Description

The WATLOW CLS216 is a compact, single-loop temperature controller designed for precise thermal regulation in industrial heating applications such as ovens, furnaces, molding machines, packaging sealers, and laboratory equipment. Housed in a space-saving 1/16 DIN (48 x 48 mm) form factor, it mounts directly onto a standard 35 mm DIN rail, making it ideal for panel retrofits or new machine builds with limited space.

Featuring universal input compatibility (supporting J/K/T/E/N/R/S/B thermocouples, Pt100 RTDs, and 4–20 mA signals), autotuning PID control, and programmable ramp/soak profiles, the CLS216 delivers accurate, stable temperature management even in dynamic processes. With optional RS-485 Modbus RTU communication, dual alarm relays, and sensor break detection, it bridges basic control needs with modern connectivity—perfect for OEMs and end users seeking reliability without complexity.

Application Scenarios

At a medical device manufacturer in Minnesota, inconsistent heat sealing on IV bag packaging caused field recalls. The legacy controller lacked autotuning and drifted during shift changes. Engineers replaced it with the WATLOW CLS216. leveraging its adaptive PID algorithm and sensor break alarm to maintain ±1°C stability across 24/7 production. The built-in ramp-to-setpoint feature prevented thermal shock to sensitive films during startup. Within one month, seal failure rates dropped by 92%, and validation documentation was simplified thanks to the controller’s consistent performance logs. “It’s small, but it solved a six-figure quality problem,” said the process engineer.

Technical Principles and Innovative Values

Innovation Point 1: True Universal Input with Auto-Detection – The CLS216 automatically recognizes sensor type during setup, eliminating manual DIP switches or software configuration—reducing wiring errors and commissioning time.

Innovation Point 2: Adaptive Autotune with Load Compensation – Unlike basic controllers that tune only at setpoint, the CLS216 continuously adjusts PID parameters based on load changes (e.g., door openings in ovens), maintaining stability under real-world disturbances.

Innovation Point 3: Embedded Safety via Sensor Break Detection – If a thermocouple fails open or shorts, the controller triggers a configurable safety output (e.g., de-energize heater), preventing runaway temperatures—a critical feature for UL 508 compliance.

Innovation Point 4: Seamless SCADA Integration via Modbus – With optional RS-485. the CLS216 reports process value, setpoint, output %, and alarm status to PLCs or HMIs, enabling remote monitoring without additional I/O hardware.

Application Cases and Industry Value

A snack food producer upgraded its oil fryer line with WATLOW CLS216 units to replace obsolete analog controllers. The Modbus-enabled models fed real-time oil temperature data into their Rockwell PlantPAx system, allowing operators to correlate cooking temp with product color consistency. Energy use dropped 8% due to tighter control reducing overshoot. Maintenance teams now receive SMS alerts when a thermocouple fails—cutting downtime by 75%.

In semiconductor wafer processing, a lab used CLS216 controllers for low-temperature annealing stations. The RTD input accuracy (±0.2°C) and quiet relay operation (no EMI) ensured repeatable results across 50+ batches—critical for R&D reproducibility.

Related Product Combination Solutions

WATLOW CLS218: Enhanced version with analog output (4–20 mA) for valve or SSR control

WATLOW EZ-ZONE RM: Modular multi-loop controller platform for complex thermal zones

OMRON G3NA-210B: Solid-state relay (SSR) for switching higher heater loads with CLS216

WATLOW FLX-TC: Touchscreen operator interface for centralized monitoring of multiple CLS216 units

THERMOCOUPLE TYPE K: Standard sensor commonly paired with CLS216 in industrial ovens

PHOENIX CONTACT MINI MCR-SL-R-PT100: Signal conditioner for long RTD runs (if needed)

WATLOW D44-0000-000: DIN rail mounting kit with strain relief for cable management

Installation, Maintenance, and Full-Cycle Support

Installing the WATLOW CLS216 is straightforward: mount on DIN rail, connect power, sensor, and load wiring (observe polarity for DC inputs), then set desired units and control mode via front-panel buttons. Autotune is initiated with a single keypress. For Modbus versions, baud rate and slave ID are configured through the menu.

Maintenance involves periodic verification of sensor calibration and relay contact integrity. The bright LED display ensures readability in low-light panels, while the sealed front panel (IP66-rated when installed) resists dust and washdown splashes.

We supply genuine WATLOW CLS216 controllers—either standard (relay output) or Modbus-enabled variants—in original packaging with full factory warranty. Each unit is tested for input accuracy, relay function, and alarm logic before shipment. Our application engineers provide free support for sensor selection, PID tuning, and integration into existing control panels. Contact us for a thermal control solution that combines Watlow’s 100+ years of heating expertise with modern simplicity and reliability.