TEMPERATURE
CONTROLLER
SPECIFICATIONS
:
O
(4,7mm)
.187
(4,7mm)
.187
DIA
(4)
11IUAYNCO
INC
.
W'NONA
.
MINNESOTA
55987
1265FAST
EIGHTH
STREET
DATA
SHEET
1-8-76
CONTROLLER
SUPPLY
VOLTAGE
:
115
volts
_+
10%,
50/60
Hz
.,
4
V
.A
.
maximum
230
volts
+
100,
50/60
Hz
.,
also
available
.
MODEL
22-00-19
CONTROLLER
OUTPUT
:
Isolatedzero
cross-over
solidstate
switch
rated
at
10
amps
maximum,
0
.5
amps
minimum
.
HEAT
ER
TEMPERATURE
RESISTANCE
CHARACTERISTICS
:
The
proper
heater
material
and
selection
depends
upon
the
application
.
Consultfactory
'
for
information
.
Page
1
of
13
PHONE
507
454-5300
HEATER
SUPPLY
VOLTAGE
:
This
will
vary
depending
upon
application
.
Power
bridge
must
be designed,
for
the
application
.
The
supply
voltage
for
the
heater
an be
the
same
as
is
used
for
the
controller
.
Hcwever,
the
heater
can
be
operated
fr3m
a
separate
source
from
24
to
230
volts
A
.C
.,
50/60
Hz
.
SPECIFICATIONS
:
SET
POINTRANGE
:
Set
point
is
adjustable
by
a remote
connected
potentiometer
.
The
range
of
adjustments
are
selected
forthe
application
.
Heaters
are
available
for
operation
up
to
2000°F
.
CYCLE
TIME
:
Thesampling
rate
is
adjustable
over
a
range
of
1
to
5
seconds
minimum
.
OPERATINGAMBEINT
TEMPERATURE
:
50°F
to
125°F
.
LED
INDICATOR
:
A
red
LED
indicator
lamp
on
the
terminal
board
indicates
the
operational
status
of
the
controller
.
TheLED
is
on
when
the
controller
is
applying
power
to
the
heater
.
EXTERNAL
WIRING
DIAGRAM
:
Heater
WAYNCO
INC
.
24
to
230 VAC
~
TFOS
1(I1(1
10,11
IFS101(0®
I
S
CYCLE
1(11(1
il0(
01
101
.
71I
l
.
C
I[Ii(1
11s,
1
.C
.
5040
1¢
rXlilfl~
-SOKII-1
L :
t,
ID
WINONA,
MINNESOTA
55987
1265
EAST
EIGHTH
STREET
L2
DATA
SHEET
-
~,
.=-I-')"~='-
."--
MODEL
.
4t-
TEMPERATURE
CONTROLLER
1-8-76
Temperature
Set
Pot
115
VAC,
50/60
Hz
.
Page
2
of
13
PHONE
507
454-5300
APPLICATION
OF
HEAT-SENSE
CONTROL
1-8-76
r~~~
-~
~t
Y-OJ
;J
;
The
Model
22-00-19
heat-sensetemperaturecontroller
utilizes
the
principle
of
change
in
resistanceof
the
heater
with
temperature
to
provide
the
feedback
signal
to
the
controller
to
maintain
a
constant
temperature
of
the
heater
.
In
other
words,
the
resistance
heater
supplies
the
thermal
requirements
of
the
system
as well as
the
feedback
signal
for
control
.
The
response
time
is
essentially
instantaneous
since
the heater cannot
change
temperature
without
a
corresponding
change
in
resistance
.
In
a
conventional
temperature
control
system
the
feedback
signal
is
obtained
by
means
of
a
separate
sensor
such
as
a
thermocouple,
thermistor,
RTD,
etc
.
Normally,
the
heater
used
in
a
conventionalsystem
maintains
a
relatively
constant
resistance
over
a
wide
range
of
temperatures
.
The
response
time
in
a
conventional
system
depends
upon
the
thermal
time
constant
between
the
heater
and
sensor
.
Both
systems
have
obvious
advantages
.
The choice
depends
upon
the
control
application
.
In
some
applications
superior
results
can
be
obtained
by
a
combination
of
both
systems
.
There
are
othertypes
available
to
suit
various
applications
.
This
bulletin
covers
only
one
type of
heat-sensecontroller
.
The
key
to
successful
applicationof
the
heat-sense
technique
is
to
satisfy
the
thermal
requirements
of the
system
before
choosing
a
particular
heat-sense
control
or
designing
the
powerbridge
.
A
temperature
control
system
utilizing
the
heat-sense
principle
consists
of
a
resistance
heater,
power
bridge,
electronic
controller
package
and
solid state
power
relayor
switch
.
Since
the
heater'supplies
the
thermal
requirements
as
well
as
the
feedback
signal,
a
powerbridge
is
required
.
Fig
.
1
illustrates
the
basic
heat-sense
powerbridge
.
Fig
.
1
DATA
SHEET
;)_-
;-_-,-'
MODEL
-aZzz=9
TEMPERATURE
CONTROLLER
The
heater
and
shunt
resistor
form
one arm
of
the
bridge
and the set pot
and
associated
resistors
form
the
opposite
arm
of
the
bridge
.
The
voltage
(el)
Page
3
of
13
&4
WAYNCO
INC
.
WIN
NA
MINNESOTA
55987
O
1265
EAST
EIGHTH
STREET
PHONE
507
454-5300
BRIDGEBOARDASS'Y
.
RESISTORS
:
Qty
: 1
ea
.
R1,
R2,
R5,
R6
Waynco
P/N
:
803-017
+
1%,
1/2W
Manufacturer
:
IRC
(TO-60)
Standard
1%
resistance
values
available
.
TRIM
POTS
:
Qty
:
l
.
ea
.
R3,
R4
Waynco
P/N
:
005-032
15
turn
Manufacturer
:
Bourns
(3006P)
Standard
resistance
valuesneeded
:
lK, 2K,
5K,
10K,
20K ohm
SHUNT
RESISTOR
:
Qty
.
1
ea
.
Waynco
P/N
:
803-025
+ 1%,
5W
Manufacturer
:
Dale
(LVR-5)
Resistance
values
needed
:
.025,
.05, .10,
.25,
.50
ohms
r
.04
DIA
WAYNCO
INC
.
W1NONA,
MINNESOTA
55987
The
following
is
a
list
of
discrete
ccmpcnents
needed
to
make
up
this
BridgeBoard
Assembly
.
Use
as
listed
or
equivalent
.
i
F+--
.76MAX+{
~-
.06
2s
~~4
2
.00
r
1265
EAST
EIGHTH
STREET
LEADS
WILL
FIT
A
.04DIA
HOLE
.20
W
~F
13
7
.20
SCHEMATIC
SYMBOL
D~`
;TA
SHEET
M03EL
TEMP2RATURE
CONTROLLER
r
1
.SMINj
-+j
O
(r
.15D1A
MAX
00
SCHEMATIC
SYMBOL
2
WIPER
CLOCKWISE
SCHEMATIC
SYMBOL
Page
5
of 13
PHONE
507
454-5300
TERMINALS
FOR
SHUNT
RESISTOR
:
Qty
.
2
ea
.
-~
P/N
:
0817-400-00o0
Manufacturer
:
VACO
(11208)
REMOTE
SET
POT
:
Qty
.
1
ea
.
77Lo
W
P/N
:
0005-
0
012-00
,
3
,
c)
Manufacturer
:
Clarostat
(Series
43
H.T
.)
WAYNCO
INC
.
WINONA,
MINNESOTA
55987
Standard
resistance
values
:
25,
100,
200,
250,
500,
1K
ohms
DATA
SHEET
MODEL
-2
~
TEMPERATURE
CONTROLLER
1-8-76
DIA
FOR
NO
.8
SCREW
~-~
~-
.14
D1A
--r~
~--DIA
FOR
NO
.18
THRU
22
GA
.WIRE
SCHEMATIC
SYMBOL
Page
6
of
13
1265
EAST
EIGHTH
STREET
PHONE
507
454-5300
D E N
T
I
A
L
PROCEDURE
FOR
POWER
BRIDGE
a)
Line
Voltage,
E L
b)
Resistance
of
the
heater
at
room temperature,
R
H @
72°F
DATA
SHEET
MODEL
TEMPERATURE
CONTROLLER
1-8-76
l
.
The
value
of
the
following
parameters
must
be
determined
prior
to
design
of
the
bridge
circuit
.
c)
Resistance
of
the
heater
at
the
low
end
of
the
temperature
range,
R
HL
d)
Resistance
of
the
heater
at
the
high
end
of
the
temperature
range,
RHH
2
.
The
maximum
value
of
the
shunt
resistor
RS
MAX
. i
s
now
calculated
.
Its
value
should
be
the
maximum
allowable
by
the
following
two
constraints
:
a)
The
maximum
power
dissipation
rating
of
the
shunt
resistor,
PS
MAX
.
b)
The
maximum
input
voltage
of
the
temperature
control,
0
.6
volts
.
RS
MAX
.
<
P
S
MAX
.
and
RS
MAX
.
<
0
.6
VOLTS
I
H
@
72°F
=
EL
(IH
@
72°F)2
,
where
iH
@
72°F
RH
@
72°F
The
value
of
the
shunt
resistor
is
now
selected
.
3
.
The
current
through
the
heater
at
the low
(IHL)
and
high
(IHH)
end
of
the
temperature
range
is
now
calculated
.
h
ES
=
ESL
ESH
4
.
The
voltage
across
the
shunt
resistor
at
the
low
(ESL
)
and
high
(E
SH
)
end
of
the
temperature
range
can
now
b~
calculated
.
E
SL
I
HL
R
S
,
E
SH
I
HH
R
S
The
change
in
the
voltage
across
the
shunt
resistor,
is
needed
to
determine
the
value
of
the
set pot
.
5
.
The
total
power
dissipated
by
the
resistors
in
the
bridge
circuit
should
be
limited
to
approximately
0
.6
watts
to
avoid
changes
in
the
resistance
due
to
the
temperaturecoefficientof
the
resistors
.
Therefore
for
operation
on
120V
line,
the
bridge
current
should
be
approximately
0
.010
amps
and
on
240V
line
:005
amps
.
The
currents
for
other
line
voltages
can
be
calculated
from
the
equation
:
I
=
1
.2
NOTE! Power
Dissipation
=
RMS
(Power)
,
since
bridge
circuit
is
EL
2
half
wave
.
Page
7
of
13
WAYNCO
INC
.
WINONA,
MINNESOTA
55987
1265EAST
EIGHTH
STREET
PHONE
507
454-5300
C O N F
I
D E N T
I
A
L
6
.
The
approximate
value
of
the
setpot
can
now
be
calculated
from
:
Rp =
10
AES
The
closest
standard
value
pot
is
chosen,
R
pS
.
The
currentthrough
the
pot,
IRP,
is
calculatedusing
the
selectedstandard
pot
value
with
theequation
:
IRP
=
10
AES
RpS
7
.
To
provide
for
calibration
of
the set pot
at
the
lowend
of
the
temperature
range,
R4
and
R5
are
connected
in
parallel
with
the
set
pot
.
These
resistors
provide
+20%
calibration
adjustment
.
The
value
of
R5
is
determined
by
:
R5
=
10
A
ES
.2
IRP
R4 is
selected
to
have
a
minimum
value
20
times
RPS
.
8
.
The
value
of
R6
is
now
determined
from
the
equation
:
R6
=
10
ESN
IRP
+
.2
(IRp)
9
.
The
total
resistance
of
the
bridge
circuit
is
determined
next
.
RTOTAL
=
EL
IRp
`
.2
I
RP)
From
RTOTAL,
the
values
of
Rl,
R2
and
R3
can
be
calculated
.
Rl
+
R2
+
R3
=
RTOTAL
-
RD-R6
For
+
20°,o
adjustment
a-
the
high
temperature
end
of
the
temperature
range,
R3
should
be
made
.4
(RTOTAL
-
Rp
-
R6)
and
Rl
+
R2
=
RTOTAL
-
Rp
-
R6
-
R3
Rl
and
R2
are
made
equal
in
value
to
divide
the
power
dissipation
.
Therefore,
Rl
=
RTOTAL
-
rp
-
R6
-
R3
2
=
R2
2
The
calculation
of
the
bridge
resistors
is
now
complete
.
W
AYNCO
INC
.
WINONA
MINNESOTA
55987
1265
EAST
EIGHTH
STREET
DATA
SHEET
1
-=>
=
-=~~'°"
~'=
J
MODEL
TEMPERATURE
CONTROLLER
1-8-76
Page
8
of
13
PHONE
507
454-5300
C
O
N F
I
D
E
N
T
I
A L
DESIGN
EXAMPLE
1
.
a),
Line
Voltage,
EL
=
240VAC
b)
RH @
72°F
=
20
ohms
=
27
ohms
d)
RHH
=
55
ohms
2
.
IH @
72°F
=
240VAC
=
12
amperes
20
ohms
PS
MAX
.
=
5
watts
RS
MAX
.
< 5
watts
12
amps
2
<
.034 ohms
RS
MAX
.
<
0
.6
volts
27
ohms
=
8
.88
amps
4
.
ESL
=
(8
.88
amp)
(
.025
ohms)
_
.222
volts
ESH
= (4
.36
amps)
(
.025
ohms)
_
.109
volts
A
ES
=
.222
volts
-
.109
volts
=
.113
volts
5
.
1
=
1
.2
=
1
.2
=
.005
amps
EL
240
6
.
Rp = (10
) (
.113)
=
226
ohms
-C
.
2(
.00452
)
8
.
R6 =
(10)
(
.109)
-
200
ohms
(
.00452)
+
(
.2)
(
.00452)
12
.amps
<
.050
ohms
A
shunt
resistor
of .025
ohms,
5
watts
is
selected
.
3
.
IHL
=
240
volts
IHH
=
240
volts
55
ohms
.005
The
closeststandard
value
pot
is
250
ohms
.
IRP
=
(10)
(
.113)
=
.00452
amps
.
250
7
.
R4 =
(10)
(
.113)
=
1250 ohms
R5
=
(20)
(250)
=
5K ohms
DATA
SHEET2203-0-!
7_O
:
:)
:,
MODEL
TEMPERATURE
CONTROLLER
4 .36
amps
Page
9
of
13
eA4,
WAYNCO
INC
.
WINONA
MINNESOTA
55987
1265
EAST
EIGHTH
STREET
PHONE
507
454-5300
C 0
N F I
D
E
N T
I
A L
9
.
RTOT
(
.00452
+
.2
.00452
2
+ R3 =
44,247
-
250
-
200
=
43,797
R3 =
(
.4)
(43,797)
=
17,519
closest
pot
value
is
25K
ohms
.
Rl
+
R2
=
43,797
-
25,000
=
31,297
=
240
=
44,247
ohms
Rl
=
31,297
=
15,648
= R2
2
R1,
R2
= 15
.4K
ohms
.
2
DATA
SHEET
MODEL
TEMPERATURE
CONTROLLER
1-8-76
Page
10
of
13
(B
WAYNCO
INC
.
WINONA
MINNESOTA
55987
1265
EAST
EIGHTHSTREET
PHONE
507
454-5300
SYSTEM
CALIBRATION
PROCEDURE
DATA
SHEET
MODEL
TEMPERATURE
CONTROLLER
system
may
be
calibrated
by
utilizing
a
temperature
sensor
such
as
a
thermistor,thermocouple,
etc
.
attached
to
the
heater
surface
in
combination
with
a
suitable
temperature
indicator
.
Following
is
the
recommended
procedure
:
1-8-76
1 .
Make
all
connections
to
the
temperature
control
system
.
CAUTION
:
Check
all
connections
for
mechanical
and
electrical
integrity
.
Never
energize
the
system
with
the
shunt
disconnected
as
the
controller
may
be
permanently
damaged
.
2
.
Turn
the
temperatureset
pot
,
low
temperatureadjust
and
high
temperature
adjust
to
their
minimum
temperature
settings
counter
clockwise)
.
Turn
the
cycle
time
adjust
to
its
maximum
counter
clockwise
direction
.
Supply
power
to
the
controller
only
.
3
.
With
the
heatersupply
voltage
disconnected
and
the
cycle
time
pot
maximum
counter
clockwise,
the
LED
should remain
off
.
Slowly
turn
the
cycle
time
pot
in
a
clockwisedirection
until
the LED
turns
on
.
The
LED
shouldremain
on
.
Connect
the
heatersupply
voltage
.
The
LED
will
begin
to
cycle on-off
when
the
heater
reaches
temperature
.
This
will be
the
minimum
temperature
at
which
the
heater
can
be
operated
.
4
.
Turn
the
temperature
set
pot
to
its
maximum
temperature
setting
.
5
.
Adjust
the
high
temperature
pot
to
obtain
the
desired
maximum
temperature
of
the
surface
to
be
controlled
as
indicated
by
the
temperature
monitor
.
6
.
Turn
the
temperature
set
pot
to
its
minimum
temperature
setting
.
7
.
Adjust
the
low
temperature
pot
to
obtain
the
desired
minimum
temperature
of
the
surface
to
be
controlled
as
indicated
by
the
temperature
monitor
.
8
.
Repeat
steps
4
through
7
.
Re-adjust
the
high
and low
temperature
pots if
necessary
.
9
.
Turn
the
set pot
to
the
desired
operating
temperature
.
10
.
Decrease
the
cycle
time
if
the
temperature
is
fluctuating
to
obtain
minimum
change
in
temperature
.
NOTE
:
Decreasing
the
cycle
time
will
increase
the
minimum
obtainable
temperature
.
Page
11
of
13
C5
WAYNCO
INC
.
WINONA
MINNESOTA
-
55987
1265
EASTEIGHTH
STREET
PHONE
507
454-5300
TROUBLE
ANALYSIS
AND
SERVICE
CHART
DATA
SHEET
22o
J-
^
°,-
MODEL
TEMPERATURE
CONTROLLER
Page
12
of
13
W
AYNCO
INC
.
WINONA,
MINNESOTA
55987
1265EAST
EIGHTH
STREET
PHONE
507
454-5300
Power
On
Heater
Heater
Open
Replace
Heater
.
Also
But Not
Heat
checkwiring
and
all
connections
.
Pulses
ON-OFF
Improper
Calibration
Repeat
Calibration
But
Temp
.
Below
Procedure
.
Set
Point
Pulses
ON-OFF
High
Resistance Check
heater
resistance
But
Temp
.
Below
connection
in
heater
and
all
connections
.
Set
Point
circuit
.
Pulses
ON-OFF
Bridge
Board
not
Tighten
all
screws
on
But
Temp
.
Below
screwed
down
Bridge
Board
Set
Point
-
tightly
.
Pulses
ON-OFF
Set Pot
.
leads
Pl
Check
wiring
of
remote
Temp
.
Below
Set
and
P3
reversed
.
Set
Pot
.
Point
SYMPTOM
CAUSE
REMEDY
Over
Heats
Shorted
Solid
State
Connect
jumper
wire
across
Switch
shunt
resistor
.
If
power
turns
off,
switch
okay
.
If
not,
replacecontrol
.
Over
Heats
Controller
Indicator
If
solidstate
switch
from
Light
OFF
above
test
okay,
replace
controller
.
Over
Heats
Controller
Indicator
Check
inter-connecting
Light
ON
.
wire
to
terminals
.
If
connections
per
connection
diagram
and
system
continues
to
over
heat,
replace
controller
.
TROUBLE
ANALYSIS
AND
SERVICE
CHART
SYMPTOM
Pulse
ON-OFF
Temp
.
Be'l
ow
Set
Point
.
Unit does
not
pulse
Heater
Power
.
In-
dicator
light
on,
controller
is
off
.
Unit does
not
pulse
Heater
Power
and
Indicator
Light
On
.
WAYNCO
INC
.
O
f
WINONA
MINNESOTA
55987
CAUSE
Bad
Controller
Improper
adjustment,
cycle
rate
adj
.
Improper
wiring
.
Indicatesbroken
lead
or
open
circuit
in
HeaterSupply
or
Heater
.
1263
EAST
EIGHTH
STREET
DATA
SHEET
MODEL-&2=_9
TEMPERATURE
CONTROLLER
REMEDY
1-8-7b
Replace
Controller
.
Turn
Clockwise
until
indicator
light
comes
on
.
If
unable
to
attain
this
condition,
replace
controller
.
Check
wiring
.
If
wiring
okay,
replace
controller
.
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of
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507
454-5300
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