 Overview Detailed SpecificationsTechnical
Discussion Implementation
Notes & SoftwareCustomization for
OEM
Applications Pricing |
| Power: 900W max. 0-36vDC. 0.1-25A Temperature Resolution: 0.01°C Temperature Range: -40°C to 250°C depending on sensor |
Control Type: Bipolar Proportional or On/Off Communications: RS232 and command set Setup: Comes with PC/Windows based Setup Software |
WORKS WITH PELTIER MODULES OR RESISTIVE HEATERS, FANS, AND MORE!
The Model 5R7-001 or Model
5R7-002 temperature
controller provides automatic biphase heating
and cooling control for
Thermoelectric
(Peltier effect, or TEC) modules. (We
also have a similar thermocouple based
controller.)
If the cooling or heating function is
switched off using the Setup program, these controllers are compatible
with
resistive heaters, fans, and many other DC voltage devices that
proportionately
alter operation based on the amount of power supplied. Adding a diode
to the output allows
the controller to power a Thermoelectric module in conjunction with a
resistive
heater (for additional heating power), or other DC driven device.
Peltier modules use only the proportional control, but On/Off control
can be used instead of proportional for solenoids, relay, heaters, etc.
The user friendly Setup program requires no
prior programming
experience to establish operation. A command set is provided for
qualified
personnel to program a software interface or use as an embedded
control. The software, its C++ code, and command set documentation are
on the accompanying CD. For
examples of using this type of command set see our library page, Communications Protocol.
A
display is available as a PCB and cable (shown right). The Model
5R6-576 front panel display allows you to see the actual temperature or
set the Set Point using 0.1 degrees resolution.
The "H" bridge configuration of the solid state MOSFET output devices allows for the bi-directional flow of current through the thermoelectric modules. Highly efficient N-channel output devices are used for this control mode.
A Pulse Width Modulated controller, or PWM controller, is a type of switched-mode controller. Our PWM controllers use square waves of varying widths and at a high frequency to provide power to the "load" (heater/cooler). Low power dissipation and precision control of the load make this type of temperature controller perferrable to analog controllers.
With peltier modules it is necessary to have a smooth transition between heat and cool modes, especially when controlling the temperature of laser diodes or telecom components. Our controllers provide a smooth transition from one mode to the other.
Compensation can be made for the difference in the efficiency of a peltier module's heat and cool modes.
Once the desired set parameters are established, the PC may be disconnected and the controller becomes a unique, stand alone controller. All parameter settings are retained in non-volatile memory.
Mechanically, the controller's printed circuit board is
mounted to a
metal bracket that is suitable for either horizontal or vertical
orientation.
Input and output connections are accessible via eurostyle screw
type terminal strips, fast-on terminals, and a 0.100 center connector.
(
Mechanical
Drawing & Hookup)
The
Model 5R7-001 is PC
programmable via
an
"RS232
communications interface". One RS232 COM port on your computer will
configure and monitor one controller. The easily accessible
communications
link permits a variety of operational mode configurations. (Other types
of communications, such as I2C communications, can be added
to a customized version of the controller. This controller is also
available as the Model 5R7-002 with RS485 communications.)
The
Model 5R7-002 is PC
programmable via an
RS485 communication
port for direct interface with a compatible PC (or interface to the PC
with our
"RS485/RS232
converter"). The
"RS485
communications interface" has 1500 VAC isolation from all other
electronic
circuitry minimizing interference from noise or errant signals caused
by
common ground loops. The easily accessible communications link permits
a variety of operational mode configurations. Field selectable
parameters
or data acquisition in a half duplex mode can be performed.This
controller
will accept at least 32 addressable devices, over a maximum of 4,000
feet
of communications cable.
Each controller has two sensor inputs. The second
sensor input can be used for a sensor or optionally
be used for remote set point adjustment using ma or a voltage or a
potentiometer based dial.
All sensors are thermistors and all of our thermistors are Fenwall
Curve
16, but we can customize for other R-T curves (Resistance vs
Temperature). For a list of the various sensors used with this
controller, and their corresponding temperature ranges, see the summary
of the features in the next section.
|
LOAD SPECIFICATIONS [up] |
|
| Load
Type |
Proportional
control mode can
be used for a peltier
module (, TE
module,
Thermoelectirc module), or resistive heater
(such as a thin
film resistive heater, kapton heater, nichrome wire, etc.). On/Off mode
can be used for a suitable relay, solenoid,
heater, or fan, etc. You
can also control both a peltier module and heater at the same time for
additional heating power by adding a diode to the output. |
| Load
Power Limits |
900 Watts Max:
0-36v DC at 0.1 to 25 Amperes.
If 15A or more, it is recommended you add a
heatsink to the mounting bracket as the bracket acts as a heatsink for
the solid state power relays. You can order the controller with a
heatsink by adding "H2" or "H3" to the end of the part number (see heat sink options here). |
| Load Power Type |
Capable of
handling PWM or On/Off control. For proportional
control, the controller's output is a Pulse Width
Modulated (PWM) DC voltage. The voltage remains the same but the pulse
width is varied. This modulates the amount of overall power provided to
the load. This works with peltier modules and resistive heaters. If you
are using On/Off control there is no PWM, and
this is suitable for relays and solenoids, etc. |
|
TEMPERATURE SPECIFICATIONS [up] |
|||||||||||||||||||
| Temperature Range |
-40°C to 250°C. Actual range depends on the sensor.
|
||||||||||||||||||
| Temperature Units | °C OR °F. Celsius or Fahrenheit. | ||||||||||||||||||
| Readability/Settability |
0.01°using the Setup program or custom software. (Optional front panel display has 0.1° displayability) |
||||||||||||||||||
| Temperature Calibration | Single-point calibration is possible using a temperature offset for the sensed temperature. The offset value also helps adjust for temperature gradients of the thermal system. | ||||||||||||||||||
| Internal Temperature Resolution | 0.01°C. The controller measures the sensed temperature changes in increments of 0.01°C. For every change of 0.01°C the controller determines if the output power level should be changed. | ||||||||||||||||||
| End Point Temperature Stability |
Not a
specification. See Implementation
notes below. |
||||||||||||||||||
| CONTROLLER
SPECIFICATIONS [up] |
|
| Power
Input for Load |
Single or split
power source depending voltage required for the load. |
|
Using Single Power Source
|
12 to 36v DC. This powers the controller logic and is also passed through to the load. |
|
Using Split Power Source
|
0 to 36v DC.
The power used for controller logic must be the same voltage or higher,
and a mimum of 12v. |
| Power Input for Controller Logic | 12 to 36v DC. Less than 300ma at 12v for controller logic. |
| Power
Input Indicator |
Green LED
blinks to indicate
that the controller has power. (
Photo) |
| Power
Output |
0 to 36v DC, 0 to
25A. Split power source required for under 12v. If 15A or more,
it is recommended you add a
heatsink to the mounting bracket as the bracket acts as a heatsink for
the solid state power relays. Ask about ordering the controller with a
heatsink. Voltages can be different for the load and the logic, see Power Input
and Power
Input for Controller Logic
above. |
| Power
Output Resolution |
0.2%. There
are over 500 power levels for cooling and over 500 power levels for
heating. |
| Power Output Polarity |
Bipolar or
unipolar. Bipolar means that the controller automatically
switches
between heating and cooling modes as required by the thermal system.
Unipolar, aka single-phase, aka unidirectional, will only heat or only
cool. (Bipolar is also known as biphase or bidirectional. Unipolar is
also known as single-phase
or unidirectional). |
| Power Output Bipolar Tuning |
Heat side
multiplier and cool side multiplier. Peltier modules tend be
more
efficient at heating than at cooling. The multipliers allow you to
reduce the amount of power being supplied to heat, or to cool, and help
to balance out the heating and cooling capability of the peltier module. |
| Power Output PWM Frequency |
2.7KHz |
| Power Output Circuit | Solid State H-Bridge that handles 0.1A to 25A at DC voltages ranging from 0v to 36v. |
| Control Type |
Proportional
control, or On/Off control, or User control.
Use
Proportional control for
peltier modules (TEC). Proportional control uses a Proportional
Bandwidth (P), Integral Gain (I), and Derivative Gain (D), and it can
be tuned for P, PI, PD, or PID. On/Off
control includes an adjustable
deadband (hysteresis). Additionally, User control is available if used
as a variac, in which case you set the output power level to a fixed
value. |
| Control: Proportional
Bandwidth |
0.10°C to
50.00°C with the
Set Point being in the middle of the band. |
| Control: Integral
Gain |
0.00 to 10.00
repeats per minute. |
| Control: Derivative
Gain |
0.00 to 10.00
cycles per minute. |
| Control: Deadband
(Hysteresis) |
1.00° to 50.00° with the Set Point being in the middle of the band. |
| Sensor
and External Adjustment Inputs |
2 sensors; or 1
sensor and an
external set point adjust. Input1 is for the control and alarm
sensor.
Input2 can be used to monitor a second sensor, or use a 2nd sensor for
Differential Control. Input 2 can instead be used to set the set point
using
and externally supplied 0-20ma, or 0-5v, or a potentiometer. |
| Communications |
RS-232 or RS-485
depending on
the model of the controller. The Model 5R7-001 uses RS-232. The Model
5R7-002 uses RS-485. Requires cable. Transmit, Receive and
Shield/Ground wires are connected to the controller using the screw
down edge connector.
|
| Memory |
Non-volatile memory
on board for
operating parameters
allows for stand-alone operation. You can configure the controller
using your PC and the Setup program and then disconnect the controller
from your PC. If you configure the controller with EEPROM write
enabled, you settings are stored in the controller and on power up the
controller will use those settings. |
| Set
Point Adjustment |
Adjustment via
Software or Hardware.
|
| Expansion Connector | For external alarm cancel switch & 3 LED indicators
- Standard
configuration allows an external alarm cancel switch, and provides up
to 25mA for 3 LEDs as an external indication of the Low/No/High alarm
states. OEM
Note: With appropriate additional circuitry you could use them to trigger relays
for fans or other circuits, or to light LED's to indicate power on/off,
etc. For an NRE we can customize the behavior of this connector. We can also reprogram it to allow I2C communications. |
| Alarm Types |
Sensor Open and
Overcurrent Alarms, and these 4 PC configurable alarms:
|
| Alarm
Limits |
PC configurable High and Low alarms, and an alarm deadband. |
| Alarm
Latching |
PC configurable alarm latching. Alarm state can automatically reset when the control temperature is between the High and Low alarm settings, or you can configure the controller so that the alarm state must be cleared manually. |
| Alarm
Can Disable Output Power |
PC configurable to
disable
output power in an
alarm state, or leave outpower on. |
| Alarm
Sensor |
Input1 or Input2 as alarm sensor. PC configurable for alarms state to be triggered by either of the the two sensors (each controller is capable of supporting two sensors). |
| Alarm
Status - External |
External alarm indication and alarm cancel can be added via expansion connector. Connector supplies 5 Volts DC at 25 MA for High/No/Low alarm states. This allows you to drive LED lights to indicate the sate of the alarms visually. |
| Alarm Status - Software |
Computer software
can read the
alarm state, and clear a latched alarm.
|
| Alarm for Overcurrent at Output |
PC settable
overcurrent alarm. With the Setup program you can
set a value that indicates that the load is drawing too much power. It
is settable in increments of about 2.5A. If you set the controller to
turn off the output power when the current level is passed, then you
can also set the number of times the controller should restart the
output before maintaining an alarm state. |
| Ambient
Operating Temperature |
-20°C
to 70°C.
 Notes
on Ambient Operating Temperature |
| MECHANICAL
SPECIFICATIONS [up] |
|
| Dimensions |
Inches: 6" long x 3.63"
wide x 1.75" high. Centimieters: 15.35 cm long x 9.23 cm wide x 4.45 cm high. OEM Note: We can custom build to your form factor, or take the design to SMT. |
| Power Connectors | 0.25" Quick Disconnect Terminals are on the controller board for power input and power output. |
| Sensor
Connectors |
Edge Connector
(see below). |
| Remote
Set Point Adust Connector |
Edge Connector (see below). |
| External
Alarm Connector |
Expansion Connector (see below). |
| Edge
Connectors |
Euro-style
detachable header with screw-down terminal for bare wires.
These are used for connecting Input1 (the control sensor),
Input2 (2nd sensor or remote set point adjustment). and comunications
(3 wire). (
Photo) |
| Expansion
Connector |
Molex
P/N 22-23-2081 is on the controller. It has 8 pins. (
Photo) |
| COMPLIANCE [up] |
|
| RoHS
Compliant |
Compliant
with the Restriction of Hazardous Substances Directive (Directive on the Restriction of the Use of
Certain Hazardous Substances in Electrical and Electronic Equipment). |
| SOFTWARE [up] |
|
| Setup
Program |
 A
PC/Windows based console program for configuring the controller
comes
with the controller. |
| Source
Code |
The C source code for the Setup program is provided on the software media that accompanies the controller. |
| Custom
Software |
Command set is provided so programmers may create their own software interface for embedded controller applications. The controller's command set is provided on the software media that accompanies the controller. For more infomation, see our Library page about the Communications Protocol. Free 3rd party device drivers (ActiveX Automation Servers) for the controllers are available at Kajei.com. |
| OPTIONS &
ACCESSORIES [up] |
|
| Heat
Sink |
 Add H3 (short; 0.637"; ~1.62cm) or H2 (tall; 1.025"; ~2.6cm) to the end of the model number to order. It is recommended that you have a heat sink if your load requires 15A or more. The bracket is usually replaced by the heat sink. The heat sink is extruded aluminum with mounting flanges and has black anodizing. See the Implementation
Notes below for more specific information. |
| Front
Panel Display |
 A Model
5R6-576 front panel display is available as a PCB and cable
(shown
left). The display allows you to see the actual temperature or
set the Set Point using 0.1° readability/settability. |
The Model 5R7-001 or 5R7-002 is capable of operating from an input
supply voltage
of 12 through 36 VDC, common to many available thermoelectric modules.
However, by supplying load power separately from the controller power,
you
can use loads, such as thermoelectric modules, that are anywhere from 0
to 36 vdc. The self-contained MOSFET output devices deliver load
currents
up 25 amperes. At 15A and higher it is recommended that you add a
heaetsink to the mounting bracket. You can order the controller with a
heatsink by adding "H2" or "H3" to the end of the part number (see heat sink options here).
These units will control total load power up to 900 watts.
These controllers will control with a finite temperature resolution of 0.01°C.
OEM Note: To drive down the cost of production units we can custom build for fixed, or selectable, voltages and levels of power, such as fixed 5 VDC at 2 Amperes.
Output Signal
The output signal to the thermoelectric module is Pulse Width Modulated (PWM) at 2700 Hz. Pulse Width Modulation averages the amount of energy provided to the module and reduces the extreme temperature excursions that are experienced with an "on / off" type of control system. This tends to extend the life and reliability of the thermoelectric devices.
TuningThe controller tuning structure allows designation of a variety of control features. Proportional bandwidth (P) in degrees, Integral reset (I) in repeats per minute, and the Derivative rate (D) in minutes may be configured for P, PI, PD, or PID control. In addition, a deadband control (on/off) with an adjustable hysteresis may be selected. Differential temperature control is possible when two input sensing thermistors are used. The controller can also be used as a variac in whcih a computer set value provides for manual control of the output, either polarity, from 0% to 100% of load power.
Set Temperature Input
The temperature can be set directly through our standard Setup program or other software.
Additional external set temperature input types may be selected. They include a remote set temperature potentiometer, a 0 to 5v VDC (or 1 to 5v) signal, and a 0 to 20 ma (or 4 to 20 ma) current loop. These secondary inputs are used to define and "map" the secondary input to an adjustable temperature range. Differential set temperature control may also be selected from this configuration menu. All temperatures may be consistently displayed in °C. or °F.
Differential
Temperature Control: Differential
control is available and is accomplished by
selecting
the primary set temperature with the second thermistor input and
establishing
the offset with the computer set temperature. In other words, when
using
differential control you no longer set the temperature itself from the
computer, but rather the offset from the temperature sensed by the
second
sensor. For example, A +10 degrees offset means the control temperature
will always be held at 10 degrees above the temperature being sensed at
the second sensor. The control temperature will be the "differential"
between
Input 2 (the temperature at the second sensor, which becomes a
reference
temperature) and Input 1 (actual system temperature).
Control Output Modes
Two types of control output modes may be selected for the controllers. This determines the direction of the current flow through the thermoelectric module during the heat cycle. This current flow may be from Wire Point WP1 (+) to Wire Point WP2 (-). Alternatively, this current flow may be reversed from WP2 (+) to WP1 (-) as selected in the configuration menu.
Variac Mode
From the PC you can choose to bypass the controllers internal control algorithms and set the output power to a specific value. There are 511 negative, 0, and 511 positive power values.
Alarms
Several alarm types may be selected. The alarms provide a 5 VDC output at the expansion connector, rated for 25 ma of current. The alarms consist of a "no alarm" function, tracking alarm, and fixed value alarm. Alarm set temperature values are entered in the setup menu. The computer-controlled selection is available for additional embedded controller input/output options. The alarm setup menu also provides for selection of an alarm latching condition. The alarm sensor may be either the control temperature sensor or a secondary thermistor sensor.
Power may be maintained during an alarm condition or the output power may be shut down.
Photo,
Mechanical Drawing, and Hookup
Temperature Stability
Temperature stability is a function of the resolution of the input temperature signal. The controller can hold temperature to the finest increment of the input temperature signal. The controller can resolve temperature changes down to 0.01°C. The stability you achieve depends more on the design of the overall thermal system than on the controller's resolution. These controllers provide DC voltage control with the possibility of stabilizing to better than ±0.02°C in a very well built thermal system.
OEM Note: If you start with the standard controller that has 0.01°C resolution and determine you need a controller with greater resolution for your product, we can design and provide a controller that meets the requirements of your product.
Connections
A
PC/Windows based console program for configuring the controller comes
with the unit, but
you can go beyond the program provided and control the temperature
controller
by means of your own or other software:
FOR FIBER OPTIC COMPONENTS AND LASER DIODES...
EXAMPLES OF CUSTOMIZATION
Custom Temperature Ranges
Custom or Programmable Voltage/Current
Custom dimensions
Any Additional Circuitry / Electronics on the Same Board
Safety Features / Cutoffs / Fuses / Current Limitting
Fan Control
Custom Alarms
Ruggedized
Uniphase Output
Various Types of Sensors
Rack Mount Versions
and more (inquire)
Note: Prices shown are for the controllers only. Sensors, TE modules and power supplies may be available but are not included in the controller pricing.
Lead Time: The 5R7-001 is generally in stock and can be shipped in 2 to 4 days ARO. The 5R7-002 requires at least 2 weeks lead time. Out of stock items may have a 1 to 4 week lead time.
SENSOR PRICING
Click
here for TR141 Series Sensor Housings and Prices (5K@25°C, -40°C to 70°C)
Click
here for TR91 Series Sensor Housings and Prices (10K@25°C, -40°C
to 150°C)
Click
here for TR67 and TR136 Series Sensor Housings and Prices (15K@25°C, -20°C
to 100°C)
Click
here for TR104 Series Sensor Housings and Prices (50K@25°C, 0°C to
150°C)
Click
here for TR165 Series Sensor Housings and Prices (231.5K@25°C, 25°C
to 250°C)
MODEL 5R7-001 with Heatsink
(RS232 Communications)
MODEL 5R7-002 with Heatsink
(RS485 Communications)
See heat sink options here.
5R7-001H3 or 5R7-002H3 Quantity 01
price:
each (controller with short heatsink)
5R7-001H2 or 5R7-002H2 Quantity 01
price:
$ Ask
each (controller with tall heatsink)
Lower prices are available at higher volume starting
at quantity 2.
MODEL 5R6-576 Display
Quantity 01
price:
each
Lower prices are available at higher volume.
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