TEMPERATURE CONTROLFOR HEATING SOLUTIONS

Production locations

· Backer Calesco main office and

production in SWEDEN

· Production facility in POLAND

· Production facility in CHINA

· Sales office/warehouse in the US

WE MAKE IT HAPPEN

Heating solutions

Backer Calesco has the experience,

knowledge and capabilities to help

you develop and manufacture heating

solutions for all type of applications.

A thin flexible foil heater provides ex-

cellent heating efficiency in the area

where you need it most.

Our heating products together with

our measurement and control de-

vices offer our customers complete

solutions. Our engineers will not only

suggest solutions they can also take

part and contribute to your product

development by using our advanced

technical tools and lab facilities.

Our extensive experience and compe-

tence as well as our reliable quality

and service guarantees your success.

Our ambition is to not only be a sup-

plier, but your preferred partner.

THERMOSTAT · RESISTANCE CONTROLLED · NTC · PTC · PT100/PT1000 · THERMOCOUPLE

QUALITY ASSURANCE

Calesco is certified

According to SS-EN ISO 14001:2004 and

ISO 9001-2008 by INTERTEK

Our facility in China & Poland is certified

According to ISO 14001, ISO 9001 and

ISO-TS 16949

Third part approvals

VDE / ETL / S / UL / FDA /TüV

MEMBER OF BACKER-GROUP

BACKER CALESCO is a part of Backer group,

within NIBE Industrier. NIBE Industrier is an

international heating technology company

whose business operations are organised in

three separate business areas: NIBE Energy

Systems, NIBE Element and NIBE Stoves.

The Group has more than 10,000 employ-

ees and operates in 20 countries in Europe,

North America, Australia and Asia. The legal

structure of the Group comprises a number

of subsidiaries, who run their own operations

via their own companies or branch offices.

NIBE is listed on the NASDAQ OMX Stockholm

Exchange, Large Cap list, with a secondary

listing on the SIX Swiss Exchange.

TEMPERATURE CONTROL OUR SERVICES

Control and engergy balance

Flexible foil heaters provide excellent

thermal transfer where you need it most.

Heaters are used in thermal control design

to protect components under cold-case

environmental conditions or to make up

for heat that is not dissipated. It is usually

necessary to arrange some form of control

to ensure that the desired temperature

is maintained. Heaters are used with

thermostats, PTC, PT100/PT1000 sen-

sors, thermocouples, solid-state or digital

controllers to provide exact temperature

control of a particular component

Integrated control/smart heater

The demands for smart simple solutions

creates new applications and we can offer

solutions with integrated thermal control-

lers and sensors communicating through

RS232, WiFi or Zigbee.

R&D

· Broad product portfolio

· Product validation test laboratory

· Watt density requirements

· Material selection

· Physical design and optimization

Integration

· Heaters

· Temperature sensors

· Flex circuits

· Components

· Heat sinks

Assembly and Production

· One stop shop

· Heater forming - performance & physical

· Small series to Mass production

· Full service

Typical types of temperature control

Thermostat

Resistance controlled

NTC

PTC

PT100/PT1000

Thermocouple

Overheat protection

THERMOSTAT · RESISTANCE CONTROLLED · NTC · PTC · PT100/PT1000 · THERMOCOUPLE

TO GENERATE HEAT

Conduction

· Heat transfer by direct contact to substrate

Convection

· Heat transfer by convection, generally in air,

fluid or gas and can be forced (heat pumps or

natural convection in ex air)

Radiation

· Energy transfer of to or from a body by emis-

sion or absorption of electromagnetic radiation

Material At 25°C At 225°C

Iron 80 60

Low carbon steel 54 47

Stainless steel 16 19

Tungsten 180 150

Platinum 70 72

At 125°C

68

51

17,5

160

71

Aluminium 250 250255

Thermal conductivity (W/m°C)

Gold 310 310312

Silver 420 415418

Copper 401 398400

Thermal Conductivity

To maintain a desired temperature level heat has to be provided and suitable heat

storage capability. Thermal conductivity is the property of a material to conduct

heat. Thermal conductivity units are W/(m K) in the SI system and Btu/(hr ft °F) in

the Imperial system.

RESISTANCE CONTROLLEDOperating tables / Fluid heaters

THERMOSTATSilicone heaters / Water trough heaters / food heaters

Thermostat is an example of a closed control loop.

This can be achieved with electromechanical ther-

mostats of bimetallic type where temperature and

surface ratings are low, while electronic thermostats

are preferred where temperatures and surface loads

are high. It constantly assesses the current room

temperature and controls a heater to increase or

decrease the temperature according to user-defined

settings.This method is called Proportional control.

Thermostat (low-cost, cheap) thermostat mere-

ly switches the heater on or off, and temporary

overshoot and undershoot of the desired average

temperature. Thermostat (expensive) the difference

between the required temperature (the “set point”)

and the actual temperature. These minimize over/

undershoot.

Note

· Limited number of cycles

Benefits

· Low cost

· Proven technology

Resistance controlled temperature controller, this

is one of the most accurate ways to measure and

control temperature. No moving parts, semiconduc-

tors or thermistors to measure temperature. The

resistance of the heater is dependence on tempera-

ture. This means we are using the heater as a temp

sensor to detect temperature change exposure.

Ω -

Change

C 0 100 200 300 400 500

SS321

cu

Temperature change

Benefits

· The heater is the sensor,

no added parts on the heat-

er surface open exposure

· Robust and exact

· Quick and easy to regulate

· Cu, Brass or Al circuit

· Known technology

· Constant wattage long life

PTCRear-view mirror heaters / Heart starter heaters / Battery heaters

NTCMeteorology heaters / Camera heaters / AdBlue®

Negative temperature coefficient (NTC) De-

creases in electrical resistance when their

temperature is raised. Negative tempera-

ture coefficient (NTC) thermistor is a two

terminal solid state electronic component

with predictable change in resistance

corresponding to changes in absolute body

temperature.

Thermistor Terminology:

Thermistors exhibit a large negative

change in resistance with respect to

temperature, this relationship between

resistance and temperature follows an

approximately exponential-type curve.

Benefits

· Surface mounted integrated

in circuitry

· Exact measurement on spot or

on surface if mounted right

· Known technology

· Constant wattage long life

Negative temperature coefficient (NTC) Decreases in

electrical resistance when their Positive temperature

coefficient (PTC)

Increases in electrical resistance when their temper-

ature is raised. Materials which have useful engi-

neering applications usually show a relatively rapid

increase with temperature, i.e. a higher coefficient.

The higher the coefficient, the greater an increase in

electrical resistance for a given temperature increase.

Note

· Aging over time, shorter

lifetime

Benefits

· Self regulating

· Max. power density

0,25W/sqcm²

· No added parts

PT100/PT1000Packaging machines / Autoclaves / Process heating tables

Negative temperature coefficient (NTC)

Resistance thermometers are constructed

in a number of forms and offer greater

stability, accuracy and repeatability in

some cases than thermocouples.

Limitations

RTDs in industrial applications are rarely

used above 660 °C.

Benefits

· High accuracy

· Low drift

· Wide operating range

· Suitability for precision

applications

Thermocouples are a widely used type of temperature

sensor for measurement and control. Commercial ther-

mocouples are inexpensive, interchangeable, are supplied

with standard connectors, and can measure a wide range

of temperatures. In contrast to most other methods of

temperature measurement, thermocouples are self-pow-

ered and require no external form of excitation.

The main limitation with thermocouples is accuracy;

system errors of less than one degree Celsius (°C) can be

difficult to achieve.

Type K (chromel – alumel) is the most common thermo-

couple. Probes are available in its −200 °C to +1350 °C.

Type K is made of magnetic material, and have 2 critical

temperature s around 185 °C and near 400 °C.

THERMOCOUPLESMolding tools / Vacuum table heaters

OTHER TYPES

Overheat protection

Low resistance resistor that acts as a sacrificial device to provide overcur-

rent protection, of either the load or source circuit. Its essential component is a

metal wire or strip that melts when too much curent flows through it, interrupt-

ing the circuit that it connects. Short circuits, overloading, mismatched loads, or

device failure are the prime reasons for excessive current.

Melt fuse

A fuse interrupts excessive current (“blows”) so that further damage by over-

heating or fire is prevented. Overcurrent protection devices are essential in

electrical systems to limit threats to human life and property damage. The time

and current operating characteristics of fuses are chosen to provide adequate

protection without needless interruption. Slow blow fuses are designed to allow

harmless short term currents over their rating while still interrupting a sus-

tained overload.

Overheat thermostat

Bimetal thermal protector is an overheating protection device for electric appli-

ances and they are reusable parts that are reset when equipment cools. If the

fault still exists, the protectors continue to automatically protect the equipment.

All systems need limitations and control to guarantee precise heat

SOFTWARE PROTOCOLS

Can Bus

CAN bus (controller area network) is a

vehicle bus standard designed to allow

microcontrollers and devices to commu-

nicate with each other in applications

without a host computer. It is a mes-

sage-based protocol, designed originally

for automotive applications, but is also

used in many other contexts.

OBD

OBD (On-board diagnostics ) Automotive

term referring to a vehicle’s self-diag-

nostic and reporting capability. Modern

OBD implementations use a standardized

digital communications port to provide

real-time data in addition to a standard-

ized series of diagnostic trouble codes,

or DTCs.

Bluetooth

Wireless technology standard for ex-

changing data over short distances (2.4

to 2.485 GHz) from fixed and mobile

devices. Originally invented as a wire-

less alternative to RS-232 data cables. It

can connect several devices, overcoming

problems of synchronization.

Wi-Fi

Local area wireless technology that

allows an electronic device to partic-

ipate in computer networking using

2.4 GHz UHF and 5 GHz SHF ISM radio

bands.

LIN (Local Interconnect Network)

Serial network protocol used for commu-

nication between components in vehicles.

RS232

Standard for serial communication trans-

mission of data via a serial port.

RS485

Digital communications networks im-

plementing the EIA-485 standard can

be used effectively over long distances

and in electrically noisy environments.

Enables local networks and multidrop

communications links. It offers data trans-

mission speeds of 35 Mbit/s up to 10 m

and 100 kbit/s at 1200 m.

KNX

KNX defines several physical communica-

tion media:

Twisted pair wiring (inherited from

the BatiBUS and EIB Instabus standards)

Powerline networking (inherited from EIB

and EHS - similar to that used by X10)

Radio (KNX-RF) Infrared Ethernet (also

known as EIBnet/IP or KNXnet/IP).

THERMAL MANAGEMENTExamples temperature requirements

Batteries

· Typically between -5 to 20˚C

Propulsion components

· Typically between 5 to 40˚C

Cameras

· Typically between -30 to 40˚C

Electrical cabinets

· Typically between -20 to 40˚C

Autoclaves

· Typically between 50 to 250˚C

Automotive

· Typically between -40 to 80˚C

MOUNTING OF HEATER

Overmolded

· Encapsulated in camera encapsulation or at substrate wall

· No air bubbles

· Long life time

· Robust

· No open parts exposed to environment

Supported (envelope)

· Heater encapsulated in metal to withstand environment

and stress from ice, moisture etc.

· No parts open to environment

· Mechanically strong

Heater in housing

· Heats where it’s needed

· Laminated by adhesive or glue to inside of wall

CONCERNS | TO BE CONSIDERED

Application environment

· Clean air

· Moisture

· Environmental exposure

· Surrounding temperatures

· Vibration levels

Life time of heater

· Expected life time

Performance requirements

· Max. voltage

· Min/max. temp / Regulation

· Time allowed to use

· Temperature Over-Temp Response (time/temp)

· Reaction time temp regulation

Installation/Mounting

· Connector

· Cables vs flex tail

· Fasteners vs. Integrated

· Space Available

· Surrounding Materials

· Overheat Thermostat/ Melt fuse

Bac

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Backer BHV AB / Div. CalescoVästra Åvägen 11SE-734 51 Kolbäck

Tel: +46 (0) 220 453 00

backercalesco.se

E V E R Y D A Y · E V E R Y W H E R E