thermoelectric cooler controller dx5100 oem … cooler controller dx5100 oem quick start instruction...

Thermoelectric Cooler Controller DX5100 OEM

Quick Start Instruction

PromLegion Ltd.

Moscow, 2016 Version 1.05

PromLegion Ltd. Controller DX5100 / Quick Start

Edition July 2016

Copyright

All rights reserved.

Reproduction in any manner, in whole or in part is straightly prohibited without written permission of PromLegion Ltd.

The information contained in this document is the subject to change without notice.

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Controller DX5100 / Quick Start PromLegion Ltd.

Table of Contents How to Get Connected ....................................................................... 5 DX5100 Vision .................................................................................... 7

Thermistor Setting .............................................................................. 8

Procedure Description - General .................................................... 8

Procedure Description - Firmware Version ≥334 ........................... 9

Thermistor Current Settings ............................................................ 9 Choice of Thermistor Type ............................................................ 12

Temperature as Function of Resistance: ...................................... 12

Calibration of Temperature Measurement Channel ...................... 13

Setting Alarm Limits .......................................................................... 16

Setting Limits of TEC Voltage ....................................................... 16 Setting Temperature Limit Values ................................................. 17

PID Tuning ........................................................................................ 18

PID Tuning Tips ............................................................................ 20

Operation Modes .............................................................................. 23

Autostart ........................................................................................ 23

Mode "Program" ............................................................................ 23 T-Regulation (Relay) ..................................................................... 24

PID regulation (Constant Temperature) ........................................ 25

Constant Voltage ........................................................................... 25

Monitoring ......................................................................................... 26

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Attention! This Quick Start Manual is valid for Controller Firmware Version ≥ 334. Please download correspondent version controllers having Firmware <334 from http://www.promln.com/downloads/index.php.

How to Get Connected Assemble the Controller according to the functional scheme and connecting procedure described in ”Technical Manual” enclosed (may be also downloaded from http://www.promln.com/downloads/index.php). Be careful when matching boards and channels of two-channel controllers

Connect the Thermoelectric Cooler (TEC), observing polarity. Positive polarity corresponds to the cooling mode.

Note: The connector for TEC connection is XP4 of the Power Board DX5102, or one of the connectors XP4 or XP2 of the double-channel Board DX5105. Connection is made by the cable enclosed to the delivery set of the Power Board. Double-check the polarity using Technical Manual.

Important! Ensure proper heat dissipation from a hot side of your TEC by using proper heatsink and good thermal contact between TEC hot side and a heatsink.

Important! Any TEC must be connected according to its polarity to operate in cooling mode.

Important! The position of temperature sensor (thermistor) must be carefully selected according to the design of an object (heat load) on a cold side of TEC. The design must ensure minimum possible temperature gradient between the thermistor and TEC cold side. Perfect thermal contact between the thermistor and an object (heat load) is required

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Note command interface is RS-232 by default. Connect the device to a COM-port of your PC by the cable RS-232 given in the Standard Kit of the Digital Control Board. The connection should be made to the connector XP8 of the Digital Control Board, see “Technical Manual” for details.

Connectors XP7 and XP8 DX5101 - RS-485 interface

Pin Description 1 Signal A of the interface RS-485 2 Signal B of the interface RS-485

Connectors XP1 and XP2 DX5106 - RS-485 interface

Pin Description 1 Signal A of the interface RS-485 2 Signal B of the interface RS-485 3 Supply voltage of the galvanic isolation is 12 V. Polarity

does not matter. The operation is possible At zero voltage. 4

Connect a Power Supply. It must provide voltage of 12±10% V.

Note: The Power Supply must be connected to the connector XP1 of each Power Board DX5102, or to the connector XP5 of the Power Board DX5105.

Important! Power supply must be chosen basing on total power consumption of the controller. Power supply must provide at least 80 W output if 2 x 32 W regulation channels are used at full power. Less powerful supplies may be used otherwise. In any case, power available from power supply must exceed total power output of both regulation channels by at least 20%.

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Important! The DX5100 OEM controllers may generate a significant amount of heat. Heat generated must be adequately removed in order to prevent the controller from overheating. An external heat sink is necessary, and active air circulation may be required depending on ambient temperature and power supplied to TECs.

DX5100 Vision You will need a PC to get DX5100 controller up and running when you switch it for the first time. Install the DX5100 Vision program supplied or downloaded from the manufacturer's website http://www.promln.com/downloads/. Note you may not need PC after you stored your programs/settings in DX5100 controller.

The controller has a rate setting 19200 kbps by default. DX 5100 needs one command and one noncommand interface. When the program runs, it scans serial ports of the system and determines the command interface of the connected controller DX5100. Another COM-port is highlighted by color next to it. This is a noncommand interface. Select both COM-ports and click on «Open».

Pay attention to the version of the controller firmware. The algorithm of thermistor setting depends on the version number.

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Thermistor Setting Attention! It is strongly recommended to back up the parameters of the controller before adjusting the thermistor. See "Backup/restore of parameters".

Procedure Description - General The thermistor setting means finding and storing parameters of the ADC channels for each thermistor in the non-volatile memory.

The procedure for setting a thermistor can be divided into several stages:

• Determination of input data: o thermistor type, o nominal, o choice of function type1 to calculate temperature 𝑻𝑻 = 𝒇𝒇(𝑹𝑹),

1 The controller allows using 2 types of functions for calculating temperature versus resistance: • Polynomial 5th order function: 𝑻𝑻 = 𝑨𝑨𝟎𝟎 + 𝑨𝑨𝟏𝟏𝑹𝑹 + 𝑨𝑨𝟐𝟐𝑹𝑹𝟐𝟐 + 𝑨𝑨𝟑𝟑𝑹𝑹𝟑𝟑 +

𝑨𝑨𝟒𝟒𝑹𝑹𝟒𝟒 + 𝑨𝑨𝟓𝟓𝑹𝑹𝟓𝟓

• Steinhart-Hart equation: 𝟏𝟏𝑻𝑻

= 𝑨𝑨 + 𝑩𝑩 𝒍𝒍𝒍𝒍(𝑹𝑹) + 𝑪𝑪 𝒍𝒍𝒍𝒍(𝑹𝑹)𝟑𝟑

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o calculation (or entering) coefficients, o storage of coefficients in controller.

• Calibration of temperature measurement channel: o Controller firmware version ≤ 333 calibrating resistors supplied2 should be used, cable of four-wire resistance measurement circuit.

o Controller firmware version ≥ 334 You can choose "automatic" calibration; You can calibrate in the manual mode, as in version 333; Verification of measurement results.

Procedure Description - Firmware Version ≥334 The thermistor setting means finding and storing parameters of the ADC channels for each thermistor in the non-volatile memory.

Thermistor Current Settings At first, you can check current settings of the thermistor and estimate the accuracy of measurements. Click on «Show current Thermistor settings»

The program will read the data of thermistor currently set in controller, and will try to identify the thermistor. If the coefficients

2 During calibrating, the program will inform you on the required nominal values (depending on thermistor type). You can also use other resistors of similar resistance values.

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match to the predefined (internal library) values, the following information will be displayed:

If the coefficients do not match to data in internal library (i.e. the sensor is unknown), the program will build the dependence of temperature versus resistance to obtain the coefficients and determine the sensor nominal).

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Choice of Thermistor Type To simplify the setup procedure, the program offers a choice of predefined characteristics of thermistors from the library. The list includes 4 platinum thermistors and 47 NTC thermistors with different alpha and beta coefficients.

If the sensor you use is on the list, just select it and go to the next section, "Calibration of temperature measurement channel".

Otherwise, you must define and set the thermistor data by using "User defined" option. The program will ask you to choose a type of R(T) function (see below), and operating temperature range. It is important that normal ambient conditions (usually 25+/-5 oC) are within the range you selected.

Temperature as Function of Resistance: The controller allows using 2 types of functions for calculating temperature versus resistance:

• Polynomial 5th order function 𝑻𝑻 = 𝑨𝑨𝟎𝟎 + 𝑨𝑨𝟏𝟏𝑹𝑹 + 𝑨𝑨𝟐𝟐𝑹𝑹𝟐𝟐 + 𝑨𝑨𝟑𝟑𝑹𝑹𝟑𝟑 + 𝑨𝑨𝟒𝟒𝑹𝑹𝟒𝟒 + 𝑨𝑨𝟓𝟓𝑹𝑹𝟓𝟓

• Steinhart-Hart equation

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𝟏𝟏𝑻𝑻

= 𝑨𝑨 + 𝑩𝑩 𝒍𝒍𝒍𝒍(𝑹𝑹) + 𝑪𝑪 𝒍𝒍𝒍𝒍(𝑹𝑹)𝟑𝟑

When Steinhart-Hart equation method is selected, you must enter 3 different values of temperature and correspondent resistance. This information is usually provided by a thermistor manufacturer. Two values should be at the extremes of working range, while the the third one - in a middle between extremes. The difference between values must be at least 10 K.

The Steinhart-Hart equation describes NTC thermistors very well.

When choosing a polynomial function, correspondent coefficients must be entered, also available from thermistor manufacturer.

Results of calculations may be checked by clicking "Calc".

Calibration of Temperature Measurement Channel Click the button «Calibrate». The program will ask for the confirmation:

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Double-check parameters and click OK. Then select the calibration mode.

Automatic mode must be chosen. The controller will be preset according to parameters of your thermistor (either chosen from the list of standard thermistors, or “User defined” as described above).

If necessary, the current settings of the thermistor can be checked and the accuracy of measurements can be assessed. This procedure

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is described in details in the section «Viewing Current Settings of Thermistor. Checking Measurements.» DX5100 Vision. User Guide.

Briefly, you can check the agreement of the calculated and experimental values using the fields for resistance or temperature inputs in «Check function of approximation» (upper boxes on the screenshot below). The block «Measurement of the resistance of the thermistor» allows more detailed verification of correct functioning of the temperature measurement channel by clicking on “Measurement”.

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Setting Alarm Limits

Setting Limits of TEC Voltage Select correspondent option in DX5100 VISON menu:

Important! To prevent a thermoelectric cooler (TEC) failure, it is necessary to set correct limit values of TEC voltage. Refer to the TEC specifications.

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Setting Temperature Limit Values Select correspondent option in DX5100 VISON menu.

The tab "Limiting temperatures" allows specifying the maximum and minimum “limit” temperatures. If the temperature is out of these limits for the time specified, a corresponding alarm is on and the channel is switched off automatically.

The meaning of the parameters to be set is illustrated by the following picture.

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PID Tuning Select “PID tuning” in “Operation” menu of DX5100 VISION. There is a tab to fine-tune the PID of the controller as shown below.

Here you can set the PID controller coefficients and check transient process of reaching the setpoint at different values of the coefficients.

Finding of optimum parameters of regulation of the given object is quite a delicate and relatively long procedure. It is a consecutive experimental tuning of parameters. Details may be found in DX5100 Technical Manual.

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Controller DX5100 has “auto-PID” option allowing to simplify the choice of optimum P-I-D finding considerably. We recommend always use auto-PID for checking/setting of PID parameters for the first time.

The function realizes the Ziegler-Nichols algorithm.

To run auto-PID, select PID setpoint temperature in menu. Setpoint temperature should be the same as nominal stabilization temperature of your object. Then click on “AUTO-PID” in the PID Setting menu. When the process is finished, all coefficients will be displayed in correspondent bars and transient process will be plotted.

If you are not satisfied by transient process you can tune PID coefficients further by yourself. The chapter “PID tuning tips” below describes how different constants affect transients and overall quality of temperature stabilization. Note the “tips” describe the procedure since the very beginning. We recommend to play around values obtained by using “auto-PID” procedure, using “start” and “stop” to check the result of every change.

Attention! Factory PID settings are just the most common values. Use of the controller without initial PID check and its tuning having your particular TEC and object (heat load) connected may result in non-proper temperature control and system failure.

Attention! Maximum TEC voltage must be set BEFORE starting auto-PID

Attention! Note the manufacturer does not guarantee the parameters obtained using built-in auto-PID function are the most optimum. It is recommended to check the obtained parameters and, if necessary, to carry out more accurate

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PID Tuning Tips The tuning quality can be estimated by different criteria: by the rate of achieving the setpoint, by the minimal overshot, by accuracy of setpoint maintenance.

The tuning quality can also be estimation by the transient process of achieving the setpoint. Recommendations for PID tuning by the form of the starting curve are given below.

1. Set values of integrated and differential components equal to zero:

Ki=0; Kd=0

Modify the value of the proportional component factor Kp so that the form of the transient process corresponds to that of curve 2 or 3 (see the figure below).

Kp1>Kp2>Kp3>Kp4>Kp5

Ttarget

T0

2. Modify the value of the differential component factor Kd so that

the form of the transient process corresponds to that of curve 2.

T0

Ttarget

tuning of the PID parameters depending on the required quality of the thermal regulation.

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3. The integrated component Ki is intended to remove a residual mismatch between the temperature value achieved in the system and the setpoint. Modify the value of the proportional component factor so that the form of the transient process corresponds to that of curve 3 (one relaxation spike with minimum possible overshoot).

T0

Ttarget

The figure below shows an example of results of manual changing of PID coefficients on controller performance.

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Operation Modes There are several modes of regulation available by DX5100:

• Idle (Regulation is off)

• Mode "Program"

• T-regulation (relay)

• PID regulation

• Constant voltage maintenance

To run the device, you should select operation mode first. You should also decide whether you’ll continue to control DX5100 by PC or not.

If you will continue controlling of DX5100 by a PC, you should simply select operating mode required and start/stop regulation using VISION (see “Monitoring” section below).

If you do not plan to use PC further, you should select regulation mode and switch DX5100 to “Autostart” mode as described below. Temperature regulation will start immediately upon switching on of a DC power supply.

Autostart DX5100 may be used stand-alone (without a computer) by using “Autostart” option. Factory setting is “idle”, but controller may be switched to “Autostart” operation when operation mode is changed from “Idle”. In this case, object temperature will be controlled automatically upon applying of 12 V DC power to DX5100. The mode required must be selected by using “Boot Mode” tab in DX5100 VISION.

Mode "Program" The Controller may operate programs stored in the non-volatile memory. There is a tab “Program manager” in VISION for modifying programs of temperature change in time. Please check DX5100 Technical Manual for more details.

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Note no programs are provided by RMT unless agreed before purchase.

T-Regulation (Relay) Immediately after starting this mode, the TEC maximum allowable voltage is supplied to the TEC for the most rapid achievement of the setpoint. Heating or cooling mode is chosen depending on the sign of the mismatch between current temperature and the setpoint. After reaching the setpoint the TEC is exposed to the stepped voltage equal to the specified value UTreg (see DX5100 Technical Manual for details). Depending on the mismatch (the difference between the setpoint and actual temperature) and on the sign of the voltage, either UTreg or 0 volts is supplied.

The described process is explained by the figure below.

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UTECmax=8V

UTreg=2V

Tneed=280KU[V]

T[K]296

0

282284

286288290

292294

PID regulation (Constant Temperature) The given mode provides maintenance of constant temperature of an object (TEC). Maintenance of The mode provides maintenance of constant temperature of an object (TEC). Maintenance of temperature is carried out by TEC voltage calculated according to PID regulation. This method provides the most precise temperature stabilization by TEC. Both TEC voltage and polarity are automatically controlled in this mode.

The PID coefficients are set by the User as described above.

Constant Voltage In this mode the TEC constant voltage is maintained. A User should set a value of constant voltage including the sign. Note the sign «-» stands for the heating polarity.

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Monitoring The mode allows monitoring changes of up to two parameters in time simultaneously, as well as a current operating mode.

In addition, you can start and stop any regulation mode there. For details, please check the screenshot below.

Regulation start and stop buttons

Choice of parameter of plot 1 Monitoring start and stop buttons

Modes

Current value of parameter of plot 2

Choice of parameter of plot 2

Current value of parameter of plot 1

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Some DX5100 OEM kits may include extension board DX5103 with indicator and two control buttons . You can select parameters you wish to monitor (set and actual temperature in both channels, TEC voltage and current, etc) by using these buttons, as it is shown on the figure below. It is important that control buttons may be used for switching temperature regulation on and off independently on whether DX5100 is controlled by a PC or not.

On the LCD of the board there are the parameters corresponding to a certain mode.

There are 8 screens of indication:

E1 Indication of temperatures and setting values

E5 Device identification

E2 Indication of channel TEC1 E6 Control (launch programm)

E3 Indication of channel TEC2 E7 Set TEC1 setpoint (launch PID)

E4 Status E8 Set TEC2 setpoint (launch PID)

№ Screen Description

E1

TEC1 temperature* TEC2 temperature*

TEC1 setting TEC2 setting

E2

TEC1 temperature*

channel number

TEC1 voltage

TEC1 setpoint TEC1

regulation mode**

TEC1 current

E3

TEC2 temperature*

channel number

TEC2 voltage

TEC2 setpoint TEC2

regulation mode**

TEC2 current

E4

STATUS XXXX*** Ch1- TEC1 regulation

mode** Ch2- TEC2

regulation mode**

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№ Screen Description

E5

Name and version of the firmware

Network address and identifier

Device serial number & Date of release

E6

TEC1 if from E2 TEC2 if from E3

START Pr-NN if mode is OFF (NN=00…15

program number) STOP

if mode is not OFF If there is not pressed button for 5 seconds,

it will return to the E2 or E3 screens.

E7

TEC1 temperature*

channel number

TEC1 voltage

TEC1 setpoint

setting TEC1

setpoint

TEC1 current

E8

TEC2 temperature*

channel number

TEC2 voltage

TEC2 setpoint

setting TEC2

setpoint

TEC2 current

* Indication "------" (instead of the temperature) occurs for values of thermistor resistance, exceeding the maximum for the range, which is configured ADC.

** Mnemonic designations are applied for a mode of regulation:

OFF Regulation is disabled PRG According to program REL T-regulation (relay) PID PID temperature control VOL Constant voltage OK Temperature is within the setting. The criterion of signal of

settling is right (see command 0x49)

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ERR Temperature is beyond the limitations (see commands 0x3C 0x3D)

*** Status displays in hexadecimal. Values status bit:

0x0001 error EEPROM 0x0002 unknown command 0x0004 no ready data for telemetry (response) 0x0008 TEC voltage at Z-metering does not drop for too long 0x0010 error in parameters or command format 0x0020 reception RS-232 buffer overfilling 0x0040 reception RS-485 buffer overfilling 0x0080 voltage supply error 0x0100 TEC1 temperature is beyond the limitations 0x0200 TEC2 temperature is beyond the limitations 0x0400 TEC1 temperature is within the setting 0x0800 TEC2 temperature is within the setting 0x1000 Command performance is interrupted

Since the Firmware version 341 it is possible to set the first (after boot) screen with the command 0x54. Also, using the command 0x54 it is possible to choose unit temperature display - in Kelvin (K) or in degrees Celsius (0).

Controlling with Indication board

The Indication Board can be used not only for imaging parameters but also for management the controller.

You can launch the channel regulation of the previously prepared program or set setpoint and also stop regulation on the channels.

Important! The program should be prepared and stored in the controller.

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mode=OFFmode=PRG

N

Pr=Pr-1

L

Pr=Pr+1

R

mode=OFF1 0

Rt R

L

L

L

L

R

L

R

R

R

2

mode=PID

N L R2

Lt

Lt Rt

Rt Lt To

setpoint

To=To-1 To=To+1

mode=OFFmode=PRG

N

Pr=Pr-1

L

Pr=Pr+1

R

mode=OFF1 0

Rt

2

mode=PID

N L R2

Lt

Lt Rt

Rt Lt

To=To-1 To=To+1

To setpoint

You can set setpoint and launch the PID mode channel regulation.

Special screens (E6…E8) are used for manage the controller.

Switching between the screens graph illustrates:

The graph used the notation:

L – left button, single click;

Lt – left button,hold;

R- right button, single click;

Rt – right button,hold;

2 – two buttons click;

N – no clicks of any button

in 5 seconds

Please refer DX5100 Technical Manual for more details.

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PromLegion Ltd.

46 Warshawskoe shosee Moscow 115230 Russia e-mail: [email protected] phone: +7-499-678-3231 fax: +7-499-678-3258 website: www.promln.ru

Overseas Sales representative

TEC Microsystems GmbH Schwarzschildstrasse 8 Berlin 12489, Germany phone: +49-(0)30-6789-3314 fax: +49-(0)30-6789-3315 e-mail: [email protected] website:www.tec-microsystems.de

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http://www.tec-microsystems.de/

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