Princess Sumaya Univ.

Electronic Engineering Dept.

3441
Industrial Instruments 1
Chapter 4
Thermal Sensors
Dr. Bassam Kahhaleh
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Thermal Sensors

Objective
Understand how thermal sensors work and
how to interface them.
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Thermal Sensors
Metal Resistance
Energy bands for solids:
Energy gap: required energy for the electron to become free

W W W

Conduction
Conduction
Conduction

Valence Valence
Valence

Metals Semiconductors Insulators

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Thermal Sensors
Metal Resistance
Nickel
Platinum
3
R(25°C)

l
R
R(T)

2
A

R (T )  (T )

1 R (25)  ( 25)

Temperature
(°C)
−100 0 100 200 300 400 500 600
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Thermal Sensors
Metal Resistance
Linear Approximation

R (T )  R (T0 ) [1   0 T ] R2

1  R2  R1  R1
0   
R (T0 )  T2 T 1 
T1 T T2

Quadratic Approximation

R (T )  R (T0 ) [1  1T   2 ( T ) 2 ]
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Thermal Sensors
Resistance-Temperature Detectors (RTD)
 Sensitivity
0: 0.004/°C ~ 0.005 /°C
 Response Time
0.5 ~ 5 seconds
 Construction
Wire
 Signal Conditioning
Bridge with lead compensation
 Dissipation Constant (Self-heating) P
T 
PD
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Thermal Sensors
RTD R1 R2

Example VS a D b

0= 0.005/°C R3
c
R
T
D

R = 500 Ω at 20°C
R (T )  500 [1  0.005(0  20)]  450 
PD = 30 mW /°C
10
R1 = R2 = 500 Ω I  0.011 A
500  450
VS = 10 V P  (0.011) 2 * 450  0.054 W
RTD is at 0°C 0.054
T   1.8 C
0.030
Find R3
R3  500 [1  0.005(1.8  20)]  454.5 
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Thermal Sensors
Thermistors

30
Resistance (KΩ)

20

10

Temperature
(°C)
−20 0 20 40 60 80
100
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Thermal Sensors
Thermistors
 Sensitivity
~ 10% /°C
 Response Time
0.5 ~ 10 seconds
 Construction
Discs, beads, rods … etc
 Signal Conditioning
Divider circuit, Bridge
 Dissipation Constant (Self-heating)
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Thermal Sensors
Thermistors
10 V
Example
R = 3.5 KΩ at 20°C R1  3.50 K R1
S = - 10% /°C VD

PD = 5 mW /°C P
(5) 2
 7.1 mW
3.5 K R TH
VO = 5 at 20°C
7.1
Self-heating error? T   1.42 C
5

10% * 3.5 K
RTH  3.5 K  1.42 C  3 K
C
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Thermal Sensors
Thermocouples

T2 T1 Heat Flow T2
EMF T1

E   (T2  T1 )
I

Seebeck Effect Peltier Effect

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Thermal Sensors
Thermocouples
TR

+
TM VTC
−

TR
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Thermal Sensors
Thermocouples
Type Material Normal Range

J Iron-constantan -190°C to 760°C

T Copper-constantan -200°C to 371°C

K Chromel-alumel -190°C to 1260°C

E Chromel-constantan -100°C to 1260°C

S 90%platinum, 10%rhodium-platinum 0°C to 1482°C

R 87%platimum, 13%rhodium-platinum 0°C to 1482°C

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Thermal Sensors
Thermocouples
Type E
50
Type J
VTC (mV)

30
Type R

10
Temperature
(°C)
−200 0 200 400 600 800 1000 1200
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Thermal Sensors
Thermocouples

4 0 °C Ref.

3 20 °C Ref.
VTC (mV)

0
−20 0 20 40 60 80 Temperature
−1 (°C)
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Thermal Sensors
Thermocouples
 Sensitivity
Type J: 0.05mV /°C
Type R: 0.006mV /°C
 Response Time
0.01 ~ 20 seconds
 Construction
Welded junction
 Signal Conditioning
High-gain differential amplifier, with high CMRR
 Reference Compensation (cold junction comp.)
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Thermal Sensors
Thermocouples
 Cold junction Compensation

T
KVTC
Tref K + Vout

VC
Temperature Signal
Sensor Conditioning
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Thermal Sensors
Bimetal Strips
 Thermal Expansion γ1
T0
l  l0 1   T 
γ2 < γ 1

T > T0
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Thermal Sensors
Gas Thermometers
Constant Volume:
p1 p2

T1 T2

Liquid-Expansion Thermometers
V (T )  V (T0 )1   T 
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Thermal Sensors
Solid-State Temperature Sensors
5V
~ 12 mV / K
PD = 5 mW / °C
510 Ω
At 293 K: VT
VT = 3.516 V T
I = (5 – 3.516) / 510 = 0.0029 A
P = 3.516 * 0.0029 = 10.2 mW
ΔT = 10.2 / 5 = 2.04 °C
 Increase R
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Thermal Sensors
Solid-State Temperature Sensors
Example
J-type TC: ~ 50 μV / °C
SS sensor: 8 mV / °C
VO = 2 V @ 200 °C
 VTC (200°C) = 10.78 mV
 TC Gain = 8 mV / 50 μV
= 160
 Total Gain = 2000 / 10.78
= 185.5
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Thermal Sensors
Solid-State Temperature Sensors
Example
−8 mV / °C 10 K
11.59 K
SS 320 K

T 2K −
− 10 K
+ V out
+
2K
11.59 K
Tref 320 K
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Thermal Sensors
Example
Turn-on alarm when T = 10 ± 0.5 °C
Turn-off alarm when T ≤ 8 °C
RTH = 10 KΩ @ 10 °C
= 11 KΩ @ 8 °C
Keep self-heating within ± 0.5 °C. Use ± 0.25 °C
 P = (5 mW / °C)*(0.25 °C) = 1.25 mW
 @ 10 °C, ITH = 0.354 mA, VTH = 3.5 V

Using voltage divider with 5 V supply:

 R = (5 – 3.5) / 0.354 = 4.28 KΩ
 @ 10 °C, VD = 1.5 V
 @ 8 °C, VD = 1.41 V  Hysteresis = 0.09 V
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Thermal Sensors
Example

5V

500 K
R TH
VD 9K
+
Vout
5V −
4.28 K

2.327 K
Vref = 1.5 V

1K
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Thermal Sensors
Example
Measured T = 50 °C ~ 80 °C (error ≤ ± 1 °C)
VO = 0 ~ 2 V
RTD: R(65°C) = 150 Ω
(65°C) = 0.004 / °C
PD = 30 mW / °C
 R(50°C) = 150 [ 1 + 0.004 (50 – 65) ] = 141 Ω
 R(80°C) = 150 [ 1 + 0.004 (80 – 65) ] = 159 Ω
 Keep self-heating within ± 1 °C
 P = (30 mW / °C)*(1 °C) = 30 mW
 @ 80 °C, IRTD = 13.7 mA, VRTD = 2.17 V
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Thermal Sensors
Example
5V
10 K
220 220
10 K
−
+ V out
+
10 K −
141 RTD
10 K
138 K
10 K

@ 50 °C: RRTD = 141 Ω, ΔV = 0, Vout = 0

@ 80 °C: RRTD = 159 Ω, ΔV = 0.1447 V, Vout = 0.1447 * 13.8 = 2 V
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Thermal Sensors
Example
Measured T = 500 ~ 600 °F (260 °C ~ 315.6 °C)
VO = 0 ~ 5 V
J-type TC: Tref = 25 °C
VTC(260 °C) = 12.84 mV
VTC(315.6 °C) = 15.9 mV
 Vout = m VTC + V0
 0 = m(0.01284) + V0
 5 = m(0.01590) + V0
 m = 1634, V0 = − 21, Use Gain = 100 * 16.34
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Thermal Sensors
Example 5V

2.88 K
Vref = 1.289 V 10 K

1K

100 K
163.4 K
T 1K
− 10 K
−
+
1K + V out

Tref = 25 °C 100 K
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Thermal Sensors

End of Chapter 4