The Model 5R7-582 or Model 5R7-583 temperature controllers provide automatic biphase heating and cooling control for Thermoelectric (Peltier effect, or TEC) modules.

The two special features of this controller are that the output power can be more than 900W and that the sensor can be a thermistor or an RTD. If you can use 900W or less, and do not require compatibility with an RTD, please consider using the Model 5R7-001.

The Model 5R7-582 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.

The Model 5R7-583 Client controller has a sensor input that is used as an alarm sensor that can shut off the output power of the 5R7-583 if the sensed temperature is out of range. The Setup software of the 5R7-582 Server allows you to set the High and Low alarm values for the 5R7-583 Client.

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, relays, 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 5R7-584 front panel display allows you to see the actual temperature or set the Set Point using 0.1 degrees resolution.

The Model 5R7-582 can be used by itself for up to 1kW of output power. It can also be used as a "server" that connects to as many as 32 of the 5R7-583 Client controllers. As a group these can work together to controller many kilowatts of output power.

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. ( Photo Showing Hookup)

	The Model 5R7-582 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.
	The Model 5R7-583 Client uses RS485 to communicate with the Model 5R7-582. Using RS485, the 5R7-582 can act as a "server" for one or more 5R7-583 "client" controllers. 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.

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.

 

 
 
 


Input Supply Voltage

The Model 5R7-582 is capable of operating from an input supply voltage of 9 through 36 VDC. The self-contained MOSFET output devices deliver load currents up to 28 amperes for the 5R7-582. These units will control total load power up to 1000 watts.

The Model 5R7-582 can be used by itself, or along with one or more 5R7-583 Client controllers, in which case the 5R7-582

The Model 5R7-583 Client is capable of operating from an input supply voltage of 12 through 28 VDC. The self-contained MOSFET output devices deliver load currents up to 25 amperes. These units will control total load power up to 680 watts.

At 15A and higher it is recommended that you add a heaetsink to the mounting bracket. Ask about ordering the controller with a heatsink.

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.

Tuning

The 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.

For the 5R7-582, 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 for the 5R7-582 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

For the 5R7-582, 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.

For the 5R7-583 fixed High/Low alarm settings are available, as well as alarm latching and the ability to have the output power shut off in an alarm state.

Power may be maintained during an alarm condition or the output power may be shut down.

Server/Client Network

When the 5R7-582 is a server to many 5R7-583 Client controllers, the server's Input1  sensor is the control sensor for the entire system. The sensed temperature provided by that sensor is used by the server to determiine if output power should increase, decrease or remain the same. It then passes the information to all the client controllers so that they all act in unison.

Each controller in the network has an alarm sensor for itself. The alarm type is simply a High/Low fixed value alarm. If the temperature at one of these sensors goes too high or too low it triggers an alarm state. The controllers can be configured to shut down the output power in an alarm state. Although each controller has its own alarm setup, if the server, which has the control sensor, senses an alarm condition it shuts down the entire network.

Example: With 12v, 9A peltier modules arranged in groups of six (place 2 in series for 24v, 9A, and place 3 of those sets in parallel for 24v, 27A, which is 648W total), then with the server and 32 clients you can control 33 sets of 6 peltier modules for a total of 21,384 Watts spread over 198 peltier modules.

 
(Notes & Software)

Photo Showing 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 yourproduct.

Connections

• This unit requires a DC voltage cable that connects to the controller using two 0.25 inch quick connects (fast tab connections).
• The power connection of the heater or cooler to the relay is also made with the same type of connector as above.

Operating Temperature of the Solid State Relays (SSR, MOSFET)

The relays are mounted to the base of the angle bracket and the bracket acts as a heatsink.

In general it is recommended that the bracket have a heatsink if your system draws 15A or more. Add "HS" to the part number to include a mounted heatsink.

Specific recommendation: The ultimate goal is to cool the Mosfet junction temperature. Measure temperature at the tab of each MOSFET under normal operating conditions. The maximum operating junction temperature is 175°C.  We recommend maintaining tab temperatures at less than 100°C if possible in order to extend the life of the product.

Software

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 Programmatic Control
• Programming: Programming the controllers yourself requires an appropriate capability in a programming language (such as Microsoft's Visual Basic or National Instrument's LabView or similar). Device drivers for the controllers are available at Kajei.com. 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.
  
• Source Code: The C source code for the Setup program is provided on the software media that accompanies the controller.

Telecom, Fiber Optic & Laser Diode Notes

FOR FIBER OPTIC COMPONENTS AND LASER DIODES... Note.

 

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 5R7-582 and 5R7-583 is generally in stock and can be shipped in 2 to 4 days ARO. 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, 100°C to 200°C)

MODEL 5R7-582 Temperature Controller (Alone or as a Server)
  Quantity 01 price: each
   Lower prices are available at higher volume starting at quantity 2.

MODEL 5R7-583 Temperature Controller (Client)
  Quantity 01 price: each
  Lower prices are available at higher volume starting at quantity 2.

MODEL 5R7-584 Display
  Quantity 01 price: each
  Lower prices are available at higher volume.

• Customization
• We can custom build for fixed, or selectable, voltages and levels of power. We can customize the form factor. We can take a finalized through-hole design to SMT. This is a custom build. We can quote an NRE and per unit price based on your feature set. Email us. Give us an idea of what you are considering and we will work with you to develop the controller's specifications.
• Payment
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• General Notes on Pricing
• Controllers Only: Prices shown are for the "controllers only". 
• Currency: All prices are $US.