In most industrial settings, temperature sensing systems—like a thermostat or process sensor—rarely receive attention unless they malfunction. Even when everything seems to be operating smoothly, hidden flaws in these systems can silently compromise efficiency, product quality, and safety. These blind spots, often overlooked, stem from compromises made during system design—limitations related to space, budget or sensing precision. But with modern innovations like Watlow's thermocouple heater (TCH) control and Adaptive Thermal Systems® (ATS™), those compromises are no longer necessary.
The Problem with Today’s Temperature Sensing Systems
Most traditional temperature sensing setups—including electronic thermostats and sensors—are afterthoughts in equipment design. Instead of driving performance, they’re forced to conform to pre-existing physical and financial constraints.
For instance, limited budgets may reduce the number of process sensors used, leading to gaps in thermal data. Without a complete picture, your setpoint controller might over- or under-respond, degrading product quality or increasing energy waste.
Space is another limiting factor. Each sensor or heater added increases wiring complexity. In compact equipment, designers often wire heaters in series to reduce clutter—sacrificing the fine-tuned control needed for peak efficiency. This can cause unbalanced heating and increase wear on components. The result? Reduced product yield, more scrap, and operational inconsistencies.
These compromises might not trigger alarms on your electronic thermostat or setpoint controller, but they still impact performance—and diagnosing them isn’t always easy.
Enter Watlow’s Thermocouple Heater (TCH) Control
Watlow’s TCH control reimagines temperature sensing by embedding sensing capability directly into the heater’s power leads. It eliminates the need for separate sensors and sensor wiring—cutting costs, reducing complexity, and saving space.
The TCH uses thermocouples—well-established process sensors formed by two dissimilar conductors joined to create a voltage-sensitive junction. When placed inside or near the heater, this setup captures highly localized temperature readings with no need for additional components.
This configuration offers several key advantages:
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No discrete sensor wiring: Less clutter, reduced installation time.
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Precision sensing: Temperature data is captured right where heat is applied.
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Low latency: Measurements take just 5 milliseconds, allowing continuous heater operation.
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Affordability: One sensor per heater becomes financially viable, giving engineers a full, real-time thermal map.
TCH and Watlow’s Adaptive Thermal Systems® (ATS™)
To maximize the value of TCH, Watlow developed its Adaptive Thermal Systems suite—a full-featured thermal management ecosystem that includes heaters, sensors, electronic thermostats, and setpoint controllers, all designed to work seamlessly together.
The Harness
The ATS harness simplifies system wiring using standardized connectors that allow multiple heaters to be wired together with fewer connections. It streamlines installation and reduces potential points of failure—perfect for compact industrial systems.
The Setpoint Controller
Watlow’s EZ-ZONE® RMT controller acts as the system’s brain. This advanced setpoint controller enables closed-loop control of every heater, even in systems wired in series. It supports real-time data aggregation and EtherCAT® communication for integration into modern automation systems.
Additional benefits include:
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Voltage-agnostic performance: Delivers precise output regardless of input power.
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TCH-ready architecture: Seamlessly integrates with embedded sensors.
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Global compatibility: Designed for international applications with plug-and-play ease.
Unlocking the Full Potential of Industrial Sensing
Many industrial systems use off-the-shelf electronic thermostats and sensors that don’t deliver full insight or control. Watlow’s Adaptive Thermal Systems are modular and customizable, giving you the benefits of tailored engineering without the high costs typically associated with custom solutions.
By combining innovative process sensors like the TCH with a centralized, intelligent setpoint controller, you eliminate blind spots in your thermal strategy. The result? Better product quality, improved energy efficiency and fewer maintenance headaches.
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