Instrument

Fundamentals of

Temperature Transmitter
and Temperature Gages

Trainer : Abdulhamid Hamad

1
Introduction

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 Temperature measurement

Introduction
The accurate measurement of temperature is vital across abroad
spectrum of human activities, Including:

▪ Industrial processes (e.g. making steel)

▪ Manufacturing;
▪ Health and safety.

o In fact, in almost every sector, temperature is one of the key

parameters to be measured.

o Different people will have different perceptions of what is hot

and what is cold.
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 Temperature measurement

Definition

❑ Temperature
• Scalar quantity
• Degree of hotness or coldness
• Molecular K.E. = Temperature

❑ Heat
• Form of energy.
• Measured in calories or
• BTU’s [British Thermal Units].

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 Temperature measurement

How is heat transferred?

1. Conduction
2. Convection
3. Radiation

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 Temperature measurement

Temperature Scale
Temperature - measure of the thermal energy. Measured in
degrees [°]using scales.

1. Fahrenheit.[°F]
2. Celsius or centigrade. [°C]
3. Kelvin .[°K]

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Temperature measurement

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 Temperature measurement
Conversion between Different Units

Exercise:

1. Gallium is a metal that can melt in your hand at 302.93 K. What

is the temperature in Celsius (to the hundredth)?
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Temperature measurement

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Temperature measurement

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 Temperature measurement

Exercise:

2. Body temperature is 98.6 F. What is the temperature in Celsius?

3. The title of the book "Fahrenheit 451" refers to the temperature

that book paper burns, or 451 F. What is the temperature in
Celsius (to the hundredth)?

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 Temperature measurement

Exercise:

4. Room temperature is often used in calculations as 300 K. What is

the temperature in Fahrenheit (to the 10th)?

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 Temperature measurement

Exercise:
5. A general rule of thumb used by pilots is for every 1,000 feet of
altitude, the temperature falls 3.5 F.

If the temperature at sea level is 78 F, what would you expect the

temperature to be at 10,000 feet in Celsius (to the 10th)?

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Temperature Gauges

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 Temperature Gauges

Definition of gauge :
a : to measure precisely the size, dimensions, or other measurable
quantity of.
b : to determine the capacity or contents of.
c : to estimate, judge hard to gauge his moods

Technical Definition :
a : an instrument for measuring a dimension or for testing
mechanical accuracy.
b : an instrument with a graduated scale or dial for
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 Temperature Gauges

Temperature GAUGES

Out of many temperature sensing and measuring instruments , we

will focus on the following temperature gauges as they are the most
used in the industry.

1. Bimetallic Temperature Gauge

2. Thermometer
3. Liquid Filled Dial Temperature Gauge
4. Gas Filled Temperature Dial Gauge

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 Temperature Gauges

Bimetallic Devices
Bimetallic devices take advantage of the expansion of metals when
they are heated.
In these devices, two metals are bonded together and mechanically
linked to a pointer.

Advantages :
• Portability
• Independence from a power supply.

Disadvantage :
• They are not usually quite as accurate as are electrical devices
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 Temperature Gauges
Bimetallic Gauge principle of operation

When heated, one side of the bimetallic strip will expand more than
the other.
• The welded structure is
fixed at one end and other
end is free to move.

• A pointer is fixed on free

end which moves across
calibrated scale.

When geared properly to a pointer, the temperature measurement

is indicated.
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 Temperature Gauges

Bimetallic Gauge Specification

• Bimetal dial thermometers are simple in construction, yet rugged.

• Suitable for most industrial applications

• Temperature range (- 50°C to 600°C)

• Rigid stem with bottom or back entry and available in every angle
rotatable construction

• Accuracy ± 1% FSD

• High repeatability, low hysteresis

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 Temperature Gauges
Types of bimetallic thermometer
There are two types of bimetallic thermometers,:

1. Helix strip bimetallic thermometer gauge

2. Spiral strip bimetallic thermometer gauge

Helix and spiral strips are used to keep the thermometer size within a
manageable limit.
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 Temperature Gauges
Helix strip bimetallic thermometer
• The pointer is connected through the shaft at the free end of the
strip.
• The strip is wound helically inside the stem
• As the temperature increases, the helical strip senses the
temperature change.

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 Temperature Gauges
Helix strip bimetallic thermometer

At High Temperature :
• The strip metal with a higher coefficient of thermal expansion
expands and winds up along the stem, rotating the shaft.

• This rotation causes the pointer to move its position in the dial
which indicates the media’s temperature.

At Low Temperature:
• As the temperature decreases, the metal with a lower coefficient of
thermal expansion shrinks and rotates the shaft.

• The pointer then reads the lower temperature in the dial.

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 Temperature Gauges

Helix strip bimetallic thermometer gauge are mostly used for

industrial applications such as:
• Refineries
• Oil burners
as they can be placed inside a thermowell which provides operation in
high temperature and pressure environments.

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 Temperature Gauges

Thermowell :
are typically constructed of solid drilled-out bar stock and are designed
to protect a temperature sensor from :

• The flow,
• High pressure
• Harsh environments.

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 Temperature Gauges

Thermowell :
Thermowells are critically important for installations where the
temperature element (RTD, thermocouple, thermometer, etc.) must be
replaceable without de-pressurizing the process.

Thermo-paste assists in the fast and effective transfer of thermal

dynamics from the process to the sensing element. Application and
maintenance of this material needs to be considered.

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 Temperature Gauges
Spiral strip bimetallic thermometer
• As the temperature rises, the two metal strips expand differently.

• This creates a bending effect and the strip coils in such a way that
the metal with a higher thermal coefficient forms the outer side of
the arc.

These are mostly used for thermostats or measuring the ambient

temperature, as they’re sensitive to lower temperature variation.
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 Temperature Gauges

Bimetallic thermometer calibration

The most accurate method for calibrating the bimetallic thermometer

is the ice-point method.
To calibrate a bimetallic thermometer using this method:
1. Fill a glass completely with ice, add cold water, and let sit for
4 to 5 minutes.
2. Then, insert the stem of the thermometer into the ice water.
3. Make sure the stem is not touching the bottom or sides of
the glass.
4. Let it sit until the dial stops moving.

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 Temperature Gauges

Bimetallic thermometer calibration

If the thermometer is accurate, it should measure 0°C or 32°F.
If not, rotate the nut located under the dial so that it reads 0°C.

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 Temperature Gauges

Thermometers
Thermometers are well-known liquid expansion devices also used
for temperature measurement.

Generally, they come in two main classifications:

• Mercury type

• Organic (usually red, liquid type)

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 Temperature Gauges

Thermometers

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 Temperature Gauges
Thermometers Construction
The liquid in glass thermometer has a
glass bulb attached to a sealed glass
tube ,also called:
• The stem or
• Capillary tube.

A very thin opening, called a bore,

exists from the bulb and extends
down the center of the tube.
In the Liquid In Glass Thermometers
(LIG) the thermally sensitive element is
a liquid contained in a graduated glass
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 Temperature Gauges

• The background of the glass tube is covered with white enamel

• The front of the glass tube forms a magnifying glass that

enlarges the liquid column and facilitates with reading the
temperature.

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 Temperature Gauges

LIG Thermometers scale

A temperature scale which is

basically preset or imprinted on the
stem for displaying temperature
readings.

Scale is made to reading curlicues

degree °C of Fahrenheit degree °F

0 °C correspond to 32°F

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 Temperature Gauges

Industrial LIG Thermometer

Liquid in glass thermometers are fragile
and for industrial use, the thermometer
is :
• mounted in a protective housing

• The scale is engraved on a separate

plate that is part of the protective
case.

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 Temperature Gauges

Liquid Filled Dial Temperature Gauge.

Liquid-in-metal thermometers (liquid filled thermometers) use
the pressure rise of a liquid that comes along with an increase in
temperature, if the volume is kept constant!

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 Temperature Gauges

Liquid Filled Dial Temperature Gauge.

For liquid-in-metal thermometers, the pressure must therefore be
measured and converted into a temperature value by means of an
calibrated scale.

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 Temperature Gauges

Gas Filled Dial Thermometer Temperature Gauge.

Gas-filled Dial Thermometers, with a sensing bulb filled with nitrogen
gas, are of rugged design and all stainless steel construction for long
life in harsh environments.

Dial sizes of 2.5", 4” and 6” (63, 100

and 150 mm) are available, depending
on accuracy, resolution and readability
requirements.

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 Temperature Gauges

Gas Filled Dial Thermometer Temperature Gauge.

In order to increase the measuring sensitivity, the relative small
deformation of the tube during pressure rise is not directly output on
a scale but is first amplified by a lever mechanism with rack and
pinion.

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 Temperature Gauges

Gas Filled Dial Thermometer Temperature Gauge.

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 Temperature Gauges

Gas Filled Dial Thermometer Temperature Gauge.

Gas filled thermometers can also be equipped with a flexible capillary
tube for covering large distances.

In the case of large heights to be covered, the relatively large

overpressure in the measuring system minimizes the influence of the
hydrostatic pressure on the measurement result.

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 Temperature Gauges

Gas Filled Dial Thermometer Temperature Gauge.

• Gas filled temperature gauges overcome most of the limitations of
other temperature gauges
• Wide temperature range (-)200 to 800°C
• Almost any length stem can be offered without loss of accuracy
• Capillary length up to 25m

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 Temperature Gauges

Gas Filled Dial Thermometer Temperature Gauge.

• Inert (N2 gas), non hazardous, non toxic nature of the filled
systems makes it an ideal choice for a cross section of industries
• Suitable for sanitary application
• All Stainless Steel (SS) construction
• Rigid stem or capillary type
• Fast response
• High reliability and accuracy ± 1% FSD

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 Temperature Gauges

Limitation of Gas Filled Dial Thermometer

If the gauge and thus the Bourdon tube are exposed to an increased
temperature, then the pressure in the Bourdon tube also rises and
indicates a higher temperature than is actually present at the
measuring sensor.

In order to minimize this influence of the housing temperature, a

bimetallic strip can be applied to the Bourdon tube to compensate
such temperature effects. If the housing heats up, the bimetallic
strip will then bend the bourdon tube slightly to correct the
otherwise too high temperature displayed.

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 Temperature Gauges

Gas Filled Dial Thermometer Switch

Gas-in-metal thermometers could also be equipped with switch
contacts in order to perform control tasks. Due to the relatively low
heat capacity of gases, gas thermometers react relatively fast to
temperature changes compared to liquid-in-metal thermometers.

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Temperature Sensor Technologies

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 Temperature Sensor Technologies

Measurement Technologies
Over the years the industry has invented different technologies to
measure the temperature in different specific applications.
But why different technologies?
This is because of different applications which make one technique
better than the others for each specific case

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 Temperature Sensor Technologies

Temperature Sensor ,
Transducer and Transmitter

A sensor or transducer is a physical device which is capable of

transforming process variable to electrical signal type.

Transmitter is a sensor in
addition to electronic
circuits make the sensor
able to communicate with
control system in a
common language

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 Temperature Sensor Technologies

Types of Electrical Signals

Based on different sensor technologies, this signal may have

different ranges and for industrial applications, I need to have my
signals limited to some universally accepted electrical “signal-
ranges”.
Some of these globally accepted electrical signal-ranges are:

▪ Four to twenty milliamps (4-20 mA)

▪ One to five volts (1-5 V)

▪ Zero to ten volts (0-10 V)

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 Temperature Sensor Technologies

What does Transmitter do? :

is a device which transforms the tiny output of a “Temperature
Transducer” ( mV ) to one of the standard signal ranges of :

• 4-20 mA
• 1-5 V
• 0-10 V

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Temperature Resistance Detector RTD

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 Temperature Resistance Detector RTD
❖RTD
Resistance Temperature Detectors (RTDs) also called Resistance
thermometers,, are sensors used to measure temperature.
RTD is used in many industrial applications, domestic applications,
Household applications. RTD is the very basic sensor of temperature
measurement.

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 Temperature Resistance Detector RTD
❖RTD is passive device
Since it is a “passive” device, an external electrical current should be
applied to it and then the voltage drop across it can be measured.
This voltage is a good indication of the temperature.

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 Temperature Resistance Detector RTD

• Example of RTD is “PT100”

One of the most common RTDs is “PT100” which consists of a thin
film of Platinum on a plastic film and shows a resistance of 100Ω at
32°F ( 0 ° C).

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 Temperature Resistance Detector RTD

• RTD PT100

The relationship between resistance and temperature of PT100 is

relatively linear.

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 Temperature Resistance Detector RTD

❖ Construction of RTD Sensor

Many RTD elements consist of a length of fine wire wrapped around
a ceramic or glass core but other constructions like thin-film are also
used.

wire wrapped thin-film

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 Temperature Resistance Detector RTD

❖ RTD material selection

The RTD material is selected to have an accurate R /T ( resistance /
temperature) relationship which is used to provide an indication of
temperature

▪ The resistance of RTD varies in

direct proportion to changes in
temperature

▪ RTD exhibit a positive temperature

coefficient

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 Temperature Resistance Detector RTD

❖ Material of RTD Sensor

The element material is usually selected to be Platinum because it
has a wide range and linear relationship of resistance vs temperature.

Temperature Range of Different Metals

Metal Temperature Range
Platinum -200 °C to 850 °C
Nickle -100 °C to 315 °C
Copper -75 °C to 150 °C

The types of material used to built the RTD will determine the
temperature range of that RTD Sensor.
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 Temperature Resistance Detector RTD
❖Temperature Range of RTD element

RTD typically operate within broad temperature between ( -260 to

+850 °C ( -328 And 932 F)

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 Temperature Resistance Detector RTD
• Major Components of RTD Sensor

Sensing Element
This is the actual temperature sensing metal element.
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 Temperature Resistance Detector RTD
• Major Components of RTD Sensor

Protecting Tube
This tube protects the sensing element from the moisture and
outside environment. This protecting tube is made mostly of SS
stainless steel.

Process Connection
Process connection includes the standard fitting.
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 Temperature Resistance Detector RTD

• Major Components of RTD Sensor

RTD Process Connection: Process connection fittings include all
standard fittings used with thermocouples ,i.e:
• Compression Fittings
• Welded Fittings
• Spring-loaded Fittings
• etc.).

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Temperature Resistance Detector RTD

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 Temperature Resistance Detector RTD
• Working Principle of RTD Sensor
RTD Sensor works on this basic principle that as the temperature of
the metal increases, resistance also increases. The value of
resistance measured in ohms and equivalent temperature can be
converted based on this resistance value.

The temperature coefficient of the RTD sensor is the average

changes of resistance over the temperature range 0 °C to 100 °C
and normally denoted by the α0

Where :
R100 = Resistance at 100 °C (ohm)
R0 = Resistance at 0 °C (ohm)
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 Temperature Resistance Detector RTD
Example :
Material offered 100 Ω at temperature of 0°C, meanwhile Offred
1138.5 Ω at 100°C.
What is the temperature coefficient α0 of this material?

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 Temperature Resistance Detector RTD
• Working Principle of RTD Sensor
RTD,s are coming into two classes based on their range and accuracy:
• Class A
• Class B

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 Temperature Resistance Detector RTD
• Working Principle of RTD Sensor

As per the above equation relationship between temperature

and resistance may be expressed as,

Where :
Rt = Resistance of RTD sensor at temperature T °C (Ω ohm)
R0 = Resistance at 0 °C (ohm)
α0 = Temperature co-efficient of RTD sensor at 0 °C (Ω/°C )

The standard temperature coefficient (alpha) for Platinum is :

α0 = 0 .00385 Ω/°C
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 Temperature Resistance Detector RTD
Example :
RTD (PT100) made of Platinum, what is the expected offered
resistance if a change of 1°C is introduced to the RTD sensor?

The standard temperature coefficient alpha for Platinum is :

α0 = 0 .00385 Ω/°C
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 Temperature Resistance Detector RTD
Example :
RTD (PT100) made of Platinum, what is the expected offered
resistance at 120°C?

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 Temperature Resistance Detector RTD
• Working Principle of RTD Sensor
The below figure shows the temperature vs resistance graph of all
three elements platinum, nickel and copper.

The standard resistance for Platinum RTD is 100 Ω at 0° C.

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 Temperature Resistance Detector RTD

Examples of RTD Sensor

A PT100 RTD Sensor measures 100 Ω at 0 °C and 139.1 Ω at 100 °C.

Calculate its temperature coefficient, Calculate the resistance at 40
°C and when the resistance is 116 Ω, find the temperature.

Calculate Temperature Coefficient

Temperature Coefficient (α0) = (R100 – R0)/(R0 x 100)
= (139.1 – 100) / (100 x 100) = 0.00391 /°C
Calculate Resistance of RTD Sensor at 40 °C
Rt = R0 ( 1 + α0t) ⇒ R40 = 100 (1 + 0.00391 x 40) = 115.64 Ω
Calculate Temperature of RTD Sensor when the resistance is 116 Ω
Rt = R0 ( 1 + α0t) ⇒ 116 = 100 (1 + 0.00391 x T) ⇒
T = 0.16 / 0.00391 = 40.92 °C
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 Temperature Resistance Detector RTD
❖RTD Sensor Connection Wire Configuration
RTD Sensor is available in:
• 2-wire,
• 3-wire
• 4-wire configuration.

➢The most commonly used configuration is a 3-wire RTD

configuration and widely used in industrial applications.

One of the Greatest Accuracy challenges is dealing with relatively low

Resistance of RTD . This because any lead resistance of RTD assembly
can add significant error to measured resistance
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 Temperature Resistance Detector RTD
❖RTD Sensor Connection Wire Configuration

There are generally four types of wiring schematic as per IEC 60751
available as shown for each element

Red

White
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Temperature Resistance Detector RTD

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 Temperature Resistance Detector RTD
• RTD Sensor Wire Configuration
2 wire is available also 3 wire & 4 wire lead compensation techniques
are used to provide increasingly accurate readings from RTD:

BS 1041-3 proposes that :

❖ 2-wire RTDs are restricted to a maximum of 1 Ω to 2 Ω per
conductor resistance .

❖ Other forms of bridge (3 and 4-wire) must be used for cable

runs of 10 Ω to 15 Ω per conductor (typically 1 km).

In fact, 3 or 4-wire form compensate the conductor resistance and its

change by changing of temperature.
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 Temperature Resistance Detector RTD

RTD resistance ratio

The term “resistance ratio” describes the average slope of temperature
vs. resistance as the RTD temperature changes from 0°C to +100°C. The
expression for resistance ratio is:

(R100-R0) / R0

Where:
R100 = RTD Resistance at 100°C.
R0 = RTD Resistance at 0°C.

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 Temperature Resistance Detector RTD

Benefits of using nickel or copper RTDs

Nickel creates a high resistance at 0°C and has a high resistance

ratio, making this sensitive RTD easy to measure.

These qualities also minimize error due to lead wire resistance. For
an RTD, the approximate error due to lead wire resistance is:

Lead wire resistance / (R100-R0) x 0.01

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 Temperature Resistance Detector RTD

Benefits of using nickel or copper RTDs

For example:
A 2-wire nickel RTD measures an air duct temperature. Each lead wire
has a resistance of 0.25 Ω, for a total lead wire resistance of 0.5 Ω.

The error due to lead wire resistance can therefore be calculated as

follows:
0.5 Ω / (161.78 – 100) x 0.01 = 0.81°C. This is close enough for many
applications.

To compare, here are the numbers for a 2-wire platinum RTD with the
same lead wire resistance:
0.5 Ω / (138.5 – 100) x 0.01 = 1.3°C.

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 Temperature Resistance Detector RTD

Benefits of using nickel or copper RTDs

Copper RTDs have the same thermal expansion rate and
electromagnetic hysteresis as copper windings used in electric motors
and generators. For these reasons, copper RTDs are sometimes used
to measure winding temperature.

Copper also has an extremely linear temperature vs. resistance

relationship. Because of this, it is possible to accurately measure a
narrow temperature span without additional linearization.

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 Temperature Resistance Detector RTD

Benefits of using nickel or copper RTDs

For example:
A Cu100 RTD creates 100 Ω resistance at 0°C and 142.743 Ω
resistance at 100°C. A linear extrapolation gives the theoretical
resistance at 50°C: (R100 – R0)/2 + R0

= (142.743 – 100)/2 + 100 = 121.3715 Ω

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 Temperature Resistance Detector RTD

Benefits of using nickel or copper RTDs

A Cu100 RTD creates resistance:
• 100 Ω at 0°C
• 142.743 Ω at 100°C
• 121.3715 Ω at 50°C

• So the RTD is functionally linear between 0…+100°C.

• The non-linearity of copper does not become apparent unless

measuring a wide span. For example, if measuring 0…+200°C

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 Temperature Resistance Detector RTD
• Why we need Whetstone Bridge with RTD Sensor?
RTD measures the temperature in function of variations of its
resistance. In order to make them work (4 wire RTD), we need a low
current that is called the excitation current.

In fact, T ∝ R and V = IR
So T ∝ V

If I and R both are variable, measuring the temperature based on

voltage V will be wrong!

So, to solve this problem we can use the Wheatstone bridge with the
known resistors. This is because measurement is done at 0 Current.
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 Temperature Resistance Detector RTD
• Why we need Whetstone Bridge with RTD Sensor?

That is what has been explained in BS 1041-3: “Measurements are

made by passing current through a sensing resistor and measuring the
potential across it.

a. If the current is known, the potential is a measurement of the

resistance and hence the temperature.

b. If the current is not known exactly the potential may be

compared with the potential across a known resistor; this is
the basis of the bridge systems.”

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 Temperature Resistance Detector RTD
• Whetstone Bridge
At the point of balance, both the voltage and the current between
the two midpoints (B and D) are zero. Therefore:

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 Temperature Resistance Detector RTD
• Whetstone Bridge

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 Temperature Resistance Detector RTD
• Whetstone Bridge

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 Temperature Resistance Detector RTD
• 2-wire RTDs

▪ Lower cost
▪ Use only when lead wires are short
▪ Rarely used due to high error from lead wire resistance
▪ Used where the approximate value of temperature is required.

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 Temperature Resistance Detector RTD

▪ R(t)= RTD+2x( lead Ω )

- For example if the lead resistance is 0.5 Ω ; then the instrument
would read (2.6 ° C ) higher than it should.
i.e. 0.5 x2=1.0 Ω
1 ohms/0.385( Ω/°C) =2.6 °C

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 Temperature Resistance Detector RTD

2-wire RTD’s are mostly used with short lead wires or where close
accuracy is not required.

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 Temperature Resistance Detector RTD

RTD is a passive element, by applying some voltage or using the

Wheatstone bridge circuit we can detect the change in the
resistance.

Rt including leads resistances

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 Temperature Resistance Detector RTD
• 3-Wire RTD

▪ Good balance of Cost & performance

▪ Most Common type of RTD in Industry
▪ Good lead wire compensation

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 Temperature Resistance Detector RTD

3-wire RTD Provides two measurement:

▪ V1 =RTD + 2 X ( Lead Ω)
▪ V2=2x ( Lead Ω)

So; to get true RTD Resistance ;

▪ simply subtract V1 – V2

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 Temperature Resistance Detector RTD

➢ There is a lead resistance in each arm which will cancel out the
cable resistance as long as both leads are the same.

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 Temperature Resistance Detector RTD
Practical Issue
➢ Using 3 wires of the same AWG, length, and composition will
typically result in lead wire resistances matched within 5%.
➢ This difference will also bring some error.

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 Temperature Resistance Detector RTD
• 4-wire RTD
Four-wire RTD configuration is the most accurate temperature
measurement setup.
True 4-wire resistance measurement will effectively cancel lead
wire resistance error even if all 4 wires are not the same AWG,
length, and/or composition..

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 Temperature Resistance Detector RTD

The 4-wire circuit is a true 4-wire bridge, which works by using

wires 1 & 4 to power the circuit and wires 2 & 3 to read.
This true bridge method will compensate for any differences in lead
wire resistances.

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 Temperature Resistance Detector RTD

A current of known value (I+) is passed through the sensor along

the “current” lead wires. The voltage generated across the sensor is
measured using the “potential” lead wires (Vsensor)

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 Temperature Resistance Detector RTD
The resistance of the lead wires is not a factor because:

• The value of the current is equal at any point in the circuit. It is

independent of the resistance of the lead wire.

• The input impedance of the voltage measurement circuitry is

high enough to prevent any significant current flow in the
voltage leads. Since no current is flowing, the voltage along the
potential leads does not change along their length.

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 Temperature Resistance Detector RTD

This true bridge method will compensate for any differences in lead
wire resistances.

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 Temperature Resistance Detector RTD
Task
• Read the name plate of RTD to Identify RTD type
• Measure the resistance between the leads of two different colors

Resistance = Ω

• Refer to the RTD table find the temperature of the Room

• Temperature of the Room = °C

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 Temperature Resistance Detector RTD
Pt100 accuracy classes
Accuracy classes and tolerances defined by IEC 60751:2008 are:
•Class AA
± (0,1+0,0017 * t), ±0,1 °C (0 °C), ±0,27 °C (100 °C), defined on
range -50…+250 °C (wire wound resistor), 0…+150 °C (thin film resistor)
•Class A
± (0,15+0,002 * t), ±0,15 °C (0 °C), ±0,35 °C (100 °C), defined on
range -100…+450 °C (wire wound resistor), -30…+300 °C (thin film
resistor)
•Class B
± (0,3+0,005 * t), ±0,3 °C (0 °C), ±0,8 °C (100 °C), defined on
range -196…+600 °C (wire wound ), -50…+500 °C (thin film resistor)
•Class C
± (0,6+0,01 * t), not commonly used for industrial measuring circuits.
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 Temperature Resistance Detector RTD
• Are any configurations interchangeable?
• 4-lead RTDs can generally be used as 3-lead RTDs by eliminating
(or tying off) one of the leads
• 4-lead RTDs can be used as 2-lead RTDs, by combining (shorting)
the common leads (usually of like color – white/white and
red/red)
NOTE: combining the common leads eliminates leadwire
resistance cancellation benefits

• 3-lead RTDs can be used as 2-lead RTDs, by combining (shorting)

the common leads ((usually of like color)
Note : combining the common leads eliminates leadwire resistance
cancellation benefits
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 Temperature Resistance Detector RTD
• How to connect RTD ‘s to transmitters?

Types of Temperature Transmitters:

• DIN rail mount temperature transmitters

• In head mounting temperature transmitters

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 Temperature Resistance Detector RTD
• How to connect RTD ‘s to transmitters?

• DIN rail mount temperature transmitters

RTD Input

RTD input type

PT100 or PT1000 DIN 3-wire type (2-wire can be used
with off set calibration)

Lead wire resistance

PT100: 10Ω/wire max. PT1000: 5Ω/wire max
0.02% FSO off set error per Ω of lead resistance

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 Temperature Resistance Detector RTD
• How to connect RTD ‘s to transmitters?

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 Temperature Resistance Detector RTD
• How to connect RTD ‘s to transmitters?

The rectangle symbol shown on the

label represents the resistive
element of the RTD.

The symbol with the “+” and “−”

marks represents a thermocouple
junction, and may be ignored for
the purposes of this discussion.

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 Temperature Resistance Detector RTD
• How to connect RTD ‘s to transmitters?

• A two-wire RTD would connect between

terminals 2 and 3.

• a three-wire RTD would connect to

terminals 1, 2, and 3 (with terminals 1
and 2 being the points of connection for
the two common wires of the RTD).

• a four-wire RTD would connect to

terminals 1, 2, 3, and 4 (terminals 1 and 2
being common, and terminals 3 and 4
being common, at the RTD).
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 Temperature Resistance Detector RTD

Intelligent Temperature Transmitter Installation

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 Temperature Resistance Detector RTD
• How to connect RTD ‘s to transmitters?

• DIN rail mount temperature transmitters

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 Temperature Resistance Detector RTD
• How to connect RTD ‘s to transmitters?
It is critically important to note that the common connections shown
by the symbols for 3- and 4-wire RTD sensors represent junction
points at the sensor ;
• Do not make terminals jumpered at the time of installation
• Do not do internal jumpers inside the transmitter.

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 Temperature Resistance Detector RTD
correct and incorrect ways to connect a 2-wire RTD to a wire
transmitter:

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 Temperature Resistance Detector RTD
correct and incorrect ways to connect a 2-wire RTD to 4-wire
transmitter:

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 Temperature Resistance Detector RTD
A similar problem occurs when someone tries to connect a 3-wire RTD
to a 3-wire transmitter using a conveniently available 4-wire cable:

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Temperature Resistance Detector RTD

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Thermistors

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 Thermistors

Thermistors are temperature-dependent resistors and are widely

used in industrial purposes, such as:

• Over-current protection
• Self-regulating heating elements
• Inrush current limiters

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 Thermistors

Types of Thermistors

Thermistors can be NTC or PTC :

1. NTC (Negative Temperature Coefficient)

In this type of thermistors, resistance decreases as temperature
rises. NTC’s are commonly used as inrush current limiters.

2. PTC (Positive Temperature Coefficient)

With this type of thermistors, resistance increases as
temperature increases. PTC thermistors are commonly used as
overcurrent protection and in resettable fuses.
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 Thermistors

NTC (Negative Temperature Coefficient) PTC (Positive Temperature Coefficient)

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 Thermistors

What is the difference between RTD and Thermistor?

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Thermocouples

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 Thermocouples

❑ Thermocouple
▪ Thermocouple converts thermal energy into electrical energy.
▪ Mostly widely used in industry like furnaces , Gas Turbines
▪ Range: sub-zero to 4000 ° F (2000°C)
▪ Formed by joining two different metal alloy wires (A,B) at point
called junction

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 Thermocouples

❑ Thermocouple
▪ Junction called the measuring or “hot” junction
▪ Lead ends attached to temperature indicator or controller
▪ Connection point called reference or “cold” junction

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 Thermocouples

Thermocouple produces Voltage in mV range when subjected to

heat source, Voltage is directly proportional to temperature

Thermocouple output is a Voltage ranged in mV Scale

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 Thermocouples

Measurement of the voltage generated by a thermocouple

Unfortunately, the measurement of the voltage produced by a

thermocouple is not as simple as it might seem.

This is so because the connection of a voltmeter to a thermocouple

creates two additional junctions that result in unwanted,

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 Thermocouples

Measurement of the voltage generated by a thermocouple

The points where the voltmeter terminals and the thermocouple

wires meet produce two additional junctions, J2 and J3:

• Junction J2 is a copper-to-copper junction, so that it produces

no unwanted parasitic voltage. Consequently, V2 = 0 V.

• Junction J3, however, is a copper-to-constantan junction. It

therefore produces an unwanted parasitic voltage, V3 .
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 Thermocouples

How to Solve the Problem

As a practical approach consists in establishing J3 as the reference
junction.

This can be done using one of the following methods:

• One method is to force junction J3 at a constant, well-known

temperature. This is usually done by putting J3 into an ice bath
at 0°C .

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 Thermocouples

How to Solve the Problem

Another method consists in using a variable dc voltage source to
electronically simulate an ice point reference at J3.
• The temperature of J3 is sensed
by either an RTD or a thermistor.

• Based on the sensed

temperature, the source
generates the compensation
voltage required to balance the
voltmeter reading as if J3 were
placed in an ice bath at 0°C .
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 Thermocouples

Reference junction compensation

In order for reference junction compensation to be effective, the

compensation mechanism must “know” the temperature of the
reference junction. This fact is so obvious, it hardly requires
mentioning.

However, what is not so obvious is how easily this compensation may

be unintentionally defeated simply by installing a different type of wire
in a thermocouple circuit.
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 Thermocouples

Reference junction compensation

To illustrate, let us examine a simple type K thermocouple

installation, where the thermocouple connects directly to a panel-
mounted temperature indicator by long wires:

The indicator senses

the cold junction
temperature using a
small thermistor
thermally bonded to
the connection
terminals.
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 Thermocouples

Reference junction compensation

Now let us consider the same thermocouple installation with a
length of copper cable (two wires) joining the field-mounted
thermocouple to the panel-mounted indicator:

The reference junction

has completely shifted
position.

Thermistor has no ability

to read temperature of
cold junction for
compensation
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 Thermocouples

Correct Lead extension

These “compensating” wires were made of two different copper-
nickel alloys, each copper-nickel alloy matched with the respective
thermocouple metal

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 Thermocouples

Correct Lead extension

In this case, pure platinum and a 90%-10% platinum-iridium alloy) to
generate an equal and opposite millivoltage at any reasonable
temperature found at the thermocouple head.

Thus, the only reference junction in the thermocouple circuit is

where these copper-nickel extension wires joined with the indicating
instrument, rather than being located at the thermocouple head as it
would be if simple copper extension wires were employed.
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 Thermocouples

Correct Lead extension : Cheaper Alternative

With platinum being such an expensive metal, the cost savings
realized by being able to use cheaper extension wire to connect the
platinum thermocouple to a distant receiving instrument is
significant.

Extension-grade cable is
denoted by a letter “X”
following the thermocouple
letter.

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Thermocouples

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 Thermocouples

Thermocouple Restrictions
The main restriction of Thermocouples is the “accuracy” which
doesn’t make it the best solution for precise applications.

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 Thermocouples

Thermocouple Restrictions
Also, Thermocouples need a reference measurement point called
“Cold Junction”.

The thermocouple
junction is often exposed
to extreme environments,
while the cold junction is
often mounted near the
instrument location.

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 Thermocouples
How it works
• Measuring junction is heated, small DC voltage (millivolts)
generated in thermocouple wires.

Note: thermocouple only generates a milli-voltage signal when there

is temperature difference between “hot” and “cold” junctions “cold”
junction usually set to 0°C.
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 Thermocouples
Thermocouple Construction

Three general constructions:

❖ Insulated Wire
❖ Ceramic-beaded
❖ Metal-sheathed

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 Thermocouples
❖ Insulated Wire Thermocouples

Bare wires wrapped with insulation

Insulations
• Fibrous, woven material made of fiber-glass, mica, or ceramic fiber
• Plastics (Teflon)
• Polyimides (Kapton)
Purpose
• Electrically isolate wires
• Protects wires from contamination
• Easier wire installation
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 Thermocouples
❖ Metal - Sheathed Thermocouples
Junction and wires are assembled in small diameter metal tubes

Insulation
• Fiberglass
• MgO

Purpose
• Protects against contamination
• Defends against chemical attack
• Provides mechanical stability

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 Thermocouples
❖ Thermocouple protection
A thermocouple junction is designed in one of three different ways:

a. Grounded
• Weld junction directly to inside tip of sheath
• Ensures rapid heat transfer from sheath to junction
• Protects junction while minimizing heat transfer delays.

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 Thermocouples

b. Ungrounded
• Similar to grounded except junction isolated from metal sheath
• Electrically isolates junction from sheath
• Prevents stray voltages from inducing measuring error
• More shock resistant & better under rapid temperature changes

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 Thermocouples
DISADVANTAGE OF UNGROUNDED:

• Slows down heat transfer to junction (2x-3x slower)

• Exposed
• Junction protrudes from end of sheath, but insulated from it
• Due to direct exposure with heated material, very quick response
to temp. changes
• No sheath to slow down heat transfer
• Not protected from mechanical damage & chemical attack

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 Thermocouples

C. Bared
• Junction protrudes out of the tip of the Sheath
• Directly exposed to the process
• This design provides the best response time
• Offers no protection from hazardous or corrosive materials.
• Cannot be used in conjunction with conductive process fluids.

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 Thermocouples
• Task : testing the thermocouple using an ohmmeter

Measure the resistance between the two wire of

thermocouple:

Resistance= Ω

Measure the resistance between one of thermocouple wire &

metal Sheathed

Resistance= Ω
Is the thermocouple Grounded Or Ungrounded
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 Thermocouples

Types of Thermocouples
Based on :
• Range of temperature measurement,
• Sensitivity
• Application
different types of Thermocouples are available, for example:

• E Type
• J Type
• K Type
• M Type
• N Type
• T Type
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 Thermocouples

Types of Thermocouples
Each letter corresponds to a specific voltage-temperature relationship

The thermocouple operates

with a reference
temperature of 0°C for
which the voltage is null.

The reference temperature

is chosen to coincide with
the melting point of ice.

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 Thermocouples

Types of Thermocouples
• For instance, Type “J” is made up of “Iron-Constantan” combination
with a :
• Range of −40°F to +1380°F
• Sensitivity of about 27.8 µV/°F

• while Type “K” (Chromel-Alumel) is one of the most common

general-purpose thermocouples with a :
• Sensitivity of approximately 22.8 µV/°F.

• Type K is inexpensive and a wide variety of probes are available in :

• Range of −330°F to +2460°F .

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 Thermocouples

Types of Thermocouples

Common types of thermocouples used in the industry.

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 Thermocouples

ANSI Color coding of Thermocouples

As per ANSI standard :
• Negative wire ( -) is made RED colored
• Positive wire (+) is made color coded

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 Thermocouples

ANSI Color coding of Thermocouples

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 Thermocouples

ANSI Color coding of Thermocouples

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 Thermocouples

ANSI Color coding of Thermocouples

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 Thermocouples

ANSI Color coding of Thermocouples

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 Thermocouples

ANSI Color coding of Thermocouples

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 Thermocouples

ANSI Color coding of Thermocouples

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 Thermocouples

ANSI Color coding of Thermocouples

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 Thermocouples

ANSI Color coding of Thermocouples

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 Thermocouples

Thermocouple temperature range can be readjusted depending on

work condition

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 Thermocouples

IEC vis ANSI Color coding of Thermocouples

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Thermocouples

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Thermocouples

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Thermocouples

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 Thermocouples
Thermocouple Reference Tables

The N.I.S.T. (National Institute of Standards and Technology) is the

U.S. standards setting agency. They have determined the output
millivoltage of all type thermocouples, at all temperatures, within
their range.

The resulting tabulations are called “Thermocouple Reference

Tables” and the thermocouple output millivoltage is shown for
each degree of temperature.

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 Thermocouples

How to read thermocouple /mV table

Example Thermocouple Type K
The first column on the left (in red) shows temperatures in increments of
10, so if you have 14, then where do you find 14 on the table. Start by
finding 10 on the left. Then slide right to find the column with 4 above it
(row in blue), that gives you 14.

The numbers in the yellow box are the millivoltages. If you know the
millivoltage, then find it in the table and follow the column and row to
find your temperature.

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 Thermocouples

How to read thermocouple /mV table?

Example : based on this type K thermocouple table. So say you have
3.474 mV. Now scan the table, and you’ll find that number in the row
of 80 and the column of 5. That makes 85° C. Tada!

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 Thermocouples
How to Determine the Measuring Junction Temperature
The junction of each type thermocouple produces a specific millivoltage
across it at a specific temperature. A thermocouple consists of two
junctions connected in opposition.

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 Thermocouples
How to Determine the Measuring Junction Temperature

1. Measure the “VMEAS” millivoltage as in below.

2. Measure the actual temperature of the reference junction

with a thermometer.
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 Thermocouples

How to Determine the Measuring Junction Temperature

3. Go to the table for the thermocouple being used and look up

the millivoltage produced at that temperature.

4. Add that millivoltage to the millivoltage measured as “VMEAS” to

get a total.

5. Find that millivoltage total in the reference table. The

corresponding temperature is the temperature of the measuring
junction.

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 Thermocouples

Cold junction compensation

Example Thermocouple Type T

Example #1 – Type “T” Thermocouple

Measured “VMEAS” = 3.41 mV
Reference Junction Temperature = 22°C (71.6°F)

1. From the table: 22°C = 0.87 mV.

2. Adding 0.87 mV to 3.41 mV = 4.28 mV.

1. Finding 4.28 mV In the table; the corresponding temperature is

100°C (212°F) and is the temperature of the measuring Junction.

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 Thermocouples

Cold junction compensation

Example Thermocouple Type T

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 Thermocouples

Cold junction compensation

Example Thermocouple Type T

Example #2 – Type “T” Thermocouple

Measured “VMEAS” = 4.47 mV

Reference Junction Temperature = -5°C (23°F)
(lower than the table reference of 0°C)

1. From the table: -5°C = -0.193 mV.

2. Adding -0.193 mV to 4.47 mV = + 4.28 mV.

1. Finding 4.28 mV In the table; the corresponding temperature is

100°C (212°F) and is the temperature of the measuring Junction.
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 Thermocouples
Exercise
Given A thermocouple find out the type & from T/C Table the
equivalent mV at the following temperature :
400 ; 450 ; 610; 750 degree C
Answer :
Type of Thermocouple=

400 deg. C= mV
450 deg. C= mv
610deg. C= mV
750 Deg. C= mV

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Calibration of Temperature Transmitter
RTD & Thermocouple

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 Thermocouples

Intelligent Temperature Transmitter Wiring

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 Thermocouples

RTD Temperature Transmitter Wiring

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 Thermocouples

Thermocouple Temperature Transmitter Wiring

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 Thermocouples

Thermocouple Temperature Transmitter Wiring

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Calibration of Temperature Transmitter

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 Calibration of Temperature Transmitter
• Calibration Of temperature Transmitter:
• Connect the transmitter with Hart Communicator & signal simulators
as Shown in fig.

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 Calibration of Temperature Transmitter
• Using Hart communicator configure the transmitter for type K
thermocouple
• Using signal simulator Insert the LV for transmitter & measure the
current
• Insert upper range & measure the current
• Adjust Zero & span if required

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