What are thyristor controllers?

TYA thyristor controllers are devices that precisely manage the power supplied to heating loads - such as heaters, infrared heaters or transformers. Sound simple? In theory, yes. In practice, these are solutions that bring the dynamics of heating systems under control, eliminating voltage spikes and improving process stability.

Inside you'll find two thyristors connected in antiparallel, the so-called triac, which acts like a fast switch - it turns on or locks the voltage at the right moment. The whole thing is controlled by electronics, which, based on signals from the regulator (e.g. 0-10 V), adjusts the power supplied to the heater.

TYA controllers are available in versions:

• Single-phase (TYA 201) - ideal for simpler applications
• Three-phase (TYA 202, TYA 203) - for larger systems, such as furnaces, dryers, HVAC units

Depending on the version, you can choose:

• Phase angle control - for applications with low initial resistance (e.g., SiC heaters)
• Pulse (group) control - for resistive loads where minimizing EMC interference is important

In addition, TYA controllers can operate with a variety of algorithms
regulation - from standard voltage control (U, U²) to current control (I, I²) and power control (P), which allows to better match the characteristics of the process and save energy.

It's a solution that simply works - stably, efficiently and predictably, even in demanding industrial environments.

Industrial furnaces - precise power control in annealing, baking and brazing furnaces

In tunnel, chamber or muffle furnaces used for heat treatment of metals, ceramics and glass, it is critical to precisely match the power of the heaters to the different phases of the process - heating, quenching and cooling. A temperature rise that is too fast leads to stress, while one that is too slow leads to a longer cycle and uneven heating of the charge.

TYA allows the realization of custom temperature profiles, including a very soft start when heating components sensitive to the thermal gradient (e.g., hard-soldered electronic components). In transformer-powered ovens, it enables control of secondary power without risk of overloading the primary circuit.

In multi-zone installations (e.g., in kilns for firing technical ceramics), the use of TYA in each zone makes it possible to regulate the local temperature independently - with accuracy to maintain the thermal uniformity of the charge and avoid deformation.

In wood, ceramic or food dryers, the most common problem is maintaining an even temperature despite changing conditions - such as opening the chamber, changing batch moisture content or uneven loading. TYA allows for quick adjustments in heating power without overshooting, which reduces local overheating or underheating of the material.

Industrial dryers - how do thyristor power controllers eliminate overheating and stabilize chamber conditions?

In installations with high thermal inertia, the ability to precisely adjust power in real time proves crucial - especially in chamber dryers, where every contactor switch affects the chamber microclimate. In installations with blower fans, the elimination of current jerks during heater switching also prevents unwanted voltage drops in the system.

By integrating with a host system (e.g., a dryer line PLC), TYA makes it possible to realize time- or batch-state-dependent temperature profiles without rebuilding the power system.

Glass production - how does TYA stabilize temperature in glass forming and cooling processes?

In glass molding, uninterrupted, real-time temperature control is crucial - especially at the drawing, blowing and controlled cooling stages. Even slight instability causes deformation, cracking or internal stresses in the material.

TYA makes it possible to precisely adjust the heating power in the zones of a tunnel oven or forming chamber. It responds quickly to changes in heat load - for example, with changes in batch thickness or varying line capacities - to keep the temperature within the optimal range.

In ovens with IR heaters (short-wave for rapid mold heating or long-wave for temperature stabilization), TYA allows you to control each zone independently. In phase angle mode, it provides a soft start and reduces heater wear, which is important for 24/7 continuous operation.

Plastic processing - how does thyristor control eliminate plastic temperature fluctuations?

In plastics production, each heating zone must operate within a strict temperature range - too low a temperature means underheated plastic and defects in the molded part, too high a temperature leads to material degradation, combustion and clogging of the system.

TYA controllers allow precise control of the power of resistance heaters in the cylinder zones of an injection molding machine or extruder head. They operate in continuous mode, without switching on and off voltage, which allows to maintain the set temperature with minimal deviation.

In multi-zone heating systems (e.g., pipe, profile or film extrusion lines), TYA allows independent control of each zone separately - even with dynamically changing production rates. Combined with a PID controller or master control system, the line can respond to changes in real time, without overshoot or material losses.

UV printing - how does TYA ensure stable ink curing at variable line speeds?

In UV printing, print quality depends directly on the precision of ink curing. Too little radiator power results in under-curing and smearing of the ink, too much - overheating of the carrier material or wear and tear of the heads. In high-speed applications, such as label production for the beverage industry, the margin for error is minimal.

TYA thyristor power controllers enable infinite dynamic power adjustment of UV lamps (e.g., LED-UV, mercury or halogen) depending on the control signal from the printing machine. Speeding up the line? Increasing ink film thickness? TYA responds instantly, adjusting light intensity to changing conditions.

With the use of phase angle control, it is possible to control the power of the radiator very precisely, thus maintaining a uniform curing effect even when the heat load on the material varies. This is especially important in systems where printing is done on films, laminates or non-standard substrates.

Air handling units - how does TYA enable seamless control of heaters in HVAC systems?

In air handling units with electric heaters, controlling the heaters with contactors often results in uneven supply, overheating of the air, or excessive response inertia. TYA eliminates these problems by allowing continuous, infinite power control - according to the signal from the BMS or zone controller.

In typical HVAC systems, the TYA operates on the basis of an analog signal (0-10 V) that reflects the heat demand of a particular room or zone. The unit delivers exactly the amount of energy needed to maintain the set supply temperature - regardless of fluctuations in outdoor temperature or system load.

For outdoor installation (e.g., directly at the heater box), the controller can be integrated into an IP67-rated and corrosion-resistant (C4+) enclosure, as required for industrial and commercial building projects.

Specialty machines - how does TYA support custom applications that require reliable power control?

In applications that do not fit into standard schemes - such as laboratory ovens, test chambers, pulse welders or test benches - heating power control often needs to be flexible, fast and adaptable.

TYA works well in such projects thanks to its ability to work with a variety of control signals (analog, digital, industrial communications) and a wide range of currents and voltages. It can control both simple resistance heaters and more demanding loads - including heaters with high heating dynamics, such as in pulsed or cycled devices.

In prototype systems, these controllers enable rapid testing and reconfiguration without interfering with the control cabinet. In production systems with a high risk of overloading - such as in heat-sealing or rewinding machines - features such as soft-start, inrush current limiting and load monitoring protect actuators from damage and reduce service time.

Why use TYA? Real benefits in practice

Whether you're controlling the heating in an annealing furnace, a heater in an air handling unit or a UV light on a labeling line, TYA gives you the edge where stability, energy efficiency and the ability to respond quickly to changing process conditions are important.

The use of a thyristor power controller significantly reduces energy losses, reduces the risk of component overheating, avoids network interference problems and simplifies integration with automation. Thanks to continuous operation and smooth power control, the heating system operates precisely and predictably - and this translates into lower operating costs, longer component life and higher quality of the final product.

TYA is an engineered solution - designed for demanding environments, open to integration, overload resistant and ready to go where ordinary contactors or regulators fail.

About the author

My name is Ewelina Szmit and I have been involved in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I express my creativity by creating collages from newspaper clippings. I like to spend my free time actively, walking my dog or running.

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