LINEARISATION OF THERMOCOUPLE

(Model No : ITB - 05C)

Technical Manual

Version 1.0

Technical Clarification /Suggestion :

/
Technical Support Division,
Vi Microsystems Pvt. Ltd.,
Plot No :75, Electronics Estate,
Perungudi, Chennai - 600 096, INDIA.
Ph : 91- 44-2496 1842, 91-44-2496 1852
Mail : service@vimicrosystems.com,
Web : www.vimicrosystem.com
 CONTENTS

INTRODUCTION 1

TECHNICAL SPECIFICATION 1

FRONT PANEL DIAGRAM 3

FRONT PANEL DESCRIPTION 4

THERMOCOUPLE 5

i) Seeback Effect

ii) Thermocouple Types

iii) Thermocouple Table

iv) Need for linearisation

SYSTEM OVERVIEW 7

i) Buffer amplifier

ii) Instrumentation amplifier

iii) Adder

iv) Analog to digital converter

v) Digital to Analog converter

vi) Signal conditioning circuit

LINEARISATION CIRCUITS 9

PRINCIPLE OF OPERATION 9

EXPERIMENTAL SECTION 10

CIRCUIT DIAGRAMS 16
LINEARISATION OF THERMOCOUPLE ITB - 05C

INTRODUCTION:

Industrial temperature regulations has always been of permanent importance and becomes even
more so with the advance of technology. There are various techniques to measure the
temperature of a quantity readily available. Thermocouple is an widely used thermal sensor in
the industries to measure the medium range of temperature changes ( 140 C to 1500 C ).
The thermocouples basically working on the principle of see back effect. But the relation
between the temperature and the thermal emf of thermocouple is non-linear in nature. The non-
linear characteristic reduces the accuracy of the temperature control in process industries. This
non-linear behavior of the thermocouple is overcome by Linearization of the thermocouple
output by means of lookup table technique.

TECHNICAL SPECIFICATION

i. AD590 Sensor

Operating voltage - (-3 to -18V)DC

Output - Current in mA

Max Temp - 120 C

ii Water bath

Voltage - 230V AC/50Hz

Power - 1000 watts

Size - 200200140mm

Medium - Water

iii. ITB - 05C Unit

Surrounding Temperature - 15C - 50C

Cabinet - Mild Steel

iv. Thermocouple

Type - J type

Material - Iron/Constantan (Alloy of

copper /nickel)

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LINEARISATION OF THERMOCOUPLE ITB - 05C

Tube Diameter - 6mm

Working Temperature - (-200 to 760) C

Tube Length - 120mm

Thermowell material - Stainless steel

Coating - Nickel, Chromiums

Cable Length - 950mm

v. Power Supply

Input - 230V AC / 50Hz

Output - +5V / 1A
+12V / 500mA
-12V / 500mA

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FRONT PANEL DIAGRAM:

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FRONT PANEL DESCRIPTION:

1. Power ON/OFF - Provision to switch ON/OFF the unit.

2. T1 and T2 - Provision to connect the thermocouple

3. T3 and T4 -used to connect the AD590 sensor.

4. T6- Temperature compensation circuit output voltage is measured at T6 point

with respect to the GND T7.

5. T5 - used to connect the Temperature compensation circuit output voltage to the

adder circuit by patching the T6 and T5.

6. T8- Non - Linear output voltage is measured at the point T8.

7. T9- used to connect the Non-linear output voltage to the ADC by patching T8
and T9.

8. T10 - It is used to measured the linear output voltage with respect to GND T11.

9. Switch provision is provided to display the temperature of Non-linear output or

linear output.

10. T7 and T11 - GND.

11. Zero adjustment POT - For Zero calibration.

12. 3.5 digit display - To display the linear/ Non- linear thermocouple output ( C )

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LINEARISATION OF THERMOCOUPLE ITB - 05C

THERMOCOUPLE:

Thermocouple works based on the basics of thermoelectric principle. The basic theory of
thermocouple effect is found from a consideration of the electrical and thermal properties of
different metals. We are using thermocouple of J-type which will measure our required range.
It is an active transducer made of iron and constanstan metals. The output voltage will be in milli
volt range which is linear when compared to any other type of thermocouple.

SEEBACK EFFECT:

Using solid state theory , thermocouple its emf can be given by an integral over temperature

T2

(Q
T1
A QB )dT

Where emf produced in volts

T1 , T2 junction temperature in kelvin

Q A , QB thermal transfer cons tan t of two metals

This equation describe the seeback effect, shows that emf produced is proportional to the
difference in temperature and further to the difference in the metallic thermal transfer constants.

To use the thermocouple to measure a temperature, the reference temperature must be known
and the reference junctions must be held in same temperature.

THERMOCOUPLE TYPES:

Each type has particular features, such as range, linearity, inertness to hostile environments,
sensitivity and so, on and is chosen for specific application accordingly. In each type, various
sizes of conductors may employed for specific cases, such as oven measurements, highly
localized measurements and so on.

THERMOCOUPLE TABLE:

The thermocouple tables simply gives the voltages that results for a particular type of
thermocouple when the reference junctions are at a particular reference temperature and the
measurement junction is at the temperature of interest. In most cases, the measured voltage does
not exactly fall on the table values as in this case, that means the relation exists between the
thermocouple table and the actual thermocouple output is non-linear. When this happens, it is
necessary to interpolate between the table values that bracket the desired value.

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LINEARISATION OF THERMOCOUPLE ITB - 05C

In general the value of temperature can be found using the following interpolation equation.

T TL
TM TL H (V M V L )
VH V L

The measured voltage V M lies between an higher voltage VH and the lower voltage V L ,which
are in the tables.

NEED FOR LINEARISATION:

The actual voltage output from the thermocouple does not exactly matches with the thermocouple
tables, due to its non-linear temperature Vs voltage characteristics. It reduces the accuracy of the
thermocouples used as the temperature sensors in industries..

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LINEARISATION OF THERMOCOUPLE ITB - 05C

SYSTEM OVERVIEW:

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LINEARISATION OF THERMOCOUPLE ITB - 05C

Our linearisation of Thermocouple kit is having buffer , instrumentation amplifier, adder, ADC,
EPROM, DAC and a zero adjustment.

BUFFER AMPLIFIER: (VOLTAGE FOLLOWER)

We are using a Buffer amplifier to avoid the loading effect due to external disturbance.

INSTRUMENTATION AMPLIFIER:

Thermocouple output (mv) will not be useful for any measurement and control action. To
overcome this difficulties we are using instrumentation amplifier. To have an multiplied output
in the form of voltage which will be 300 times the input coming from the buffer amplifier. The
output coming from the instrumentation amplifier will be proportional to the output from the
thermocouple which in turn proportional to the unknown temperature.

ADDER:

In our kit we are using an Adder circuit which is adding the output of instrumentation amplifier
with a reference voltage of 1.7V which will be equivalent to the room temperature. For 0V
output from the thermocouple will be added with a reference voltage to gave the room
temperature at which the thermocouple is kept. There is an adjustable zero to set 1.7V in the
non-linear mode for zero output from the thermocouple. The kit is calibrated to give an output
as (0-5)V for the temperature (0-100C).

ANALOG TO DIGITAL CONVERTER:

Any digital logic device that can process only digital signals that are in binary form logic level.
But most of the industrial application involve physical variable such as temperature, pressure etc.,
which are continuously varying. For that purpose we are using the analog signals from the
industrial application to the digital signal using ADC.

In out kit we are using EPROM to linearise the temperature output of the thermocouple for that
we are converting the analog voltage signal to the digital voltage signal. For that we are using 8
channel, 8 bit ADC 0809 which is based on successive approximation type. We are using ADC
0809 to reduce the conversion time because temperature system is a fast system.

ADC 0809 features:

100s conversion time
8 channels multiplexer with latch
Low power consumption
Latched tristate output.

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LINEARISATION OF THERMOCOUPLE ITB - 05C

DIGITAL TO ANALOG CONVERTOR:

Any physical device respond only for the analog signal for that we are converting once again to
analog signal for the process. Now the linearised output will come out of the DAC for the
purpose of display.

We are using DAC 0800 of 8 bit nature. The output of the DAC 0800 will be in the current mode,
to convert it into voltage we are using a current to voltage convertor made up of op-amp circuit
made of IC741.

We are employing R-2R network for DAC network. And we are providing a heater with the
thermocouple along with this kit for the purpose of supplying heat to the thermocouple.

SIGNAL CONDITIONING CIRCUIT:

The key element is the use of thermocouple is very small, typical less than 50mV. This means
that considerable amplification will be necessary for practical application. In addition small
signal levels make the devices susceptible to electrical noise. In most cases, thermocouple is used
with high-gain differential amplifier. In addition, the input impedance should be high, particularly
of extension wires are used to reduce errors from voltage drops because of current drawn from
the thermocouple.

LINEARISATION CIRCUIT:

The linearisation circuit consists of the Analog to Digital Converter, clock generator, EPROM
and the digital to analog converter. The analog to digital converter provides the digital output for
corresponding signal conditioner output. The DAC converts the digital data come from the
linearisation circuit to Analog voltage.

PRINCIPLE OF OPERATION:

The thermocouple measure the temperature from the water heater and it gives mV output, which
is Non-linear. This mV output is converted into (0-5)V by signal conditioning unit The Non-
Linear output of the thermocouple is given to the input of the ADC -0809 which convert Analog
into Digital. This Digital output is further compared with prestored data in EPROM and produce
corresponding linear data.

This Linear Digital data is given to the DAC 0800 to convert Digital into Analog Voltage.

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LINEARISATION OF THERMOCOUPLE ITB - 05C

EXPERIMENTAL SECTION

EXPERIMENT-1:

AIM:

To study the Non-linear characteristics of Thermocouple.

APPARATUS REQUIRED:

1. Linearisation of thermocouple unit

2. Water Bath
3. Thermocouple ( J-Type)
4. AD590 Sensor
5. Thermometer (0 1000 C )
6. PC power Chord
7. Patch Chord.

PROCEDURE:

1. Switch ON the linearisation of thermocouple unit (ITB-05C)

2. Keep the Heater (or) Water bath in OFF position.

3. Connect the thermocouple sensors Positive & negative terminals into T1 and T2
point in the ITB -05C unit.

4. For Zero Calibration adjust the zero potentiometer at Room temperature

5. Connect the AD590 Sensor Positive &Negative terminals into T3 and T4

.
6. Keep the Switch in Non-linear output mode.

7 Now connect the T5 and T6 point using patch chord.

8. Insert the thermocouple and thermometer into the water bath without touching the
coil and switch ON the water bath.

9. Now note down the temperature in display and Non-linear output voltage at the
point T8 using multimeter.

10. Plot a graph between the

(1) Temperature vs Non-linear output.

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LINEARISATION OF THERMOCOUPLE ITB - 05C

TABULAR COLUMN:

Temperature ( C ) Non-Linear output (V)

MODEL GRAPH:
Non - Linear Output (V)

0 10 20 30 40 50 60 70 80 90 100
Temperature (C)

RESULT:

Thus the Non-linear characteristics of Thermocouple was studied and Verified.

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LINEARISATION OF THERMOCOUPLE ITB - 05C

EXPERIMENT-2:

AIM:

To study the Linearisation of Thermocouple using ITB-5C Unit.

APPARATUS REQUIRED:

1. Linearisation of thermocouple unit

2. Water Bath
3. Thermocouple (J-Type)
4. AD590 Sensor
5. Thermometer (0 1000 C )
6. PC power Chord
7. Patch Chord

PROCEDURE:

1. Switch ON the linearisation of thermocouple unit (ITB-05C)

2. Keep the Heater (or) Water bath in OFF position.

3. Connect the thermocouple sensors Positive & negative terminals into T1 and T2
point in the ITB -05C unit.

4. For Zero Calibration adjust the zero potentiometer at Room temperature.

5. Connect the AD590 Sensor Positive &Negative terminals into T3 and T4.

6. Keep the Switch in linear output mode.

7. Now connect the T5 and T6 point using patch chord

.
8. Connect the T8 and T9 using Patch chord.

9. Insert the thermocouple and thermometer into the water bath without touching the
coil and switch ON the water bath.

10. Now note down the temperature in display and Linear output voltage at the point
T10 using multimeter.

11. Plot a graph between the

(1) Temperature vs linear output.

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LINEARISATION OF THERMOCOUPLE ITB - 05C

TABULAR COLUMN:

Temperature ( C ) Linear output (V)

MODEL GRAPH:

4
Linear Output (V)

0 10 20 30 40 50 60 70 80 90 100
Temperature (C)

RESULT:

Thus the Linearization of thermocouple was done and Verified.

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LINEARISATION OF THERMOCOUPLE ITB - 05C

EXPERIMENT-3:

AIM:

To study the Characteristics of Cold Junction Compensation by using AD590 sensor.

APPARATUS REQUIRED:

1. Linearisation of thermocouple unit

2. Water Bath
3. Thermocouple (J-Type)
4. AD590 Sensor
5. Thermometer (0 1000 C )
6. PC power Chord
7. Patch Chord

PROCEDURE:

1. Switch ON the linearisation of thermocouple unit (ITB-05C)

2. Keep the Heater (or) Water bath in OFF position.

3. Connect the thermocouple sensors Positive & negative terminals into T1 and T2
point in the ITB -05C unit.

4. For Zero Calibration adjust the zero potentiometer at Room temperature

5. Connect the AD590 Sensor Positive &Negative terminals into T3 and T4.

6. Keep the Switch in Non-linear output mode.

7. Now connect the T5 and T6 point using patch chord.

8. Insert the AD590 and thermometer into the water bath without touching the coil
and switch ON the water bath.

9. Now note down the temperature in display and Non-linear output voltage at the
point T8 using multimeter.

10. Plot a graph between the

(1) Temperature vs output Voltage.

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LINEARISATION OF THERMOCOUPLE ITB - 05C

TABULAR COLUMN:

Temperature ( C ) Output Voltage (V)

MODEL GRAPH:

5
Output voltage (V)

0 10 20 30 40 50 60 70 80 90 100
Temperature (C)

RESULT:

Thus the Characteristics of Cold Junction Compensation was studied and Verified.

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CIRCUIT DIAGRAM:

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