Microchip Application Note
Microchip Application Note
Author:
AN679
Temperature Sensing Technologies
SO MANY TEMPERATURE SENSORS
The most popular temperature sensors used today are the Thermocouple, Resistive Temperature Device (RTD), Thermistor, and the newest technology, the Integrated Silicon Based Sensors. There are other sensing technologies, such as Infrared (Pyrometers) and Thermal Pile. These alternatives are beyond the scope of this application note. Each of these sensor technologies cater to specic temperature ranges and environmental conditions. The sensors temperature range, ruggedness, and sensitivity are just a few characteristics that are used to determine whether or not the device will satisfy the requirements of the application. No one temperature sensor is right for all applications. The thermocouple's wide temperature range is unrivalled as is the excellent linearity of the RTD and the accuracy of the Thermistor. Table 1 summarizes the main characteristics of these four temperature sensors. This table can be used during the rst pass of the sensor selection process. Further details concerning the construction and characteristics of these sensors are given in the following sections of this application note To complement the specications sited in Table 1, a list of typical applications for these four temperature sensors are shown in Table 2.
INTRODUCTION
Of all of the sensing technologies, temperature sensing is the most common. This phenomena can be explained by citing examples in a multitude of applications where knowing and using the actual or relative temperature is critical. For instance, other sensors such as pressure, force, ow, level, and position many times require temperature monitoring in order to insure accuracy. As an example, pressure and force are usually sensed with resistive Wheatstone bridge congurations. The temperature errors of the resistive elements of these bridges can exceed the actual measurement range of the sensor, making the pressure sensors output fairly useless, unless the temperature of the bridge is known. Flow and level sensor accuracies are dependent on the density of the liquid or gas. One variable that affects the accuracy of these sensors is the temperature of that material. Position is most typically used in motor control. In these circuits, temperature affects the efciency of the motor. Consequently, the understanding of temperature sensing is needed in order to fully understand how to accurately sense most other physical phenomena. This application note will cover the most popular temperature sensor technologies to a level of detail that will give the reader insight into how to determine which sensor is most appropriate for the application. This note is written from the perspective of catering to the complex issues of the sensing environment and required accuracy. Once the sensor is selected, subsequent Microchip application notes can be used to design appropriate microcontroller interface circuits. These circuits will offer the complete signal path from the low level output signals of the sensor, through the analog signal conditioning stages to the microcontroller. Techniques such as sensor excitation, sensor signal gain, and digital linearization are reserved for these further discussions.
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Thermocouple
Temperature Range 270 to 1800C Sensitivity 10s of V / C
RTD
250 to 900 C 0.00385 / / C (Platinum) 0.01C Requires at least a 2nd order polynomial or equivalent look up table. RTDs are susceptible to damage as a result of vibration. This is due to the fact that they typically have 26 to 30 AWG leads which are prone to breakage.
Thermistor
100 to 450C several / / C
Accuracy Linearity
0.5C Requires at least a 4th order polynomial or equivalent look up table. The larger gage wires of the thermocouple make this sensor more rugged. Additionally, the insulation materials that are used enhance the thermocouples sturdiness.
0.1C Requires at least 3rd order polynomial or equivalent look up table. The thermistor element is housed in a variety of ways, however, the most stable, hermetic Thermistors are enclosed in glass. Generally thermistors are more difcult to handle, but not affected by shock or vibration. 1 to 5 Secs Voltage Source Resistance 0.1 x 0.1 in. $2 to $10
Ruggedness
As rugged as any IC housed in a plastic package such as dual-in-line or surface outline ICs.
less than 1 Sec None Required Voltage Bead diameter = 5 x wire diameter $1 to $50
4 to 60 Secs Typically Supply Voltage Voltage, Current, or Digital From TO-18 Transistors to Plastic DIP $1 to $10
TABLE 1: The most common temperature sensors in industry are the thermocouple, RTD, thermistor, and integrated silicon based. No one temperature sensor is right for all applications. The thermocouples wide temperature range is unrivalled as is the excellent linearity of the RTD and the accuracy of the thermistor. The silicon sensor is easy to implement and install in a circuit.
Sensor Type Thermocouple RTD Thermistor Application Extremely high temperature sensing, biophysics, metal cutting research, gas chromatography, internal combustion engine temperatures, chemical reactions Cold junction compensation, bridge temperature, calibration, process control. Cold junction compensation, bridge temperature sensing, pyrometer calibration, vacuum manometers, anemometers, ow meters, liquid level, uid velocity, thermal conductivity cells, gas chromatography Cold junction compensation, personal computers, ofce electronics, cellular phones, HVAC, battery management, four speed controls
Silicon Based
TABLE 2: Listed are some examples of the applications that each temperature sensor is best suited for.
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THE VERSATILE, INEXPENSIVE THERMOCOUPLE
The thermocouple consists of two wires of dissimilar metals that are soldered together at one end as shown in Figure 1. The temperature at the Reference Junction (also know as the Cold Junction Compensation Point) is used to negate the errors contributed by the Iron-Copper and Constantan-Copper junctions. The connecting point of the two metals of the thermocouple is positioned on the target where the temperature measurement is needed. This conguration of materials produces a voltage between the two wires at the unsoldered end that is a function of the temperature of all of the junctions. Consequently, the thermocouple does not require voltage or current excitation. As a matter of fact, an attempt to provide either type of excitation could introduce errors into the system. Since a voltage develops at the open end of the two dissimilar wires, it would seem as if the thermocouple interface could be done in a straight forward manner by measuring the voltage difference between the wires. This could easily be the case if it wasnt for the fact that the termination ends of the thermocouple wires connect to another metal, usually copper.
Reference Junction Iron Signal Conditioning Electronics IronCopper Junction
This creates another pair of thermocouples, which introduces a signicant error to the system. The only way to negate this error is to sense the temperature at the Reference Junction box (Figure 1) and subtract the contributing errors of these connections in a hardware solution or a combination of software and hardware. Pure hardware calibration techniques are more limited in terms of linearization correction than the combination of software and hardware techniques. Typically, an RTD, Thermistor, or Integrated Silicon Sensor is used to sense this junction temperature accurately. In principle the thermocouple can be made from any two metals, however, in practice standard combinations of these two metals have been embraced because of their desirable qualities of linearity and their voltage magnitude drop versus temperature. These common thermocouple types are E, J, T, K, N, S, B, and R (summarized in Table 3 and Figure 2). Thermocouples are highly non-linear and require signicant linearization algorithms, as will be discussed later. The Seebeck Coefcient in Table 3 represents the average drift of the specic thermocouple at a specic temperature.
Solder Joint
Copper
CopperConstantan Junction
Constantan
Type J Thermocouple
FIGURE 1: A thermocouple is constructed of two dissimilar metals, such as the Iron and Constantan in this Type J thermocouple. The temperature of the Reference Junction Compensation (also known as the Cold Junction Compensation or Isothermal Block) is used to negate the errors contributed by the Iron-Copper and Constantan-Copper Junctions.
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. Thermocouple Type
E J T K N S B R
Conductors
Chromel, Constantan Iron, Constantan Copper, Constantan Chromel, Alumel Nicrosil, Nisil Platinum(10% Rhodium), Platinum Platinum (30% Rhodium) Platinum (6% Rhodium) Platinum (13% Rhodium), Platinum
Seebeck Coefcient
60V/C 51V/C 40V/C 40V/C 38V/C 11V/C 8V/C 12V/C
Application Environments
oxidizing, inert, vacuum vacuum, oxidizing reducing, inert corrosive, moist, subzero completely inert oxidizing oxidizing, inert oxidizing, inert
oxidizing, inert
TABLE 3: The most common thermocouple types are shown with their standardized material and performance specications. These thermocouple types are fully characterized by the American Society for Testing and Materials (ASTM) and specied in IST-90 units per NIST Monograph 175.
80
E
c0 c1 c2
J K N
-1.7600413686 x 10-2 3.8921204975 x 10-2 1.8558770032 x 10-5 -9.9457592874 x 10-8 3.1840945719 x 10-10 -5.6072844889 x 10-13 5.6075059059 x 10-16 -3.2020720003 x 10-19 9.7151147152 x 10-23 -1.2104721275 x 10-26
c3 c4 c5 c6 c7
S B
20 10 0
c8 c9
FIGURE 2: Thermocouples are sensitive to a wide range of temperatures making them appropriate for a variety of hostile environments.
At the time of shipment, the thermocouple performance is guaranteed by the vendor in accordance with NIST 175 standards (adopted by ASTM). These standards dene the temperature behavior of the thermocouple as well as the quality of the material used. Thermocouples are extremely non-linear when compared to RTD, Thermistor, and Integrated Silicon Sensors. Consequently, complex algorithms must be performed with the processor portion of the circuit. An example of the complexity of the calculation is shown in Table 4. These are the Type K Thermocouple coefcients that can be used to linearize the output voltage results for a temperature range of 0C to 1372C. These coefcients are used in the equation V = c 0 + c 1 t + c 2 t + c 3 t ... where V is equal to the voltage across the thermocouple junction, and t is equal to the temperature.
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2 3
TABLE 4: These are the Type K thermocouple coefcients that can be used to linearize the output voltage results for a temperature range of 0C to 1372C. These coefcients are used in the equation V = c0 + c1t + c2t 2 + c3t 3 ... where V is equal to the voltage across the thermocouple junction, and t is equal to the temperature.
The alternative to using these complex calculations is to use program memory for a look-up table. The replacement look-up table for the equation coefcients of the Type K thermocouple in Table 4 is approximately an 11 x 14 array of decimal integers ranging from 0.000 to 13.820. Additionally, the thermocouple can quantify temperature as it relates to a reference temperature. The reference temperature is dened as the temperature at the end of the thermocouple wires furthest from the soldered bead. This reference temperature is usually sensed using an RTD, Thermistor, or Integrated Silicon Sensor. The thermal mass of the thermocouple is smaller than the RTD or Thermistor, consequently the response of the thermocouple as compared to larger temperature sensors is faster. The wide temperature ranges of the sensor makes it exclusively appropriate for many hostile sensing environments.
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Thermocouple Error Analysis
Thermocouples are generally low cost, rugged and available in smaller sizes than the other temperature sensors. Any stress on the material due to bending stretching or compression can change the characteristics of the thermal gradients. Additionally, corrosive material can penetrate the insulation material and cause a change in the thermal characteristics. It is possible to encase the thermocouple bead in protective tubing such as a ceramic tube for high temperature protection. Metallic wells can also provide mechanical protection. The thermocouple voltage drop occurs along the temperature gradient down the length of the two dissimilar metals. This does not imply that shorter versus longer wires will necessarily have differing Seebeck Coefcients. With shorter wires, the temperature gradient is simply steeper. However, the longer wires do have an advantage in terms of conduction affects. With the longer wires the temperature gradient is lower and conduction losses are reduced. On the down side, these types of temperature sensors have a very low output signal. This places additional requirements on the signal conditioning circuitry that follows the thermocouple. In addition to this low level output signal, the linearity of the device requires a considerable amount of calibration. This calibration is typically done in rmware as well as software. In rmware, an absolute temperature reference is needed which serves as a cold junction reference. In software, the linearity errors of the thermocouple are reduced with look-up tables or high order polynomial equations. And nally, EMI signals are easily coupled in to this two-wire system. Lower gage wires are required for higher temperatures and will also have a longer life. However, if sensitivity is a prime concern, larger wire gages will provide better measurement results. To summarize, thermocouples are usually selected because for the wide temperature range, ruggedness, and price. Accuracy and good linearity are hard to achieve in precision systems. If high accuracy is desirable, other temperature sensors may be a better alternative.
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RTD Detector Material Platinum Nickel Copper Thermal Response (at 0C) 0.00385 //C (IEC 751) 0.00672 //C 0.00427 //C Typical Material Resistivity (at 0C) 9.81 x 10-6 cm 5.91 x 10-6 cm 1.53 x 10-6 cm
TABLE 5: RTD temperature sensing devices are available in a variety of materials. The temperature coefcient of these devices is specied in terms of ohms, per ohms per C.
In most applications, linearization is not required. Table 6 shows the temperature versus resistance of a 100 platinum RTD. With a 100 PRTD, the change in resistance from 0C to 100C changes resistance by:
Typical Absolute Resistive Value () 23.0 61.5 100.0 138.5 177.0 215.5 254.0 292.5 331.0 369.5 408.0
TABLE 6: OMEGA Platinum Resistance Elements Allowable Deviation from Ideal Values for a 100 Sensor. The PRTD in this illustration is manufactured to have a thermal response of 0.00385/ / C (IEC 751) near 0C, Class B.
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For example, if the package thermal resistance is 50C/W, the RTDs nominal resistance is 250, and the element is excited with a 5mA current source, the articial increase in temperature ( C) as a result of self heating is:
10
NTC THERMISTERS
PLATINUM RTD
.1
.01
.001
.0001
-50
TEMPERATURE (C)
50
100
150
200
250
300
FIGURE 4: The temperature response resistance of the NTC thermistor and the RTD.
versus
The temperature characteristics of a typical NTC thermistor along with a 100 RTD is shown in Figure 4. In this gure, the difference between the temperature coefcients of these two sensors is noticeable. The thermistor has a negative temperature coefcient as expected and the absolute value of the sensor changes by 10,000 times over its usable temperature range. In contrast, the RTD shown has a positive temperature coefcient and only changes by four times over is usable temperature range.This higher sensitivity of the thermistor makes it attractive in terms of accuracy in measurements.
FIGURE 3: RTD elements are available in two-wire, three-wire or four-wire congurations. Two-wire RTDs are the least accurate because the contribution of the wire resistance and wire resistance drift to the measurement. With four-wire RTDs, this error can be eliminated by using force and sense techniques in the circuit design.
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The Thermistor is less linear than the RTD in that it requires a 3rd order polynomial for precise temperature corrections. The linearity equations for the Thermistor are: B1 B2 B3 In R T = B 0 + ----+ - + ----2 3 t - ----t t over the entire temperature range where BX are the material constants of the thermistor This linearization formula can resolve to a total measurement uncertainty of 0.005C. However, it is tedious when implemented in the microcontroller. Alternatively, look-up tables can be generated to serve the same purpose with slightly less accuracy. At this point, increases in temperature cause a rise in the PTC's resistance and the PTC resistive / temperature characteristics become very steep. A second type of PTC thermistor is known as the Silistor. This device is constructed of a thermally sensitive silicon material and also has a positive temperature coefcient (-60C to 150C) that is linear over the entire operating range. Both of the thermal characteristics of the PTC type thermistors are shown in Figure 5.
PT C
LOG
Sw it
i ch
ng
Ty
pe
Silis
tor
T TEMPERATURE
LIN
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CHOOSE THE RIGHT TEMPERATURE SENSOR
Of the temperature sensors on the market today, the thermocouple, RTD, Thermistor, and Integrated Silicon Sensors are continuing to dominate. The thermocouple is most appropriate for higher temperature sensing, while the RTD is best suited for lower temperatures were good linearity is desirable. The Thermistor is typically used for applications with smaller temperature ranges, but it offers greater accuracy than the thermocouple or the RTD. All four of the sensors mentioned in this application note have the capability of providing good, accurate, and reliable performance, making the nal sensor selection appear somewhat trivial. However, once the temperature sensor has been selected, the next step is to design the analog and digital signal conditioning circuit. The design of this circuit will determine the actual performance that is nally achieved. Several application notes can be found in the Microchips library that elaborate on these circuits. Each of these application notes will present circuit alternatives that take into account simplicity, accuracy and cost.
REFERENCES
Baker, Bonnie, Low Power Temperature Sensing with Precision Converters, Sensors, (February 1997) p 38. Baker, Bonnie, Precision Temperature Sensing with RTD Circuits, AN687, Microchip Technology Inc. (1998). Baker, Bonnie, Single Supply Temperature Sensing with Thermocouples, AN684, Microchip Technology Inc. (1998). Baker, Bonnie, Thermistors in Single Supply Temperature Sensing Circuits, AN685, Microchip Technology Inc. (1998). Klopfenstein, Rex, Software Linearization of a Thermocouple, Sensors, (December 1997) p 40. Product Book, Thermometrics, Inc. (1997). Schraff, Fred. Thermocouple Basics Measurement & Control, (June 1996) p 126. Sulciner, James, Understanding and Using PRTD Technology, Part 1: History, Principles and Designs, Sensors, (August 1996). http://www.omega.com/techref/
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NOTES:
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NOTES:
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