Fluke Calibration

Web Seminar Series

Principles and practical tips
about electrical, flow, pressure,
RF and temperature calibration

How to Set-up a Thermocouple

Calibration System
2016 Fluke Corporation

Todays Web Seminar

How to Set-up a Thermocouple Calibration System

April 7, 2016
Thermocouples are broadly used in many industrial and scientific applications. Attend this free
web seminar to learn the fundamentals of how thermocouples work and the components needed
to set-up a thermocouple calibration system. Well give you the basics to understand the main
techniques for calibrating thermocouples (including the pros and cons) at both the industrial level
and in the calibration lab. System uncertainties, best practices, and tips/tricks for conducting a
successful thermocouple calibration will be covered.
This web seminar is for those who are currently using a thermocouple calibration system and
want to improve it or those new to thermocouple calibration who are building a calibration
system.

Fluke Calibration
Fluke Calibration

Electrical (Everett, WA)

RF (Norwich, UK)
Temperature (American Fork, UT)
Pressure/Flow (Phoenix, AZ)

Fluke Calibration, Temperature, American Fork, UT

Presenter: Michael Coleman

Director of Temperature Metrology

With Fluke/Hart Scientific 16 years

Primary Temperature Calibration Lab
TCAL Service Department
3

Learning Objectives

Thermocouple characteristics
Theory of operation
Thermocouple types
Calculations voltage to temperature
conversion, readout accuracy
Typical calibration scenarios
Calibration schemes and equipment

Type S or R Thermocouple Standard

9118A Thermocouple
Calibration Furnace

1586A Super-DAQ and

DAQ-STAQ Multiplexer
4

Thermocouple Characteristics
Most common temperature sensor in
industry
Simple operation voltage generated
by joining dissimilar metals
Rugged and available in many shapes
styles, sizes, and ranges
Appear to be very simple but
controlling all sources of error is very
difficult

Typical Accuracies
Base metal thermocouples (Type E, K, N, etc.) range from
about 1 C to 10 C accuracy
Noble metal thermocouples (Type S, R) accuracies range
from 0.6 C to 2.7 C but can be calibrated to improve
accuracy
Special thermocouple types (gold vs. platinum, platinum
vs. palladium) may achieve accuracies in the 0.01 C to
0.05 C range with calibration
Main source of error is inhomogeneity (wire inconsistency)

Inconsistent alloy distribution

Oxidation
Metal migration
Strain in the wire
6

Useful Tips (from NMI New Zealand)

Bending the wire in a temperature gradient region can
cause a 3 C shift in a Type K temperature reading
Prolonged high temperature exposure can cause a Type K
to change as much as 100 C due to oxidation
1% change in Seebeck coefficient per 1000 hours at 1000 C

A simple test for checking inhomogeneity:

1. Lay a thermocouple on a bench and connect it to a readout
2. Blow a heat gun over different sections of the wire while watching
the readout display
3. If the readings fluctuate significantly, the thermocouple is
inhomogeneous
4. Replace if inhomogeneity is detected
Source: Making Sense of Thermocouples, Measurement Standards Laboratory of New Zealand,
https://www.msl.irl.cri.nz/sites/all/files/training-manuals/TG14-July-2009.pdf

Thermocouple Types
Type

Wire Composition

Typical EMF
Output and Range

Platinum- 30%
Rhodium

Platinum 6% Rhodium

0 to 13 mV
0 to 1820 C

Nickel Chromium
Alloy

Constantan (Copper-Nickel Alloy)

-10 to 77 mV
-270 to 1000 C

Iron

Constantan (Copper-Nickel Alloy)

-8 to 70 mV
-210 to 1200 C

Nickel Chromium
Alloy

Nickel Aluminum Alloy

-6 to 55 mV
-270 to 1372 C

Nickel Chromium Silicon Alloy

Nickel Silicon Alloy

9 to 46 mV
-270 to 1300 C

Platinum 13%
Rhodium

Platinum

2 to 12 mV
-50 to 1450 C

Platinum 10%
Rhodium

Platinum

2 to 11 mV
-50 to 1450 C

Copper

Constantan (Copper-Nickel Alloy)

4 to 19 mV
-270 to 400 C

Thermocouple Theory of Operation

Thermocouples measure relative temperature: a differential
measurement between the hot junction (T1) and the cold
junction (T2), between which a voltage potential is generated
A

T1

T2
B

T1: Hot junction (also called

measuring junction)

V
C

T2: Cold junction (also called

reference junction)

A: thermocouple wire
B: thermocouple wire
C: copper wire
9

Theory of Operation Further Detail

Potential (voltage output) varies as overall
temperature differential changes
Voltage output ranges from -15 to 70 mV (depending
on type of thermocouple and measurement
temperature)
Voltage output is proportional to temperature, but the
effect is not linear
Voltage potential is caused by differing electron
densities along temperature gradients
Voltage is created in zones of temperature gradient only
Entire thermocouple is the sensor
Measured voltage is net total of infinitesimally small
temperature gradients (Seebeck effect)
10

Measure Junctions
Need 2 junctions to work reference junction and measure junction
Junctions can be created by twisting, crimping, soldering, or
welding the wire
Voltage isnt generated by the junction itself Why?
The junctions are kept in isothermal zones (no gradients) so no voltage is
generated (uniform zone in furnace, uniform zone in ice bath)

A
T1

Majority of voltage generated in this region

T2
B

V
C

11

Reference Junctions 2 Approaches

Reference junction is where the transition from
thermocouple wire to copper wire is made Why?
Copper wire can be connected to a meter with no additional voltage
potential

We need to know the temperature of the reference junction

so we can correct the measured voltage
Keeping it at 0 C is easiest, no correction needed: Use an ice bath
or ice point furnace
Can be kept at other temperatures but correction is required

So what are the 2 main approaches?

1. External reference junction (copper wires attached and junction placed in a
stable temperature environment) Best Accuracy! (as good as 0.005 C)
2. Internal reference junction (connect TC wire to the meter, the meter
compensates automatically) Accuracy varies from meter to meter ( 0.05
to 0.6 C)
12

Typical Ice Bath Reference Junction Setup

Vacuum insulated dewar flask

Shaved ice mixed with water
Thermistor probe monitors
temperature of ice bath

13

External Reference Junction

+
+

VTC(TTC)

Vo=VTC(TTC)

0C
VJ1(0C)

VJ2(0C)

Ice Bath

[VJ1(0C)+VJ2(0C)=0]

14

Internal Reference
Junction Compensation Circuit

+
VTC(TTC)

VJ1(TJ)
+
VJ2(TJ)

Vo=VTC(TTC)+[VJ1(TJ)+VJ2(TJ)]

TJ

1586A Super-DAQ
Internal High-Capacity Module

15

Meter Accuracy Specifications

1586A Super-DAQ thermocouple measurement specs:

1560 Black Stack with 2565 Module thermocouple measurement

specs:

16

Convert Voltage Uncertainty to Temperature

UV
UT V
S MJ

UT(V): equivalent temperature uncertainty

UV: voltage measurement uncertainty
SMJ: thermocouple sensitivity at the
measuring junction temperature

Useful Tip:
SMJ (sensitivity) is also called Seebeck Coefficient or
EMF Slope
Calculate SMJ by using thermocouple voltage table
It is: change in voltage (mV) per 1 degree C change
(V/T)
17

Accuracy Calculation Example

The thermocouple is type S

The temperature is 1000 C

The voltage at 1000 C is 9.6 mV
The specified voltage accuracy in this range is 0.002 mV

The TC has a sensitivity of 0.0115 mV/C at 1000 C

What is the equivalent temperature uncertainty?

0.002 mV
U T V
0.17C
0.0115 mV C
18

Reference Junction Accuracy Calculation

U T RJ

U RJ S RJ

S MJ

UT(RJ): equivalent temperature uncertainty

URJ: reference junction uncertainty
SMJ: thermocouple sensitivity at the measuring
junction temperature
SRJ: thermocouple sensitivity at the reference
junction temperature

19

Reference Junction Example

The thermocouple is type S
The temperature is 1000 C
The reference junction accuracy is 0.05 C
The TC has a sensitivity of 0.0115 mV/C at 1000 C
The TC has a sensitivity of 0.006 mV/C at 25 C
What is the equivalent temperature uncertainty?

U T RJ

0.05 C 0.0060 mV C

0.026C
0.0115 mV C
20

Combine Voltage and

Reference Junction Accuracies

U Total U

T (V )

T ( RJ )

21

Two Calibration Options

Tolerance test

Characterize

Measure temperature points

Verify if results are in or out of
tolerance
Replace if out of tolerance

Gather temperature vs. voltage data

Measure enough points to calculate
coefficients or offsets
Typically only applies to noble metal

Cautions
Difference in gradient profiles between cal setup and
application/point of use will introduce errors with inhomogeneous
thermocouples
Removing and calibrating base metal thermocouples can cause
them to shift. If measuring above 300 C, may be best to just
replace.
22

Calibration Schemes
In situ
Comparison
Simulation

Cal lab
Comparison
Fixed-point
Simulation

23

Basic Comparison Calibration Scheme

Compare UUT thermocouples against a reference
temperature probe or display of the heat source
Probes are inserted into a heat source (drywell, furnace, or bath)
UUTs are connected to a reference meter or stay connected
to own readout for system calibration (readout and probe
calibrated as a system)

24

Comparison Calibration Equipment

Heat source

Drywell or Metrology Well for -90 to 700 C

9150 vertical furnace up to 1200 C
9118A horizontal furnace up to 1200 C
Stability and uniformity are important specs
Furnaces and drywells with zone control are best

914X Field
Metrology Well

9150 Vertical
Furnace

Readout
Largest errors typically from internal RJ circuit
Readouts that measure both PRTs and TCs are
most useful
Tip: Take your calibration lab productivity to the next level. Use
the 1586A Super-DAQ with a 9118A furnace to automate
thermocouple calibration. Watch the video
9118A Thermocouple
Calibration Furnace

1586A Super-DAQ and

DAQ-STAQ Multiplexer

25

Comparison Calibration Equipment

Reference probe
For -200 to 962 C, use PRT or SPRT (0.05 C or
better) (Fluke model 5628, 5624, 5699)
For higher temperatures, use noble metal Type S or
Type R (0.3 C and up)

PRT or SPRT

External reference junction

Ice bath works well
Can use stirred-liquid bath or specialized
drywell set to 0 C

Type S or R Thermocouple Standard

9101 Zero-Point Drywell

26

Measurement Tips
In open cavity, mount UUT
probes around reference probe
Allow sufficient time for stability
and uniformity to be achieved
Use heat source ramp control
to avoid over-shooting

[Calibrating a bundle of thermocouples without a block]

[Calibrating ceramic-sheathed thermocouples with a block]

27

Total System Uncertainty Analysis

Readout accuracy (for reference probe and UUT)

Reference junction accuracy (external or internal)

Reference probe accuracy (calibration uncertainty and drift)
Heat source uniformity (axial and radial gradients)

Heat source stability (affects measurement standard

deviation)
Other (ambient conditions, inhomogeneity of UUT, etc.)

28

References and Useful Links

NIST thermocouple database
http://srdata.nist.gov/its90/main/

Making Sense of Thermocouples, Measurement Standards

Laboratory of New Zealand, https://www.msl.irl.cri.nz/sites/all/files/trainingmanuals/TG14-July-2009.pdf

ASTM E230
NIST SP250 (NIST TC calibration program)
NIST Monograph 175

Thermocouple Application Note Series

Thermocouple calibration:
What you need to know
We've developed four application notes designed to
help you learn what you need to know about
thermocouples. The series includes:
1. Thermocouple fundamentals
2. How to select thermocouple calibration equipment

3. Calculating uncertainties in a thermocouple

calibration system
4. How to calibrate a thermocouple
Visit our website to download the app notes
>> Thermocouple App Note Series (us.flukecal.com/node/80380)

30

Future web seminars

Temperature Calibration seminars coming soon:
April 20: Automating Temperature Calibration (presented
in Spanish)
May 4: How to Calibrate Temperature Sensors and
Electronics Using Three Common Methods (presented in
English)
June 1: Lets Talk About Temperature Measurement with
Fluke Metrologist Mike Coleman (presented in English)
For the latest schedule visit
www.flukecal.com/calwebsem
Our seminar topics cover principles and practical tips about electrical, flow,
pressure, RF and temperature calibration

2016 Fluke Corporation

2016 Temperature
Calibration classes
Instructor-led Training
Advanced Topics in Temperature Metrology, Apr. 12-14
Infrared Calibration, May 17-19
Get a 20% discount on this class if you register by end
April
Practical Temperature Calibration, Sep. 20-22
Installation and Training Supplemental Services
(courses scheduled on-demand)
For more information go to:
http://us.flukecal.com/tempcal_training
2016 Fluke Corporation

Thank you
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2016 Fluke Corporation