Practical Temperature Measurements

Hewlett-Packard Classroom Series Practical Temperature Measurements 001

Hewlett-Packard Classroom Series Agenda • Background, history • Mechanical sensors • Electrical sensors • Optical Pyrometer • RTD • Thermistor, IC • Thermocouple • Summary & Examples A1

Hewlett-Packard Classroom Series What is Temperature? • A scalar quantity that determines the direction of heat flow between two bodies • A statistical measurement • A difficult measurement • A mostly empirical measurement 002

Hewlett-Packard Classroom Series How is heat transferred? • Conduction 003 • Metal coffee cup • Convection • Radiation

Hewlett-Packard Classroom Series The Dewar 004 • Glass is a poor conductor • Gap reduces conduction • Metallization reflects radiation • Vacuum reduces convection

Sensor Sensor Hewlett-Packard Classroom Series Thermal Mass 005 • Don't let the measuring device change the temperature of what you're measuring. • Response time = • f{Thermal mass} • f{Measuring device}

Hewlett-Packard Classroom Series Temperature errors • What is YOUR normal temperature? • Thermometer accuracy, resolution • Contact time • Thermal mass of thermometer, tongue • Human error in reading 006 97.6 98.6 99.6 36.5 37 37.5

96 12 1 0 Hewlett-Packard Classroom Series History of temperature sensors • 1600 ad • 1700 ad 007 • Fahrenheit • Instrument Maker • 12*8=96 points • Hg: Repeatable • One standard scale • Galileo: First temp. sensor • pressure-sensitive • not repeatable • Early thermometers • Not repeatable • No good way to calibrate

0 100 100 0 Hewlett-Packard Classroom Series The 1700's: Standardization • 1700 ad • 1800 ad 008 • Thomson effect • Absolute zero • Celsius: • Common, repeatable calibration reference points • "Centigrade" scale

d Hewlett-Packard Classroom Series 1821: It was a very good year • 1800 ad • 1900 ad 009 • The Seebeck effect • Davy: The RTD • Pt 100 @ O deg.C

Hewlett-Packard Classroom Series The 1900's: Electronic sensors • 1900 ad • 2000 ad 010 • 1 uA/K • Thermistor • IC sensor • IPTS 1990 • IPTS 1968 • "Degree Kelvin">> "kelvins" • "Centigrade">> " Celsius"

Freezing point H O Boiling point H O 2 2 Hewlett-Packard Classroom Series Temperature scales Absolute zero 011 • Celsius 100 0 -273.15 • Kelvin 0 273.15 373.15 • Fahrenheit 32 212 -459.67 • Rankine 671.67 0 427.67 • "Standard" is "better": • Reliable reference points • Easy to understand

Hewlett-Packard Classroom Series IPTS '90: More calibration points • 1357.77: FP Cu • 273.16: TP H2O • 234.3156: TP Hg 012 • 1337.33: FP Au • 1234.93: FP Ag Large gap • 933.473: FP Al • 692.677: FP Zn • 83.8058: TP Ar • 505.078: FP Sn • 54.3584: TP O2 • 429.7485: FP In • 24.5561: TP Ne • 20.3: BP H2 • 17 Liq/vapor H2 • 302.9146: MP Ga • 13.81 TP H2 • 3 to 5: Vapor He

200 100 300 0 400 Hewlett-Packard Classroom Series Bimetal thermometer • Forces due to thermal expansion • Two dissimilar metals, tightly bonded 013 • Result • Bimetallic thermometer • Poor accuracy • Hysteresis • Thermal expansion causes big problems in other designs: • IC bonds • Mechanical interference

100 0 Hewlett-Packard Classroom Series Liquid thermometer; Paints 014 • Thermally-sensitive paints • Irreversible change • Low resolution • Useful in hard-to-measure areas • Liquid-filled thermometer • Accurate over a small range • Accuracy & resolution= f(length) • Range limited by liquid • Fragile • Large thermal mass • Slow

Hewlett-Packard Classroom Series Optical Pyrometer 015 • Infrared Radiation-sensitive • Photodiode or photoresistor • Accuracy= f{emissivity} • Useful @ very high temperatures • Non-contacting • Very expensive • Not very accurate

Hewlett-Packard Classroom Series Resistance Temperature Detector 016 • Most accurate & stable • Good to 800 degrees Celsius • Resistance= f{Absolute T} • Self-heating a problem • Low resistance • Nonlinear

Hewlett-Packard Classroom Series RTD Equation • R= 100 Ohms @ O C • Callendar-Van Deusen Equation: • R=Ro(1+aT) - Ro(ad(.01T)(.01T-1)) • Ro=100 @ O C • a= 0.00385 / - C • d= 1.49 For T>OC: for Pt R 300 200 100 Nonlinearity T • 0 200 400 600 800 017

d Hewlett-Packard Classroom Series Measuring an RTD: 2-wire method Rlead Rx + 100 V I ref= 5 mA d Rlead Pt - • R= Iref*(Rx + 2* Rlead) • Error= 2 /.385= more than 5 degrees C for 1 ohm Rlead! • Self-heating: • For 0.5 V signal, I= 5mA; P=.5*.005=2.5 mwatts • @ 1 mW/deg C, Error = 2.5 deg C! • Moral: Minimize Iref; Use 4-wire method • If you must use 2-wire, NULL out the lead resistance 018

d d Hewlett-Packard Classroom Series The 4-Wire technique Rx + 100 V 019 Rlead=1 I ref= 5 mA - • R= Iref * Rx • Error not a function of R in source or sense leads • No error due to changes in lead R • Twice as much wire • Twice as many scanner channels • Usually slower than 2-wire

d Hewlett-Packard Classroom Series Offset compensation Voffset + 020 100 V I ref (switched) - • Eliminates thermal voltages • Measure V without I applied • Measure V I applied With V R= I

d 100 1000 d V d 1000 d Hewlett-Packard Classroom Series Bridge method 021 100 • High resolution (DMM stays on most sensitive range) • Nonlinear output • Bridge resistors too close to heat source

d d V d d Hewlett-Packard Classroom Series 3-Wire bridge 100 1000 Rlead 1 022 3-Wire PRTD Sense wire 1000 Rlead 2 100 • Keeps bridge away from heat source • Break DMM lead (dashed line); connect to RTD through 3rd "sense" wire • If Rlead 1= Rlead 2, sense wire makes error small • Series resistance of sense wire causes no error

Hewlett-Packard Classroom Series Agenda A5 • Background, history • Mechanical sensors • Electrical sensors • Optical Pyrometer • RTD • Thermistor, IC • Thermocouple • Summary & Examples

d d d d d Hewlett-Packard Classroom Series Electrical sensors: Thermistor Rlead=1 + V 5k I= 0.1 mA • Hi-Z; Sensitive: 5 k @ 25C; R = 4%/deg C Rlead=1 - • Limited range • 2-Wire method: R= I * (Rthmr + 2*Rlead) • Lead R Error= 2 /400= 0.005 degrees C • Low thermal mass: High self-heating • Very nonlinear 023

d V Hewlett-Packard Classroom Series I.C. Sensor d AD590 I= 1 uA/K • High output • Very linear • Accurate @ room ambient • Limited range • Cheap + 100 - 5V = 1mV/K 960 024

I.C. AD590 RTD Thermistor • High output • Fast • 2-wire meas. • High output • Most linear • Inexpensive • Most accurate • Most stable • Fairly linear • Very nonlinear • Limited range • Needs I source • Self-heating • Fragile • Expensive • Slow • Needs I source • Self-heating • 4-wire meas. • Limited variety • Limited range • Needs V source • Self-heating Hewlett-Packard Classroom Series Summary: Absolute T devices 025

Ta Tx V Tx V= e(T) dT Ta Hewlett-Packard Classroom Series Thermocouples The Gradient Theory 026 • The WIRE is the sensor, not the junction • The Seebeck coefficient (e) is a function of temperature

Ta Tx B V A Ta Tx V= e dT Ta Hewlett-Packard Classroom Series Making a thermocouple 027 • Two wires make a thermocouple • Voltage output is nonzero if metals are not the same Ta + e dT B A Tx

Ta Tx A V A Ta Tx V= e dT Ta Hewlett-Packard Classroom Series Gradient theory also says... 028 • If wires are the same type, or if there is one wire, and both ends are at the same temperature, output= Zero. Ta + e dT = 0 A A Tx

a Fe Tx b Con Fe Cu Cu Fe = Tx Tx V V Con Cu Con Cu Hewlett-Packard Classroom Series Now try to measure it: • Theoretically, Vab= f{Tx-Tab} • Result: 3 unequal junctions, all at unknown temperatures • But, try to measure it with a DMM: 029

Fe Cu Cu Fe Tx Add Tx Con V Con V Tref = 0 C Tref o Cu Fe Cu Fe Hewlett-Packard Classroom Series Solution: Reference Thermocouple • Problems: a) 3 different thermocouples, b) 3 unknown temperatures 030 • Solutions: a) Add an opposing thermocouple b) Use a known reference temp. Isothermal block

Hewlett-Packard Classroom Series The Classical Method Cu Fe 031 • If both Cu junctions are at same T, the two "batteries" cancel • Tref is an ice bath (sometimes an electronic ice bath) • All T/C tables are referenced to an ice bath • V= f{Tx-Tref} Tx Con V Tref = 0 C o Cu Fe • Question: How can we eliminate the ice bath?

Fe Cu Tx Con V Cu Fe Hewlett-Packard Classroom Series Eliminating the ice bath • Don't force Tref to icepoint, just measure it • Compensate for Tref mathematically:V=f{ Tx - Tref } • If we know Tref , we can compute Tx. 032 Tice Tref Tice Tice

Fe Cu Tx 2 Con V Cu Fe 1 2 1 Hewlett-Packard Classroom Series Eliminating the second T/C 033 • Extend the isothermal block • If isothermal, V1-V2=0 Fe Cu Tref Tx V Tref Con Cu

Fe Cu Tx Tref V Con Cu Hewlett-Packard Classroom Series The Algorithm for one T/C • Measure Tref: RTD, IC or thermistor • Tref ==> Vref @ O C for Type J(Fe-C) • Know V, Know Vref: Compute Vx • Solve for using Vx o Tx Compute Vx=V+Vref Vx V Vref Tx Tref 0 o 034

Hewlett-Packard Classroom Series Linearization V 035 Small sectors T Tx Tref 0 o 2 9 3 • Polynomial: T=a +a V +a V +a V +.... a V • Nested (faster): T=a +V(a +V(a +V(a +.......))))))))) • Small sectors (faster): T=T +bV+cV • Lookup table: Fastest, most memory 0 1 2 3 9 0 1 2 3 2 0

mV E E E 60 K J N 40 20 R T S deg C 0 500 1000 2000 Hewlett-Packard Classroom Series Common Thermocouples 036 Platinum T/Cs Base Metal T/Cs • All have Seebeck coefficients in MICROvolts/deg.C

Hewlett-Packard Classroom Series Common Thermocouples Seebeck Coeff: uV/C 037 Type Metals • Microvolt output is a tough measurement • Type "N" is fairly new.. more rugged and higher temp. than type K, but still cheap Fe-Con Ni-Cr Cu-Con Pt/Rh-Pt Ni/Cr-Con Ni/Cr/Si-Ni/Si 50 40 38 10 59 39 J K T S E N

Hewlett-Packard Classroom Series Extension Wires • Possible problemhere 038 Large extension wires Small diametermeasurementwires • Extension wires are cheaper, more rugged, but not exactly the same characteristic curve as the T/C. • Keep extension/TC junction near room temperature • Where is most of the signal generated in this circuit?

Normal Mode ac NOISE HI DMM Normal Mode Input LO Resistance dc SIGNAL HI DMM Input Resistance LO Common Mode ac NOISE Hewlett-Packard Classroom Series Noise: DMM Glossary 039 • Normal Mode: In series with input • Common Mode: Both HI and LOterminals driven equally

Electrostatic Noise Magnetic Noise HI DMM Input LO Resistance dc SIGNAL HI DMM Input R lead Resistance LO R leak Common Mode ac source Common Mode Current Hewlett-Packard Classroom Series Generating noise 040 Normal Mode • Large surface area, high Rlead: Max. static coupling • Large loop area: Max. magnetic coupling • Large R lead, small R leak: Max.common mode noise

Electrostatic Noise Magnetic Noise HI DMM Input LO R HI DMM Input R - + LO R leak Common Mode ac source Common Mode Current Hewlett-Packard Classroom Series Eliminating noise 041 Normal Mode dc SIGNAL • Filter, shielding, small loop area(Caution: filter slows down the measurement) • Make R leak close to

Hewlett-Packard Classroom Series Magnetic Noise • Magnetic coupling 042 DMM InputResistance Induced I • Minimize area • Twist leads • Move away from strong fields

Hewlett-Packard Classroom Series Reducing Magnetic Noise • Equal and opposite induced currents 043 DMM InputResistance • Even with twisted pair: • Minimize area • Move away from strong fields

Hewlett-Packard Classroom Series Electrostatic noise AC Noise source 044 Stray capacitances DMM InputResistance Inoise Stray resistances • Stray capacitance causes I noise • DMM resistance to ground is important

Practical Temperature Measurements