Thermo Controllers

When working with pneumatic machines, you want to prevent temperature extremes as a result of regular functions. Overheating can cause an air compressor’s functions to fail, which in turn affect performance. 

Meanwhile, cold air can thicken the lubricating oils used in compressors, strain any pumps, and even dry up control lines. Water can turn to ice, which means it expands and hurts the machine, and other liquids may similarly solidify. Blazing heat or freezing cold can lead to potential dysfunction and slowed-down operations. In some cases, the air compressor will not even start.

In the worst-case scenario, temperature extremes can cause machine failure, which necessitates repairs or replacements. No one wants this, least of all you the machine owner. You have assignments on the clock, and clients expecting their projects finished efficiently. 

Factor in all the potential scenarios when considering temperature regulation. You want automatic systems embedded into the machine to regulate heat and cold, sometimes in tandem. A broken machine means getting behind on assignments and accumulating fixed costs for your business.  

Ideally, machines have a feedback control system to keep functions from hurting the valves and engines. These fail-safes exist precisely to prevent engine and parts damage, though they aren’t perfect. SMC Pneumatics carries the parts for both the machines and the feedback systems. It’s our best interest to ensure that you have these components on hand, in the right size to suit your air compressors. 

Certain controls monitor the feedback and bring the machine back to the baseline. They have certain parts and facets that help with these parts. The primary control focuses on bringing down or regulating temperature. 

What Is A Thermo Controller?

A thermo controller is a device that regulates temperature, working with an actuator and a sensor. It can also be called a temperature controller, the more common term. In any case, its purpose is to prevent excessive heating or cooling from hurting your devices. Think of it as a thermostat for industrial purposes. 

In a pneumatic device, a thermo controller essentially measures temperature and rising heat within a threshold, usually around 225 degrees Fahrenheit. While the actuator converts energy, the sensors and controller monitor changes. 

If temperatures exceed the threshold, functions will suffer at 300 degrees and failure will occur at 350 degrees Fahrenheit. Once the actuator reaches that threshold, the controller takes steps to either implement an off switch, reduce the power for various functions, or automatically creates changes relative to pneumatic functions and proportions. 

Types of Thermo Controllers And Their Countermeasures

Thermo controllers have three types; you can go for the basic on/off switch. The switch acts based on temperature thresholds and notes when the machine exceeds these limits. This is best for when the machine’s output doesn’t fluctuate rapidly because you don’t want to constantly have it shut down when working. If so, you’ll need to add a differential to deal with the fluctuations. 

Proportional control takes a more measured approach. It doesn’t want to have any fluctuation or cycles. Instead, it gradually cools down the machine and slows the actuator, by decreasing the power flow. That way the temperature becomes stable, rather than going up and down and needing a quick shutoff.  

The PID system is the most complicated of the three types of controllers. PID stands for “proportional with integral and derivative control”. It uses calculus integrals and derivatives in addition to proportional control, so as to stabilize temperature over time with RESET and RATE as their inversions. One setback is that you need to make sure that the functions stay consistent because they can change gradually over time. 

What Can Cause A Machine To Overheat?

One fact of life is that machines break down. Some break down more than others depending on overuse or underuse. We have to monitor our pneumatics and air controllers. Below are several probable causes for machine overheating and failure.

Varying pressure levels can affect internal temperatures. These include low suction pressure, which means a high compression ratio has occurred. Usually, this happens if a mechanic has improperly installed parts or incorporated faulty meters. Human error even at the smallest level can have large impacts on these machines. 

Excess discharge pressure can also occur and in turn, leads to too much heat. This can happen if the discharge line is the wrong size, the coils are dirty, or condenser air flow suffers from blockages. Make sure your coils are clean, and that the machine isn’t overcharging any refrigerant. 

Does your space have enough cooling or venting for your machine? You need to make sure to have enough external air flow. The lack of this ventilation can be another potential cause of overheating. 

If the machine doesn’t have the means by which to get rid of excess heat, then it will build up over time. A space with no ventilation means that air isn’t flowing in and out of the area. Devices need breathing room, especially when they run on airflow and pressure. 

On a similar note, is the workspace temperature appropriate for machine functions? Ambient environments will strain or enhance your air compressors and pneumatic devices. As we discussed, excessive heat or cold can affect machine functions, even shutting down compressors before they can do work. 

Is your oil flow consistent? Pneumatic machines need oil for lubrication so that the valves and parts can move. If the oil is not flowing, the backlog can lead to excessive heat, and less lubrication means that parts wear and tear as they press against each other. 

You need to make sure the levels are consistent, clear out any clogs, and replace any burnt liquids. The burnt-oil smell is usually a red flag. Trust your nose, and trust any air flows. 

Check to make sure that all of your machine’s parts are working. That can be another reason for thresholds being crossed too early. Thermal valves are the most important component regarding this step because a broken valve means overheating. 

The older the parts are, the more strain the machine has for functions, which creates more waste energy. If say a valve is faulty or clogged, then the resulting strain can also cause excessive heat. 

Schedule intermittent evaluations to monitor when you need to replace valves, engines, or other components. Maintenance will cost more in the short run but save more on repair costs in the long-term. In the worst-case scenario, you may need to replace your entire air compressor. It’s not ideal, but knowing the problem means that you know how to fix it. And better to replace a part than to replace an entire pneumatic system. 

Find Out More From SMC Pneumatics

At SMC Pneumatics, we are dedicated to providing the parts you need for machine maintenance. With thermo controllers, we are interested in ensuring that your machines keep performing at one hundred percent. We can recommend if going digital for your thermo controller would be a good idea, or if you need more than a simple on/off switch. 

Do you want to find out more? Reach out to us and we will recommend the right thermo controllers for your needs.