Controller Unit.

In an On-Off unit, after reaching the set-point of temperature, is either switch to on or off.

On the contrary, in a PID unit, after reaching a set-point it maintains that point of temperature for the desired period.

What are the Installation Instructions for Temperature Controller Unit?

Proper installation is very necessary for it to operate properly.

Every Temperature Controller Unit comes with specific installation guidelines provided by the manufacturing company.

Almost all the installations are mechanically by the experts.

Below mentioned are some of the most common mechanical installation instructions that can be applied to almost every Temperature Controller Unit.

-Before the installation, do a detailed inspection of the device. In case of any fault instantly replace a device with the proper one to save your time and energy.

• Follow the instructions provided by the manufacturer to open screws, straps, and other parts.
• Choose a suitable, location for the installation.
• Install the Temperature Controller Unit and give it a try.
• Fix it on location tightly. Don’t fix it loosely.
• Fix noise-proof soft pads in between the ground and for a proper tight fit.
• Make a test run to check if it is working properly.
• Note down the chilling Flow Rate, Speed, and other parameters to analyze its efficiency.
• When everything is ready, apply it to the process.

What are the Major Safety Guidelines while Operating a Temperature Controller Unit?

The safety of the process and the people working is very crucial for every industry.

In the case of a Temperature Controller Unit, a certain amount of safety measures and guidelines are necessary to be followed.

Following are the major safety measures that are necessary for it.

• Do no longer use the Temperature Controller Unit within the following places:

Locations uncovered radiations and heat waves from heating appliances.

Locations are subject to direct daylight.

Locations that are exposed to mist, dirt, and certain gases (particularly, sulfide gasoline and ammonia fuel).

Places where high-temperature fluctuations are expected to occur.

Places with a high amount of noise and vibration exposure.

• Use and keep it inside the rated temperature or humidity range suitable for every model.
• While one or more than one Temperature Controller Unit is installed horizontally close to each different or vertically next to one another, the inner temperature will increase. It happens due to the heat content they radiate.
• In such cases, pressured cooling by different means of airflow may be required to calm down the temperature controllers.
• Permit sufficient space around the temperature controller to make certain right heat release.
• Do does not block the ventilating holes. Make sure to wire nicely with the accurate polarity of terminals.
• After wiring is finished, do not pull on or bend a terminal block.
• Make certain that the power supply voltages and loads are installed within safe ranges before the usage of the
• Make sure that the desired voltage is attained within two seconds of turning the electricity on.
• Permit a minimum of 30 seconds extra for the temperature controller to heat up.
• When the use of self-tuning, turn on energy for the load (e.g., heater) at the same time as or earlier than starting power to the Temperature Controller Unit.
• Turn off the power before drawing out the temperature controller frame.
• Use alcohol to smooth the temperature controller. Do now not use thinner or other solvent-based substances.
• Wear heat-resistant and electric shock-resistant gloves while repairing a Temperature Controller Unit.

What are the Common Errors while Handling and Running a Temperature Controller Unit?

Following are the most common and dangerous errors that must be avoided while operating a Temperature Controller Unit.

1. Improper Installation of sensor:

If a case of this error the temperature errors can occur in wide ranges.

A wide range of temperature errors will make the whole process and its efficiency unvalued.

2. Incorrect programming at the initial level:

Any type of faulty programming of the Temperature Controller Unit system will cause an incorrect display. You won’t be able to get desired set of values or results.

3. Operating it beyond the safety range:

Excessive use of it for a prolonged period can be fatal.

Using it beyond the safe limit of time and voltage will break the whole system. It will face failure and will cost you a huge loss.

4. Not following safety guidelines and standards:

Operating a Temperature Controller Unit while ignoring all the safety measures can be fatal for the process.

It can cause unwanted accidents. It can cause harm to people and the efficiency of the process.

How to Maintain Your Temperature Controller Unit for a Long-lasting Performance?

A sudden failure of its whole system or some of any parts can result in a huge loss for your company.

This loss can be a loss of money, time, energy, and resources. You might have to spend a lot of money to repair your Temperature Controller Unit.

In the worst cases, you might have to buy a new one and replace the old ones.

To avoid all the losses, you should follow the below major maintenance guidance so that your Temperature Controller Unit can last longer.

1. You should inspect wires, joints, and other electric parts on daily basis. This inspection should be done before the start of the process.
2. In case of extreme environmental conditions, keep your Temperature Controller Unit covered.

Several measures can be used to cool the temperature around it.

3. Under extreme moist weather conditions, keep it covered with a waterproof cover.

The cover should be transparent enough so that you can monitor the display meter of the Temperature Controller Unit.

4. In case of failure of any part, replace it as soon as possible.
5. Keep it clean all the time. Frequent cleaning should be made on regular basis to avoid the accumulation of dust.
6. Maintenance work should be done on a monthly or weekly basis.
7. Frequent and proper monitoring of the Temperature Controller Unit will make your device last longer and allow a smooth efficient process.

Regular maintenance work will make it perform efficiently. In case of any small level of repair, get it repaired instantly.

8. Minor faults can become big disasters in the future, and regular repair work will save you from facing any long-term disaster.
9. Replace the old, used part with new ones.

FAQ of Temperature Controller Unit.

What does “Hysteresis” in Temperature Controller Unit?

On/off control action turns the output on or off based on the set point.

The output frequently changes in step with minute temperature adjustments as a result.

This shortens the existence of the output relay or unfavorably impacts a few devices related to the temperature controller.

To save this from taking place, a temperature band referred to as hysteresis is created between the on and rancid operations.

What is Meant by “Self-Tuning” of Temperature Controller Unit?

With self-tuning, the controller itself determines the start of tuning and tuning is viable without disturbances within the temperature being managed.

What does the Term “Hunting” and “Overshooting” Mean linked with Temperature Controller Unit?

On/off control motion often entails the waveform shown in the following diagram.

A temperature upward pushes that exceeds the set factor after temperature management starts evolved is referred to as overshoot.

Temperature oscillation close to a specific point of temperature (set-point) known as looking.

Advanced temperature control is to be expected if the degree of overshooting and looking are low.

What is a “Thermocouple” and its Role in the Temperature Controller Unit?

Thermocouple temperature sensors are built using two diverse metals which might be joined together.

Thermocouple temperature sensors can measure the best temperatures among contact temperature sensors via using this dimension technique.

Why Sometimes a Huge Error in Temperature Occurs in a Temperature Controller Unit?

This error is most probably due to the failure of the input sensor.

Sometimes, the sensor or some part of the sensor gets old or failed accidentally. This failure results in faulty results.

Is Temperature Controller Unit Waterproof?

Almost all of its parts come with waterproof features.

Not all devices are waterproof. One can cover a temperature controller with a suitable cover and make it waterproof.

Why Sometimes the Temperature Controller Unit Make the Buzzy Sound?

It is possible due to loose parts. Over time, some internal parts of a temperature controller may get loosen and while operating make a sound.