Technical Explanation for Temperature Controllers

CSM_Temperature_TG_E_6_5

Introduction
What Is a Temperature Controller?

Sensors
A Temperature Controller is a device that is used to control a heater or other equipment by comparing a sensor signal with a set
point and performing calculations according to the deviation between those values. Devices that can handle sensor signals other
than for temperature, such as humidity, pressure, and flow rate, are called Controllers. Electronic controllers are specifically called
Digital Controllers.

Switches
Temperature Control
Temperature Controllers control temperature so that the (1) Response where the process value settles on the set
process value will be the same as the set point, but the point while repeatedly overshooting and undershooting

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response will differ due to the characteristics of the controlled
object and the control method of the Temperature Controller. Set point
Typically, a response shown in Figure (2), where the set point
is reached as quick as possible without overshooting, is
required in a Temperature Controller. There are also cases
such as the one shown in Figure (1), where a response
quickly increases the temperature even if it overshoots is Time
required, and the one shown in Figure (3), where a response (2) Proper response

Relays
slowly increases the temperature is required.
Set point

Control Components
Time
(3) Response where the process value slowly reaches the
set point

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Set point

Time

Motion / Drives
Temperature Control Configuration Example
The following example describes the basic configuration for temperature control.

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Environment Measure Equipment
• Relay output • SSR • Thermocouple
• Voltage output • Magnetic Switch • Platinum resistance thermometer
• Current output • Power Controller • Thermistor
Controlled object
Temperature Controller Power Supplies /
In Addition

Control output Controller

● Temperature Sensor
A temperature sensor measures the temperature
of the location where the temperature control is
required. It converts the temperature to a physical
quantity of a voltage or resistance and outputs
that.
Others

● Temperature Controller ● Controller

A Temperature Controller converts the output from a A controller is a magnetic switch that turns the current to
temperature sensor to the process value and outputs a heater ON and OFF, a valve that supplies fuel, or
the control output to the controller so the process some other type of device that is used to heat or cool a
value will approach the set point. furnace, tank, or other controlled object. If the output of
the Temperature Controller is a relay output, a relay may
also function as the controller.
Common

1
 Technical Explanation for Temperature Controllers

Temperature Controller Principle

Sensors
The following figure shows an example of a feedback control system used for temperature control.
The major parts of the feedback control system are built into the Temperature Controller. A feedback control system can be built
and temperature can be controlled by combining a Temperature Controller with a controller and temperature sensor that are
suitable for the controlled object.

Configuration of a Feedback Control System

Switches
Temperature Controller External disturbances
Manipulated
Deviation
variable Controlled variable
Set point Control Controlled
Controller
block object
Process value

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Measured variable
Temperature Sensor

Noise

Temperature Controller Configuration

Relays
Control block
Deviation
PID control Output
Set point Manipulated variable
ON/OFF control section
Process value

Control Components
Input section

Measured variable

Automation Systems
Characteristics of the Controlled Object
Before selecting a Temperature Controller or temperature sensor, it is necessary to understand the thermal characteristics of the
controlled object for proper temperature control.

Heat capacity ······· Heat capacity, which indicates the ease of heating, varies with the capacity of the furnace.

Motion / Drives
Static ······· Static characteristics, which indicate heating capability, vary with the capacity of the heater.
Characteristics characteristics
of the controlled
object Dynamic Dynamic characteristics, which indicate the startup characteristics (i.e. excessive response)
·······
characteristics of heating, vary with heater and furnace capacity that can affect each other in a complex way.

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External External disturbances cause temperature changes. For example, the opening or closing of a door on a
·······
disturbances constant temperature tank can cause external disturbances that generate temperature changes.

Power Supplies /
In Addition
Others
Common

2
 Technical Explanation for Temperature Controllers

Control Methods

Sensors
ON/OFF Control Action A narrow proportional band is set.

Control output
(%)
100 A wide proportional band is set.
As shown in the graph below, if the process value is lower
than the set point, the output will be turned ON and power will 50
be supplied to the heater. If the process value is higher than
the set point, the output will be turned OFF and power to the 0

Switches
heater will be shut off. This control method, in which the output
is turned ON and OFF based on the set point in order to keep Set point

the temperature constant, is called ON/OFF control action. A narrow proportional band is set.
Overshooting
With this action, the temperature is controlled using two
Set point
values (i.e., 0% and 100% of the set point). Therefore, the

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operation is also called two-position control action. Offset
Hunting
Characteristics of ON/OFF control action A wide proportional band is set.
Hysteresis
Set point Time

I Action (Integral Control Action)

Time
I action (or integral action) increases or decreases the

Relays
ON manipulated variable according to the size and duration of the
Heater
OFF deviation.
The temperature will stabilize at a temperature off from the set
point (offset) with only the proportional action, but the

Control Components
P Action (Proportional Control Action) deviation with the passage of time will be decreased and the
P action (or proportional control action) is used to output a process value will be the same as the set point by combining
manipulated variable (control output variable) that is the proportional and integral actions.
proportional to the deviation in order to decrease the deviation
Offset ceases to exist.
between the process value and set point. A proportional band

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is set centering on the set point, and the output is determined Set point

with the following rules. PI

Offset (proportional and
• A manipulated variable that is proportional to the deviation is integral control) action
output when the process value is within the proportional band. P
(proportional control)
• A 100% manipulated variable is output when the process action only

value is lower than the proportional band.

Time
• A 0% manipulated variable is output when the process
Control output

Motion / Drives
(%)
value is higher than the proportional band. 100

Smoother control than the ON/OFF control action is possible

50 A short integral time is set.
because the output is gradually changed near the set point
according to deviation. However, if the temperature is
0
controlled with the proportional action alone, it will stabilize at A long integral time is set.

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Environment Measure Equipment
a temperature that is off from the set point (offset). Time
A short integral time is set.
Control output

ON
100%
Set point
50%

0%
OFF A long integral time is set.
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In Addition

90°C Set point 100°C 110°C Temperature Time

Proportional
band
Note: If a Temperature Controller with a temperature range of 0°C to
400°C has a 5% proportional band, the width of the
proportional band will be converted into a temperature range of
20°C. In this case, a full output is kept turned ON until the
process value reaches 90°C, and the output is OFF periodically
Others

when the process value exceeds 90°C, provided the set point
is 100°C. When the process value is 100°C, there will be no
difference in time between the ON period and the OFF period
(i.e. the output is turned ON and OFF 50% of the time.)
Common

3
 Technical Explanation for Temperature Controllers

D Action (Derivative Control Action) Two PID Control

Sensors
D action (or derivative action) provides a manipulated variable Conventional PID control uses a single control block to control
in response to abrupt changes in the process value, due to the responses of the Temperature Controller to a set point and
factors such as an external disturbance, so that control will to external disturbances. Therefore, the response to the set
quickly return to the original status.The proportional and point will oscillate due to overshooting if importance is placed
integral actions both corrects the control results, so the on responding to external disturbances with the P and I
response to abrupt changes is delayed. The derivative action parameters set to small values and the D parameter set to a

Switches
compensates for that drawback and provides a large large value in the control block. On the other hand, the
manipulated variable for rapid external disturbances. Temperature Controller will not be able to respond to external
PD
disturbances quickly if importance is placed on responding to
(proportional and
derivative control) action
the set point (i.e., the P and I parameters are set to large

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Set point
values). This makes it impossible to satisfy both the types of
response in this case.
External
disturbance P Two PID control provides good response for both response to
(proportional control)
action only the set point and an external disturbance.

PID Control
Time
(1)
Control output

(%)
100

Relays
A long derivative time is set.

A short derivative time is set.

50

Control Components
Time
A long derivative time is set. Response to the set point will be slow if response to the external
disturbance is improved.
Set point
(2)
A short derivative time is set.

Automation Systems
Time

PID Control
Response to the external disturbance will be slow if response to
PID control is a combination of proportional, integral, and the set point is improved.
derivative control actions. The temperature is controlled

Motion / Drives
smoothly here by proportional control action without hunting, Two PID Control
automatic offset adjustment is made by integral control action, (3)
and quick response to an external disturbance is made
possible by derivative control action.

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Environment Measure Equipment
Response to set point Response to
external disturbance

Controls both the set point and the external disturbance

response.
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In Addition

PID control
Others
Common

4
 Technical Explanation for Temperature Controllers

Explanation of Terms
Control Terminology

Sensors
Hysteresis Time-proportioning Control Action
ON/OFF control turns the control output ON and OFF at the Relays and SSRs can output only ON (100%) and OFF (0%).
set point, so if there are small amounts of noise near the set PID control, however, outputs the manipulated variable
point, the output will turn ON and OFF frequently (which is between 0% and 100%. Time-proportioning control action is
called chattering). This will shorten the life of the output relay an output method that adds a time parameter (control period)
or unfavorably affects some devices connected to the to the manipulated variable, which allows for a 0% to 100%

Switches
Temperature Controller. To prevent this from happening, a output when using an ON/OFF output. A manipulated variable
temperature band (hysteresis) is created between the ON and between 0% and 100% can be output by turning the output
OFF operations. This gap is called hysteresis. ON for the control period (seconds) multiplied by the
manipulated variable (%), and then turning the output OFF for
Hysteresis (Reverse Operation)
the remainder of the control period. Because the output turns

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Hysteresis
ON and OFF only once during the control period, a long
Control output

ON
control period delays the control response, and a short control
period speeds up the control response. If the control period is
short, the life expectancy of output devices with contacts such
OFF as relays will decrease. As a general rule, set the control
period for relay outputs to 20 seconds, and set the control
period for SSR outputs to 2 seconds.

Relays
99.2°C 100°C Temperature
20 s
Note: Hysteresis indicates 0.8°C.
ON for 16 s OFF for 0.4 s
Control period: 20 s
Hysteresis (Direct Operation) Manipulated variable: 80%
2s
Hysteresis ON for 1.6 s OFF for 0.4 s
Control output

Control Components
ON
Control period: 2 s
Manipulated variable: 80%

Proportional Band
OFF
The proportional band is a parameter that sets the range in
which control performs the proportional action. When the

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Temperature process value enters the proportional band, the proportional
100°C 100.8°C
Note: Hysteresis indicates 0.8°C. action outputs a manipulated variable between 0% and 100%
that is proportional to the deviation between the set point and
Offset the process value. When the process value is outside the
Proportional control action causes an error in the process proportional band in heating control, the manipulated variable
value due to the heat capacity of the controlled object and the is output at 100% when the process value is lower and 0%
capacity of the heater. The result is a small discrepancy when higher than the band.

Motion / Drives
between the process value and the set point in stable Actual temperature
Temperature Proportional band
operation. This error is called offset. Offset is the difference in
temperature between the set point and the actual process Set
temperature. It may exist above or below the set point. point

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Offset

Environment Measure Equipment

The higher the temperature is the shorter the ON period will be.
Set point
ON
Proportional Offset OFF
T T T T T T T T
band
T: Control cycle
TON TON: ON period
MV= ×100(%)
TON + TOFF TOFF: OFF period
ON
Power Supplies /

OFF Example:
In Addition

If the control cycle is 10 s with an 80% control output, the ON and OFF periods
will be as follows.
Hunting and Overshooting TON: 8 s
ON/OFF control action often involves the waveform shown in TOFF: 2 s
the following diagram. A temperature rise that exceeds the set
point after temperature control starts is called overshooting.
Temperature oscillation near the set point is called hunting.
Improved temperature control is to be expected if the degree
Others

of overshooting and hunting are low.

Hunting and Overshooting in ON/OFF Control Action
Overshooting
Set
point
Common

Hunting

5
 Technical Explanation for Temperature Controllers

Derivative Time Autotuning

The derivative action are not used alone for control. It is used The PID constants that can be used for good temperature

Sensors
for control together with the proportional action. The control control depend on the characteristics of the controlled object.
method that combines the proportional action and the The method to derive suitable PID constants for the differing
derivative action is called the PD actions. When a ramp-type characteristics of controlled objects is called autotuning.
deviation (i.e., a deviation with a constant slope) is provided in Typical methods are the step response method and limit cycle
the PD actions as shown in the figure, the time until the method.
derivative manipulated variable reaches the same

Switches
Step Response Method
manipulated variable as the proportional action is called the
derivative time. Therefore, this shows that the longer the A manipulated variable of 100% is output in steps, the
derivative time is, the stronger the correction by the derivative maximum temperature ramp R and dead time L are measured
action will be. from the response of the controlled object, and the PID

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constants are calculated from the values of R and L.
PD Action and Derivative Time
Derivation

Deviation = Set point (SP) - Process value (PV) Set point

0
Ramp-type Deviation R

PD action
(with a short derivative time)
PD action
(with a long derivative time)

Relays
L
Control output

P action Time

D2 action
Limit Cycle Method
D1 action
Outputs a manipulated variable at 100% and 0% alternately,

Control Components
and the PID constants are calculated from the hunting cycle
TD: derivative time and amplitude values that occur in the controlled object.
TD1
(with a short derivative time)
Autotuning typically refers to the limit cycle method.
TD2
(with a long derivative time)
Amplitude

Integral Time Set point

A

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When a step-type deviation is added in the PI actions that
combine the proportional and derivative actions or the PID
Hunting cycle
actions that combine the proportional, integral, and derivative
actions, the time until the integral manipulated variable Time

reaches the same manipulated variable as the proportional

action is called the integral time. Therefore, the shorter the

Motion / Drives
integral time is, the stronger the integral action will be. But if
the integral time is too short, the correction will be too strong
and hunting may occur.
PI Action and Integral Time
PI action

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Deviation

(with a short integral time)

0
Step-type Deviation

PI action
(with a long integral time)
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Control output

P action
In Addition

T11 T1: Integral time

(with a short integral time)

T12
(with a long integral time)

Constant Value Control

Others

For constant value control, control is preformed at a specific

set point.

Program Control
Program control is used to control temperature for a set point
that will change at predetermined time interval according to a
Common

program.

6
 Technical Explanation for Temperature Controllers

Readjusting PID Constants Response to Change in Derivative Time

Control can usually be performed without problems using the Wider The process value

Sensors
PID constants that are calculated with autotuning. Depending reaches the set point
within a comparatively
on the application, the priorities of overshooting suppression, short time with
External disturbance
response speed improvement, and stability improvement may comparatively small
Set
be different. In those cases, the individual values of the PID point amounts of
overshooting and
constants can be adjusted by referring to the following undershooting. Fine-
examples to make the response behave closer to the

Switches
cycle hunting will result
anticipated response. due to the change in
process value.
Response to Change in the Proportional Band Nar- The process value will
Wider It is possible to rower External disturbance take a relatively long
time to reach the set

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Set suppress overshooting Set
point
point
although a point with heavy
comparatively long overshooting and
startup time and set undershooting.
time will be required.
Nar- The process value
Self-tuning
rower reaches the set point The PID constants are calculated with the step response tuning
within a comparatively when the Temperature Controller operation begins and when the
Set
short time and keeps
point set point is changed. Once the PID constants have been

Relays
the temperature stable
although overshooting calculated, self-tuning is not executed when the next control
and hunting will result operation is started as long as the set point remains unchanged.
until the temperature
becomes stable.

Set point

Control Components
Response to Change in Integral Time
Wider The set point takes
longer to reach. It is
possible to reduce
Set
point hunting, overshooting,
Time
and undershooting ST

Automation Systems
although a
comparatively long Models and Tuning Methods
startup time and set
time will be required. Model Tuning Methods
Nar- The process E5C AT, ST
rower temperature reaches E5N * AT, ST
Set the set point within a
point comparatively short E5R AT

Motion / Drives
time although E5CS-U/E5CSV AT, ST
overshooting,
undershooting, and E5CB AT
hunting will result. EJ1 AT
E5ZN AT

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Environment Measure Equipment
C200H-TC AT
C200H-TV AT
C200H-PID AT
ST: Self-tuning
AT: Autotuning
Note: Not including the E5ZN
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In Addition

Control Outputs

Contact relay output used for control methods with comparatively low switching
Relay output
frequencies. A load may also be driven directly.

ON/OFF output SSR output Non-contact solid-state relay output for switching 1 A maximum.
Others

Drives an external SSR with a large capacity by a 12-VDC ON/OFF pulse

Voltage output. This output is ideal for a high switching frequency in ON/OFF control
Control output
and the time-proportioning control action in PID control.
output
Continuous 4- to 20-mA or 0- to 20-mA DC output used for driving power
Current controllers and electromagnetic valves. Ideal for high-precision control. A preset
output
Common

linear output is produced if the load resistance falls below allowable levels.
Linear output
Voltage Continuous 0 to 5 or 0 to 10 VDC output used for driving pressure controllers.
output Ideal for high-precision control.

7
 Technical Explanation for Temperature Controllers

Alarm Terminology

Sensors
Alarm Output SSR Failure Alarm
Some Temperature Controllers output an alarm signal to the SSRs often fail structurally in a short-circuit mode, and if there is
alarm output, while others allow you to assign an auxiliary a short-circuit failure, there is a risk of a hazardous situation
output or control output as the output destination. where the temperature of the heater may continue to increase.
The SSR failure alarm detects an SSR short-circuit failure and
Alarm Operation outputs an alarm. The heater current is detected using a current

Switches
The process value, alarm value, and set point are compared, transformer (CT), and the SSR failure alarm is output if the
and a signal is output according to the operating mode current continues flowing to the heater even though the output
specified by the alarm type. The main operating modes are a from the Temperature Controller that drives the SSR is OFF.
deviation alarm, absolute-value alarm, standby sequence
alarm, heater burnout alarm, SSR failure alarm, and loop
Heater Burnout Alarm

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burnout alarm. These alarms may also be combined. If equipment continues to operate when people are not aware
that the heater has burned out, products may become faulty,
Deviation Alarm and in the worst case, the equipment may be damaged. The
The deviation alarm turns ON according to the deviation from heater burnout alarm detects burnouts in heaters and
the set point in the Temperature Controller. disconnected heater cables. The heater current is detected
Setting Example using a current transformer (CT), and the heater burnout
Alarm temperature is set to 110°C. Alarm set point
alarm is output if the current does not flow to the heater even
though the output of the Temperature Controller that drives

Relays
The alarm set point is set to 10°C. 10°C
the heater is ON. A heater burnout in a three-phase heater
Set point (SP) Alarm value can also be detected if the type of Temperature Controller that
100°C 110°C
can be connected to two current transformers (CTs) is used.
* When the Temperature Controller output is a current output, the heater
Absolute-value Alarm

Control Components
burnout alarm cannot be used.
The absolute-value alarm turns ON according to the alarm
Current value

temperature regardless of the set point in the Temperature Heater burnout

A Heater burnout alarm setting
Controller.
Setting Example
0 T
Alarm temperature is set to 110°C. Alarm set point

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The alarm set point is set to 110°C.
Set point (SP) Alarm value
100°C 110°C
Heater current waveform (CT waveform)

Standby Sequence Alarm

It may be difficult to keep the process value outside the
The wires connected
specified alarm range in some cases (e.g., when starting up to the Temperature

Motion / Drives
Current Controller have no
polarity.
the Temperature Controller), and the alarm turns ON abruptly Transformer (CT)

as a result. This can be prevented with the standby sequential

function of the Temperature Controller. This function makes it
Control output
possible to ignore the process value right after the
Temperature Controller is turned ON or right after the

Energy Conservation Support /

Environment Measure Equipment
Heater

Temperature Controller starts temperature control. In this Switch

case, the alarm will turn ON if the process value enters the Alarm Latch
alarm range after the process value has been once stabilized. An alarm latch can be used to keep the alarm ON until the
latch is canceled regardless of the temperature after the alarm
Example of Alarm Output with Standby Sequence Set
output has turned ON.
Temperature rise
Power Supplies /

Upper limit Upper limit

alarm setting
In Addition

alarm setting

Set point Set point

Lower-limit
alarm setting
ON
Alarm output ON
Alarm setting
OFF
OFF
Temperature drop
Others

LBA (Loop Burnout Alarm)

Upper limit An alarm is output by assuming the occurrence of control loop
alarm setting
failure when deviation is a certain value or higher and the
Set point input does not change in the direction that reduces the
Lower-limit deviation, even though control is being performed. This alarm
alarm setting can be used when operation is started but the sensor has not
Common

ON
Alarm output been installed after replacing the heater and as a method for
OFF
detecting missing sensors.

8
 Technical Explanation for Temperature Controllers

Temperature Sensor Terminology

Sensors
Cold Junction Compensation Compensating Conductor
A thermocouple produces a voltage (i.e., a thermoelectromotive If the thermocouple temperature sensor cable does not reach
force) from the temperature difference between the hot junction the Temperature Controller and the cable between the sensor
and the cold junction on the opposite side. For this reason, a and the Temperature Controller is extended with copper wire,
thermocouple outputs a relative temperature, not an absolute a large temperature error will occur.
temperature. In order for the Temperature Controller to calculate A compensating conductor must be used to extend the

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the absolute temperature from the relative temperature that is thermocouple temperature sensor cable. A compensating
output by the thermocouple, the effect of the cold junction conductor is a cable that produces nearly the same
temperature is compensated for, or canceled out, by detecting thermoelectromotive force as the thermocouple around room
the temperature of the cold junction and adding a temperature, and a compensating conductor that is suitable

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thermoelectromotive force that corresponds to that temperature for the thermocouple must be used. Compared to a
to the thermoelectromotive force of the thermocouple. The thermocouple cable, a compensating conductor is generally
method of calculating the absolute temperature of the hot junction inexpensive. Compensating conductors suitable for various
by adding a voltage is called cold junction compensation. thermocouples are available commercially.
Terminal
20°C Example of Compensating Conductor Use
Sensing point
350°C Temperature Connection
VT
terminal Compensating Terminal

Relays
Controller
conductor

Cold junction 20°C

Cold junction compensating circuit 350°C 30°C Temperature

Controller
In the above diagram, the thermo-electromotive force (1) VT that

Control Components
is measured at the input terminal of the Temperature Controller is
equal to V (350, 20). V (350, 30) + V (30, 20) + V (20, 0)
Here, V (A, B) gives the thermo-electromotive force when the Thermo- Thermo- Voltage from
cold junction is A °C and the cold junction is B °C. electromotive electromotive cold junction
force from force from compensation
Based on the law of intermediate temperatures, a basic behavior of thermocouple compensating
conductors
thermocouples, (2) V (A, B) = V (A, C) - V(B, C).

Automation Systems
= {V (350, 30) - V (30, 0)} + {V(30, 0) - V (20, 0)} + V (20, 0)
= V (350, 0)
When the ambient (terminal section) temperature is
20°C, the temperature sensor inside the Temperature
Controller detects 20°C. If we add the voltage V(20, 0) If you extend the cable of a platinum resistance thermometer
that corresponds to 20°C in the standard electromotive
force table to the right side, we get the following: or thermistor temperature sensor, using a compensating
V(350, 20) + V(20, 0)
conductor will actually cause a large temperature error.
Extend the cable using a cable with sufficiently low conductor

Motion / Drives
Thermo-electromotive Electromotive force generated resistance.
force from thermocouple by the cold junction
compensation circuit
Input Shift
If we expand the first part of formula (2) with
A = 350, B = 20, and C = 0, we get the following: As the process value, the Temperature Controller displays the
= V{(350, 0) − V(20, 0)} + V(20, 0) = V(350, 0). result of adding an input shift to or subtracting it from the

Energy Conservation Support /

Environment Measure Equipment
V(350, 0) is the thermo-electromotive force for a cold temperature measured by the temperature sensor. You can
junction temperature of 0°C. This is the value that is
defined as the standard thermo-electromotive force use the input shift to compensate the Temperature Controller
by JIS, so if we check the voltage, we can find the
temperature of the hot junction (here, 350°C). display when the temperature sensor measurement point and
the point at which you intend to measure temperature are
different and the temperature difference is already known.
Power Supplies /
In Addition

110°C
Furnace

120°C
Others

Input compensation value: 10°C (Displayed value is 120°C.)

(120 − 110 = 10)
Common

9
 Technical Explanation for Temperature Controllers

Output Terminology

Sensors
Reverse Operation (Heating) MV (Manipulated Variable) Limiter
Reverse operation is used to increase the manipulated The MV upper limit and MV lower limit are used to set the
variable when the temperature is lower than the set point. upper and lower limits of the manipulated variable that will be
Heating control is reverse operation. output. When the manipulated variable calculated by the
Temperature Controller is outside the range of the MV limiter,
Control output (%)

100 the actual output will be the upper limit or the lower limit.

Switches
Output (%)
100
Upper MV limit

Lower MV limit

Safety Components
Low Set point High 0
PV
Direct Operation (Cooling)
With heating and cooling control, the cooling MV is treated as
Direct operation is used to increase the manipulated variable
a negative value. Generally speaking then, the upper limit
when the temperature is higher than the set point.
(positive value) is set to the heating output and the lower limit
Cooling control is direct operation.
(negative value) is set to the cooling output as shown in the
Control output (%)

100
following diagram.

Relays
Output (%)
100
Upper MV limit
0
Lower MV limit

Control Components
Low Set point High Heating Cooling
output output
Heating and Cooling Control 0
Set point
PV

Temperature control over a controlled object would be difficult

if heating was the only type of control available, so cooling
Rate of Change Limit
control was also added. Two control outputs (one for heating The rate of change limit for the MV sets the amount of change
that occurs per second in the MV. If the MV calculated by the

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and one for cooling) can be provided by one Temperature
Controller. Temperature Controller changes significantly, the actual
output follows the rate of change limiter setting for MV until it
Temperature
Controller in
Heating approaches the calculated value.
Controlled
heating and Cooling object
Output (%)

cooling
control 100

Heating and Cooling Outputs

Rate of

Motion / Drives
Output Output change
1s limit setting

0
Time
Heating Cooling Heating Cooling Change point
output output output output
PV PV

Energy Conservation Support /

Dead Band

Environment Measure Equipment

0 0
Set point Set point
The overlap band and dead band are set for the cooling
output. A negative value here produces an overlap band and
a positive value produces a dead band.
Output Dead band:
Dead band width: Positive
Power Supplies /
In Addition

The heating side output and cooling

side output will not be simultaneously
output.
Heating Cooling
output output
PV
0
Set point

Output Overlap Band:

Dead band width: Negative
Others

The heating side output and cooling

side output will be simultaneously
output near the set point.
Heating Cooling
output output
PV
0
Set point
Common

10
 Technical Explanation for Temperature Controllers

Cooling Coefficient Positioning-Proportioning Control

For Temperature Controllers capable of heating/cooling control This is also called ON/OFF servo control. When a Control

Sensors
that do not have separate PID constants for the heating and Motor or Modutrol Motor with a valve is used in this control
cooling, it may not be possible to obtain good control system, a potentiometer for open/close control reads the
performance with the same PID constants when the heating and degree of opening (position) of the control valve, outputs an
cooling characteristics of the controlled object differ greatly. In open and close signal, and transmits the control output to
this case, adjust the proportional band on the cooling side Temperature Controller. The Temperature Controller outputs
(cooling side P) with the cooling coefficient until heating and two signals: an open and close signal.

Switches
cooling side control are balanced. The P for heating and cooling Floating control (feedback of the valve position is not provided
side can be calculated using the following formulas. with a potentiometer; control is possible even without a
Heating side P = P potentiometer) can also be selected.
Cooling side P = Heating side P x cooling coefficient
For cooling side P control when heating side characteristics are

Safety Components
different, multiply the heating side P by the cooling coefficient.
Open
Heating Side P × 0.8 Temperature
Controller in
Controlled
position- M
Output

object
proportioning
control Close
Heating side
P × 1.0
Potentiometer
Heating Cooling reading the

Relays
side P side P control valve
0 position
PV

Heating Side P × 1.5 Transfer Output

There may be situations where you want to send the process
Output

Control Components
Heating side P × 1.0 value and set point to a recorder, another Temperature
Controller, or a PLC using a method other than communications.
Heating Cooling
The transfer output converts one value out of process value, set
side P side P point, or other value to a current between 4 and 20 mA and
0
PV outputs it. The device that receives the transfer output must
support a current input between 4 and 20 mA.

Automation Systems
Heating/Cooling PID Control
For Temperature Controllers that can set PID control
Temperature
separately for heating and cooling, the PID constants for Controller with
these will be automatically set by selecting an adjustment transfer output

method with the heating/cooling tuning method according to

the control characteristics of the cooling side, and then
executing autotuning. Recorder

Motion / Drives
Parameter Setting
Temperature Sensor
Same as heating control
20 mA
Linear
Heating/Cooling Tuning Method
Transfer output

Air cooling

Energy Conservation Support /

12 mA

Environment Measure Equipment

Water cooling
4 mA
Linear Tuning
0°C 100 200
Control that is suitable for an application that has linear PV
Lower limit Upper limit
cooling characteristics is performed.
Air Cooling/Water Cooling Tuning
Power Supplies /

Control that is suitable for an application that does not have

In Addition

linear cooling characteristics (such as plastic molding

machines) is performed. The response is fast and the
response characteristics are stable.
Water Cooling Air Cooling
100
Others
Cooling capacity (%)

Linear
Common

0
MV (cooling) (%) 100

Cooling Characteristic

11
 Technical Explanation for Temperature Controllers

Setting Terminology

Sensors
Set Limit Set Point (SP) Ramp
The range in which the set point can be set is determined by Use this function to increase the temperature at a
the type of temperature sensor, so a large value can be set. predetermined rate or to increase the temperature to the
The set limit can restrict the temperature range that can be set target temperature in a predetermined time. When the SP
in cases where the equipment will be damaged if a ramp is enabled, the set point will be set and the temperature
temperature is set that is higher than the temperature that will will be controlled until it reaches the set point as shown in the

Switches
actually be used. following figure.
−200°C 1300°C K SP
SP ramp
Set point
after changing

Safety Components
SP ramp
0°C 500°C
set value
Possible setting range
SP ramp
Multiple Set Points Set point
time unit
before changing
Multiple set points can be preset and then switched using the Change point
Time
front keys or event inputs.
Remote Set Point (SP) Input
Setting Memory Banks The remote SP is used to set and change the set point with an

Relays
Temperature Controllers that have multiple set points, PID external analog signal (4 to 20 mA). Enable the remote SP to
constants, and alarm values save these parameters in groups control the temperature using the remote SP as the set point.
called banks. The parameters registered in a bank can be
changed at once by switching banks during control. Event Input
The event input is used to input an ON/OFF signal to the

Control Components
Memory Bank 00
Temperature Controller. A function can be assigned to the
Set point Bank 1
P constant input, such as switching multi-SPs or RUN/STOP, and this
I constant Bank 7
D constant allows the Temperature Controller to be externally controlled.

Input Digital Filter

The input digital filter is used when the external noise in the

Automation Systems
sensor input signal is large and control or measurements are
unstable. The process value that will be used for control is a
value that has passed through the input digital filter. The input
Select bank 1.
digital filter setting value is the time constant of the digital filter.
The following figure shows the relationship between the time
constant and the process value (PV) after passing through the

Motion / Drives
Temperature control using
constants in memory bank 1 filter.
PV before passing through the filter

PV after passing through the filter

Energy Conservation Support /

Environment Measure Equipment
0.63 A

(Time Time
constant)
Input digital filter
Power Supplies /
In Addition
Others
Common

12
 Technical Explanation for Temperature Controllers

Further Information
Connection Examples between Temperature Controllers and SSRs

Sensors
Temperature Controller SSRs
Load
+
+
Voltage output Heater
terminal INPUT LOAD Load power supply
(for driving SSR)

Switches


Directly connectable

Number of
Connectable G3PF (SSR with built-in Current Transformer)
Temperature Controllers with voltage output of 40 mA at 12 VDC

Safety Components
SSRs in parallel
25 A or 35 A at 240/480 VAC
E5EC/E5AC
E5AN-H/E5EN-H 8 Rated input voltage:
E5EC-T/E5AC-T
4 12 to 24 VDC
With built-in CT. Detects
heater burnout and SSR
short-circuit failures.

Relays
G3PE (Single-phase)
*1 15 A, 25 A, 35 A, or 45 A at 240/480 VAC
5 Rated input voltage:
3 12 to 24 VDC

Control Components
*2 Extremely thin Relays
Temperature Controllers with voltage output of 21 mA at 12 VDC
integrated with heat sinks.
E5CC/-T E5CN-H
G3PE (Three-phase)
15 A, 25 A, 35 A, or 45 A at 240/480 VAC
4 Rated input voltage:

Automation Systems
2 12 to 24 VDC
E5CC-U E5GC Slim design with 3-phase
output and built-in heat sinks.
STOP
TUNE

Note: Refer to your OMRON website for details.

G3PA
E5CB E5CS Series 10 A, 20 A, 40 A, or 60 A at 240 VAC

Motion / Drives
*3 20 A, 30 A, or 50 A at 480 VAC
5 Rated input voltage:
5 to 24 VDC
3 or 12 to 24 VDC
EJ1 *4 Thin Relays integrated with
E5DC

Energy Conservation Support /

Environment Measure Equipment
PWR
RUN
ERR
ALM

CDE
EJ1N-
COM1
COM2
COM3
heat sinks.
89AB
F 0 12

3 4 5 67
SW1

ON

G3NA
1 2 3 4 5 6 7 8

5 A, 10 A, 20 A, 25 A, 40 A, 50 A, 75 A, or 90 A at 240 VAC
SW2

*5 10 A, 20 A, 25 A, 40 A, 50 A, 75 A, or 90 A at 480 VAC
5 Rated input voltage:
3 5 to 24 VDC
Power Supplies /

*6 Standard model with

In Addition

screw terminals.
G3NE
5 A, 10 A, or 20 A at 240 VAC
2 Rated input voltage:
● Calculating the Number of Connectable SSRs in Parallel 1 12 VDC
Others

(A): The maximum load current for the voltage output (for Compact, low-cost model
driving SSR) of each Temperature Controller. with faston terminals.
(B): SSR input current
(A) ÷ (B) = Number of connectable SSRs G3PH
*1. Two G3PE-BL SSRs can be connected. 75 A or 150 A at 240/480 VAC
*2. One G3PE-BL SSR can be connected. 8
*3. Two G3PA-BL SSRs can be connected. Rated input voltage:
Common

*4. One G3PA-BL SSR can be connected. 4 5 to 24 VDC

*5. Two of the -UTU models of the G3NA SSRs can be connected.
*6. One of the -UTU model of the G3NA SSRs can be connected. For high-power heater
Four of the 480-VAC models of the G3NA SSRs can be connected. control.

13
 Technical Explanation for Temperature Controllers

FAQs

Sensors
The temperature error of the Temperature Why does overshooting or undershooting
Controller seems large. What is the cause of this? occur?

The following are possible causes. The following are possible causes.
• Narrow proportional band or small P constant

Switches
• The input type of the temperature sensor is • Short integral time or small I constant
incorrect (temperature sensor type setting). • Long derivative time or large D constant
• ON/OFF control is enabled.
• Control period is long for a control system with a
fast thermal response.

Safety Components
• Setting the overlap band in the heating and
cooling control to a dead band by mistake.

Why are process values not being displayed

correctly? And why is S.Err displayed?

• Temperature sensor lead wires and power lines

Relays
are in the same conduit, causing noise from the The following are possible causes.
power lines (generally, display values will be • The input type in the Initial Setting Level is set
• unstable). incorrectly.
Countermeasures • The temperature unit in the Initial Setting Level is

Control Components
Wire the lead wires and power lines in separate set incorrectly.
conduits, or wire them using a more direct path. • The input shift value in the Adjustment Level is
set incorrectly.
Power line • The data setting unit is incorrect.
• The temperature sensor polarity or connected
terminals are incorrect.

Automation Systems
• A temperature sensor has been connected that
Lead wire cannot be used with the installed Temperature
Controller.
• The temperature sensor has burnt out, short-
• Connection between the Temperature Controller circuited, or deteriorated.
and thermocouple is using copper wires. • The temperature sensor has not been connected.
• The thermocouple and compensating conductor

Motion / Drives
Countermeasures
Connect the thermocouple’s lead wires directly, types are incorrect.
or connect a compensating conductor that is • A device using metal other than a thermocouple or
suitable for the thermocouple. compensating conductor has been connected between
the thermocouple and Temperature Controller.
• The connection terminal screws are loose and a

Energy Conservation Support /

Environment Measure Equipment
Thermocouple contact failure occurs.
• The thermocouple lead wires or compensating
Copper wire conductors are too long and the conductor
resistance is affecting the Temperature Controller.
• The resistance of the three conductors connected
between the platinum resistance thermometer and
• The measurement location of the temperature the Temperature Controller terminals is different.
Power Supplies /
In Addition

sensor is not suitable. • Noise emitted by devices around the Temperature

Controller is affecting the Temperature Controller.
• The temperature sensor lead wires and power lines
are close, causing inductive noise from the power lines.
• The thermal response is slow because the
installation location of the temperature sensor is
far from the control point.
Others

• The ambient operating temperature of the

• The incorrect input shift value has been set.
Temperature Controller exceeds the rating.
• A wireless device is used around the
Temperature Controller.
• The temperature of the thermocouple-input-type
terminal block varies due to heat radiated from
Common

peripheral devices.
• Wind is blowing on the thermocouple-input-type
terminal block.

14
 Technical Explanation for Temperature Controllers

Why does the process value exceeds the set Why are communications not possible or why
point? are there communications errors?

Sensors
The following are possible causes. The following are possible causes.
• The contacts for the relay driven by control • The communications wiring is not correct.
outputs are welded. • The communications line has become
• The SSR has a short-circuit fault. disconnected.

Switches
• The PID constants are not suitable. • The communications cable is broken.
• Restricted MV limit values are set. • The communications cable is too long.
• The controlled object is heating by itself. • The wrong communications cable has been used.
• More than the specified number of
communications devices are connected to the

Safety Components
Why does the process value oscillate around
same communications path.
the set point and not stabilize at the set point?
(RS-422/RS-485 only)
• Terminating resistance has not been connected
The following are possible causes. at each end of the communications line.
• Narrow proportional band or small P constant (RS-422/RS-485 only)
• Short integral time or small I constant • The specified power supply voltage is not being
• Long derivative time or large D constant supplied to the Temperature Controller.

Relays
• ON/OFF control is enabled. • The specified power supply voltage is not being
• Control period is long for a control system with a supplied to an Interface Converter.
fast thermal response. • The same baud rate and communications method
• Setting the overlap band in the heating and are not being used by all of the Temperature

Control Components
cooling control to a dead band by mistake. Controllers, host devices, and other devices on
• The heating capacity of the heater is too large for the same communications line.
the heating capacity of the controlled object. • The unit number specified in the command frame
• There is periodic external disturbance, which is different from the unit number set by the
changes the heating capacity of the controlled Temperature Controller.
object. • The same unit number as the Temperature

Automation Systems
• AT execution is in progress. Controller is being used for another node on the
same communications line.
(RS-422/RS-485 only)
• There is a mistake in programming the host
device.
• The host device detects an error before it
receives a response from the Temperature

Motion / Drives
Controller.
• The host device detects the absence of a
response as an error after a broadcast command
or a software reset command (except for
SYSWAY).

Energy Conservation Support /

Environment Measure Equipment
• The host device sent another command before
receiving a response from the Temperature
Controller.
• The host device sent the next command too soon
after receiving a response from the Temperature
Controller.
• The communications line became unstable when
Power Supplies /

the Temperature Controller power was turned ON

In Addition

or interrupted, and the host device read the

unstable status as data.
• The communications data was corrupted by noise
from the environment.
Others
Common

15