CALIBRATION OF THERMOCOUPLE FOR

TEMPERATURE MEASUREMENT
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INSTRUCTION MANUAL
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TEMPERATURE MEASUREMENT AND CALIBRATION

THERMOCOUPLE SENSOR

A thermocouple is a temperature-measuring device consisting of two dissimilar conductors that

contact each other at one or more spots, where a temperature differential is experienced by the
different conductors (or semiconductors). It produces a voltage when the temperature of one of
the spots differs from the reference temperature at other parts of the circuit. Thermocouples are a
widely used type of temperature sensor for measurement and control, and can also convert a
temperature gradient into electricity. Commercial thermocouples are inexpensive,
interchangeable, are supplied with standard connectors, and can measure a wide range of
temperatures. In contrast to most other methods of temperature measurement, thermocouples are
self powered and require no external form of excitation. The main limitation with thermocouples
is accuracy; system errors of less than one degree Celsius (°C) can be difficult to achieve.

Any junction of dissimilar metals will produce an electric potential related to temperature.
Thermocouples for practical measurement of temperature are junctions of specific alloys which
have a predictable and repeatable relationship between temperature and voltage. Different alloys
are used for different temperature ranges. Properties such as resistance to corrosion may also be
important when choosing a type of thermocouple. Where the measurement point is far from the
measuring instrument, the intermediate connection can be made by extension wires which are
less costly than the materials used to make the sensor. Thermocouples are usually standardized
against a reference temperature of 0 degrees Celsius; practical instruments use electronic
methods of cold-junction compensation to adjust for varying temperature at the instrument
terminals. Electronic instruments can also compensate for the varying characteristics of the
thermocouple, and so improve the precision and accuracy of measurements.

Thermocouples are widely used in science and industry; applications include temperature
measurement for kilns, gas turbine exhaust, diesel engines, and other industrial processes.
Thermocouples are also used in homes, offices and businesses as the temperature sensors in
thermostats, and also as flame sensors in safety devices for gas-powered major appliances.

Principle of operation

In 1821, the German–Estonian physicist Thomas Johann Seebeck discovered that when any
conductor is subjected to a thermal gradient, it will generate a voltage. This is now known as the
thermoelectric effect or Seebeck effect. Any attempt to measure this voltage necessarily involves
connecting another conductor to the "hot" end. This additional conductor experiences the same
temperature gradient and also develops a voltage, which normally opposes the original.
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Fortunately, the magnitude of the effect depends on the metal in use, and so a nonzero voltage
will be measured if two dissimilar metals are used. After carefully calibrating the temperature-
voltage dependence for a given pair of metals, these metals can be used as a thermometer.

K-type thermocouple (chromel–alumel) in the standard thermocouple measurement

configuration. The measured voltage can be used to calculate temperature , provided that
temperature is known.

The standard configuration for thermocouple usage is shown in the figure. Briefly, the desired
temperature Tsense is obtained using three inputs—the characteristic function E(T) of the
thermocouple, the measured voltage V, and the reference junctions' temperature Tref. The solution
to the equation E(Tsense) = V + E(Tref) yields Tsense. These details are often hidden from the user
since the reference junction block (with Tref thermometer), voltmeter, and equation solver are
combined into a single product.

Summery

The general circuit for the working of thermocouple is shown in the figure 1 above. It comprises
of two dissimilar metals, A and B. These are joined together to form two junctions, p and q,
which are maintained at the temperatures T1 and T2 respectively. Remember that the
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thermocouple cannot be formed if there are not two junctions. Since the two junctions are
maintained at different temperatures the Peltier emf is generated within the circuit and it is the
function of the temperatures of two junctions.

If the temperature of both the junctions is same, equal and opposite emf will be generated at both
junctions and the net current flowing through the junction is zero. If the junctions are maintained
at different temperatures, the emf’s will not become zero and there will be a net current flowing
through the circuit. The total emf flowing through this circuit depends on the metals used within
the circuit as well as the temperature of the two junctions. The total emf or the current flowing
through the circuit can be measured easily by the suitable device.

The device for measuring the current or emf is connected within the circuit of the thermocouple.
It measures the amount of emf flowing through the circuit due to the two junctions of the two
dissimilar metals maintained at different temperatures. In figure 2 the two junctions of the
thermocouple and the device used for measurement of emf (potentiometer) are shown.

Now, the temperature of the reference junctions is already known, while the temperature of
measuring junction is unknown. The output obtained from the thermocouple circuit is calibrated
directly against the unknown temperature. Thus the voltage or current output obtained from
thermocouple circuit gives the value of unknown temperature directly.

CIRCUITRY :

The thermocouple sensors are connected to an amplifier. A milli volt source connected in
series with thermocouple to produce cold junction compensation mv instead of cold junction
thermocouple immersed in ice flask. Signal received from the cold junction thermocouple is
added to hot junction The total signal (sum of cold junction sensor + hot junction sensor)
connected to an amplifier and further connected to a variable gain amplifier.. This amplified
signal is connected to a digital voltmeter, which is calibrated to display temperatures from 0º -
100ºC.
OPERATING INSTRUCTION (CALIBRATOR)
AIM : To calibrate the thermocouple based indicator with the help of simulated input

EQUIPMENT REQUIRED :

1. Digital millivolt meter

2. Thermocouple sensor

3. Electric kettle
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4. Thermometer

PROCEDURE :

1. Plug in two pin power chord to mains supply of 230V, 50Hz, connect a multi meter at
Mv source (thermocouple simulated output) and set 0 mv.(zero degree)

2. Connect a patch chord between T/C simulated output(Mv source) and terminal "E"
without connecting thermocouple sensor.

3. The indicator will show 000.0 ˚cadjust zero if required, now connect a multi meter
across the simulated output and set 8.138 mV.(199.9) degree centigrade (for Ktype)

4. Adjust the span potentiometer up to 199.9 ˚c now the indicator is calibrated for 0 to 200
˚C.

5. now connect patch chord between Mv source and "C" plug in thermocouple sensor and
set room temperature ˚C by the help of Mv source (cold junction compensation).

6. Fill the electric kettle 3/4 with water, immerse thermocouple sensor and thermometer
Connect the two pin power chord of the kettle to mains supply of 230V, 50Hz

8. The water will start heating. This change in the temperature of the water will be sensed
by the thermocouple sensor and temperature will be indicated by the digital indicator.

9. Observe the readings on thermometer 30o c up to 100o c at the intervals of 5oc note down
the changes in temperature with indicated temperature in a tabular form

10 plot the graph of temperature versus indicated temperature.

TEMPERATURE INDICATED VALUE

300 C

400C

500C

600C

700C

800C

900C

follow above step for J type sensor /different range calibration, referring below calibration chart.
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