Experiment setup for thermocouple calibration

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1 Experiment setup for thermocouple calibration Objectives The objectives of this experiment are to introduce the concept of a measurement system, and to study one measuring device used to measure temperature: the thermocouple. We will (1) calibrate two thermocouples, and (2) examine some of their properties and behavior. In Part A, you will calibrate two thermocouples by comparing induced voltages measured with a data acquisition (DAQ) system and temperatures measured with a thermometer. In Part B, you will examine the effect of inserting an intermediate metal into a thermocouple. Finally, Part C you will more closely examine the relationship between their voltages and temperatures. 2.1 Introduction: How Measuring Devices Work In the lecture notes, we paraphrased a Russian writer by saying the measurement is not the thing. For example, if you are measure the length of a wire with a ruler, the length of the wire is the thing, and the ruler gives you the measurement. The measured value is merely a representation, or numerical characterization, of the length of the wire, flaws and all. We say flaws and all, because perhaps the ruler isn t perfectly accurate. Perhaps the wire wasn t perfectly straight. Perhaps the wire was unusually warm, and we know that the wire changes length with temperature. The bottom line is that there is a difference between the physical quantity we are trying to measure and the measurement itself. It gets more complicated from there. In the wire example, the measurement device outputs the same physical dimension as the object; in other words, length is what we wanted to measure, and length is what the ruler reads. We were comparing length to length. Measurement devices aren t always so direct. Take a graduated cylinder, for example: while the marks on the side read units of volume (e.g., milliliters), the marks are technically a linear scale they reflect the height of the liquid. Someone designed the cylinder so that those marks were converted to volume, the dimension we are interested in. It turns out that many measuring devices use sensors that respond indirectly in some physical way to the physical quantity being measured. Take a glass-bulb thermometer, for example. Glass-bulb 2-1

2 thermometers contain a liquid that expands as the temperature rises. The expanding liquid rises up a capillary tube, and the height of the liquid is an indication of the temperature in the system. The dimension of temperature is being converted, in a sense, to the dimension of height. Now that we ve established that measurement devices are complicated, let s describe the basic parts of a generic device. As depicted in Figure 2.1, the system begins with the physical quantity we want to measure. In the case of the thermometer, the physical quantity might be, say, your body temperature. The sensing element is the liquid. In this example, the liquid changes volume with temperature. The next step is some kind of conversion element that translates the physical response of the sensor to something easily detectable or readable form. In the thermometer, it s the capillary tube that converts the volume change to a length change along the glass tube. By the way, the combination of the sensing element and the conversion system is called the transducer, which is the common term for any measuring element that converts one physical quantity to another (and engineers often use the term transducer when referring to the entire measuring device). Temperature Physical Quantity Sensing Element Conversion Element Signal Conditioning Output Transducer Figure 2.1. A glass-bulb thermometer, depicting the common elements of a measuring system. After the transducer stage, there is often some kind of signal conditioning that makes the output more readable. In the case of thermometer, the capillary tube has a small diameter, so that even small changes in volume will show relatively large changes in the length of the liquid; the signal, in effect, has been amplified. Finally, the output is the final product, which in this case is the marks and labels on the glass. Of course, the lines and labels on the glass aren t arbitrary the device must be calibrated so that the placement and spacing of the lines and labels correspond to what we expect the temperature of the system to be. Calibration involves exposing both the device and some other device we trust (a standard) to the same physical quantity and correlating the two outputs; in this case, measuring the temperature some other way, and marking the length of the thermometer say, every 0.1 degrees Fahrenheit. With this introduction in hand, let s examine another way to measure temperature: the thermocouple. 2-2

3 2.2 The Thermocouple The thermocouple is probably the most popular type of temperature sensor (at least among engineers), primarily because it is inexpensive, easy to use, and can withstand harsh environments. Unlike a glass-bulb thermometer, a thermocouple is an electronic sensor whose output is usually read on a digital device (a thermocouple reader). You may have seen thermocouples before: in the home, it is sometimes used to monitor the temperature of the oven, and one is even used as a safety device in gas water heaters; in the automobile, it is used to monitor coolant and oil temperature. Thermocouples are not the most accurate technique available to measure temperature standard thermocouples are accurate to around one or two degrees Celsius but for many applications this accuracy is acceptable. Thomas Johann Seebeck ( ) discovered that a circuit comprised of dissimilar metals produces a voltage (and current) when the two dissimilar junctions are exposed to different temperatures. This phenomenon, called the Seebeck Effect, is depicted in Figure 2.2. The voltage produced is proportional to the temperature difference between the junctions. The voltage produced is small, on the order of millivolts, so it is not very suitable for producing power 1. But the device can easily be calibrated to measure temperature. T 1 metal A metal B T 2 T 1 voltmeter leads voltmeter Figure 2.2. Dissimilar wires connected in a circuit. When the ends of wires A and B are at different temperatures, a voltage is read on the voltmeter. This is called the Seebeck Effect. Now, to calibrate a thermocouple, it is customary to build the circuit shown below in Figure 2.3. In this thermocouple pair, we vary T 1, and the second junction is held at some constant reference temperature, typically in an ice bath (at 0 C). It turns out that in this circuit, the temperature of the voltmeter leads does not affect the voltage. This is called an ice bath-referenced thermocouple. In Part A of this experiment, we will use this technique to calibrate two thermocouples. Later in this course, we will develop a simpler method that eliminates the ice bath, and will result in a wiring scheme that looks more like that of Figure If you put enough thermocouples together, and expose them to a high enough temperature difference, you can generate enough power to, say, power a space probe. This is called thermoelectric power (or a thermopile), and is used in deep space probes where solar power is not sufficient. 2-3

4 metal A T 1 metal B T voltmeter metal B T 2 = T ref voltmeter leads voltmeter Figure 2.3. Thermocouple pair connected to a voltmeter for calibration. When the reference temperature T ref equals 0 C, this is called an ice bath-referenced thermocouple. There are many different pairs of dissimilar metals that can be paired up to create a thermocouple. It s a matter of finding pairs of metals that are sensitive enough that is, produce a voltage that changes significantly with temperature. 2.3 Experiment Part A. Thermocouple Calibration Equipment: Procedure Thermocouple Kit, including: Liquid-in-glass (A.K.A. glass-bulb) thermometer 24-gage thermocouple pairs: a. Red and orange wire pair (with orange banana plugs) b. Red and purple wire pair (with purple banana plugs) Thermos for ice bath hot hands mitts PolyDAQ data acquisition (DAQ) system electric hot plate 600 ml beaker chemistry stand hand-operated ice crusher 1. Make an ice bath by crushing ice cubes and filling the Thermos with crushed ice and just enough water to barely cover the ice. 2. Fill the 600 ml beaker to full (500ml) and place it on the hot plate. DO NOT PLUG IN OR TURN ON THE HOT PLATE YET. 3. Check the liquid-in-glass thermometer to see if there are any separations (bubbles) in the liquid column. If it does, ask the instructor for a replacement. 4. You are given two thermocouple pairs, each made from 24-gage wire: one has red and orange wires, and the other has red and purple wires. These are the thermocouples with the attached banana plugs. Connect these thermocouples to the voltage terminals on PolyDAQ labeled M1 and M2, as shown in Figure 2.4(a) on the next page. 2-4

5 Note: if the thermocouple leads were to not have banana plugs, bare wires can be inserted into the holes on the side of the banana terminals and locked down by tightening the banana lug as shown in Fig. 2.4(b). DO NOT OVERTIGHTEN. 5. Arrange each thermocouple pair as shown in Figure 2.5. The junction closest to the NEGATIVE lead in the circuit is inserted in the ice bath, and the other junction into the beaker on the hot plate. NOTE: the thermocouple wires that you connect to the millivoltage ports are the same; it is the locations of the two junctions (one in the ice bath, one in heated water) that are different. Refer back to Figure Connect thermocouples to these ports via banana plugs (a) (b) Figure 2.4. (a) Thermocouples connected to millivoltage ports (M1 and M2) on PolyDAQ. (b) Connection of bare wires to banana terminals when banana plugs are not present. Glass bulb thermometer red thermocouple wire Chemistry stand with thermometer clamp Calibration Line purple wire + purple wire - PolyDAQ (millivoltage inputs) hot plate ice bath Figure 2.5. Calibration setup, showing wiring diagram of one of the thermocouple pairs (the one with the red and purple wires). 2-5

6 7. Make sure the junctions inserted in the ice bath remain submerged, and that the bare wires do not touch one another or the side of the Thermos (to ensure that the wires do not short out). TIP: if you twist the two together, it will be easier to ensure that the junctions will stay put. 8. Wrap the two junctions located in the beaker around the bulb of the thermometer as shown in Figure 2.6(a). Keeping the junctions near the bulb of the thermometer helps ensure that all three measuring devices are experiencing close to the same temperature. Make sure the bare wires of the thermocouples do not touch each other: otherwise, they may short out. 9. Place the thermometer in the beaker of water using the chemistry stand and the thermometer clip. Insert the thermometer into the water so that the bulb is about a half an inch or so from the bottom of the beaker, and make sure that the water surface reaches the solid line on the thermometer, about an inch or two above the bulb; this line is called the calibration line, and will ensure the accuracy of your temperature readings. Secure the thermometer to the chemistry stand using the thermometer clip. If the clip is loose, hang the thermometer on the clip using the red, triangular anti-roll ring that comes with the thermometer. This setup is depicted in Figure 2.6(b). (a) (b) Figure 2.6. (a) Thermocouple junctions wrapped around thermometer bulb. (b) Rubber anti-roll ring used to hang thermometer on clamp. 10. Turn the PolyDAQ system on, log in, and open the PolyDAQ operating software. Instructions for how to do so are provided in the PolyDAQ Quick Start Guide on the computer cart (an electronic copy of the Quick Start Guide is also on the computer s desktop). Configure the channels and time parameters as follows: Select M1 and M2 as the channels to record. Rename the channels so that you know which voltage corresponds to which thermocouple. These names will be recorded to the data file. DO NOT FORGET THIS STEP. Select a sampling rate of 0.2 s between measurements. Do NOT select Auto-Stop. 2-6

7 11. Click START. You are now recording the voltages on channels M1 and M2. The data are being saved to the file automatically you will not have to save the data to the file. Adjust the plot window using mouse controls so you can view the data. You may also remove the unused plots by clicking and dragging the edge of the plot windows. See the Quick Start Guide, or Help>Plot Navigation Guide for details. 12. Check the initial voltages: at this point, the voltages should be approximately 1 mv (they won t be the same voltage, as they are different thermocouple types). If the voltages are significantly lower, say, less than 0.2 mv, you may have wired the thermocouple pairs backwards. The millivoltage channels will not read negative values; instead, they will bottom out near zero. Ask your instructor for assistance before you change the wiring. 13. Do not turn the hot plate on yet. Call your instructor over to inspect your setup before continuing. 14. Begin the calibration, but do not turn the hot plate on yet. Your first data point is the temperature of the unheated tap water. Record that temperature that you read on the thermometer the thermometer is the standard to which you are comparing the voltages and note the moment in the data file that corresponds to that temperature. Later, you will retrieve from the data file the voltages that correspond to that temperature. Identifying the time in the data file that the temperature reached a certain value can be done one of two ways: a. Write down the Elapsed Time that is indicated in the status box on the interface. Elapsed time is recorded in the data file, so you can locate the time the temperature reached that value. b. Earmark the data file: Go to Tools/Earmark Data File You can type a note like The temperature just reached 60 deg. C ahead of time, and add the note to the file at the moment it occurs. The note will appear on the rightmost column of the data file at the time you added the note. 15. Plug in the hot plate and adjust the setting to full power. At increments of 5 C, record the temperature and note the elapsed time when the temperature reached that value. Note that the voltage readings will fluctuate. Therefore, when you analyze the data, estimate the nominal value as the local average (the average of the temperatures spanning about one second before to one second after your recorded time). 16. Continue taking data for about a minute after the water begins boiling. Record the temperature of the water at full boil, and note the elapsed time and/or earmark the file. 17. Obtain one more calibration point: Remove the junctions and thermometer from the hot water bath, LET THEM COOL TO ROOM TEMPERATURE, and then place them in the ice bath, to obtain the voltage corresponding to the ice bath temperature. WARNING: to avoid thermally shocking the thermometer, DO NOT put the thermometer directly in the ice bath from the boiling water! 18. Halt execution of the PolyDAQ software by pressing the STOP button on the software. The data was already saved to the file as it was being collected. 2-7

8 CALL YOUR INSTRUCTOR OVER TO DISCUSS YOUR DATA BEFORE CONTINUING. 19. Take a copy of the data file: either copy it to a USB drive or it to you and your team. The.csv file can be imported by Excel for analysis. See the PolyDAQ Quick Guide for more details. 20. Do not dismantle the experiment setup yet. You will need many of these parts (including the ice bath and the boiling water) for parts B and C. [[[ NOTE: For the next two parts, a data sheet is not required -- an assignment sheet will be provided separately for you to fill out. ]]] Part B. Effect of Intermediate Metal Equipment Procedure Digital thermometer (Keithley Digital Multimeter, set to read temperature) Ice bath Type K (chromel-alumel) thermocouple with quick connector on one end, and a greeninsulated wire spliced in the middle (it is not the same metal as the metals in the thermocouple) In this part of the experiment, you will use a thermocouple together with a digital thermocouple reader to measure temperature. However, the thermocouple itself has been modified by splicing a different metal wire into one of the legs of the circuit. The effect of this modification will reveal several key behaviors of thermocouples. 1. Plug the thermocouple into the thermocouple socket on the digital multimeter. Set the upper knob to F and the lower knob to the TEMP position. 2. Record the temperature readings for the following conditions: a. All junctions exposed to room-temperature air. b. End junction exposed to the ice bath. When finished, dry off the junction and let it come back to room temperature. c. Place one of the splice junctions into the ice bath as shown in Figure 2.7, and record the temperature again. Remove the junction, dry it off, and let it return to room temperature. d. Repeat step c for the other junction. e. Repeat step c, this time submerging the center of the spliced wire into the ice bath, taking care not to submerge either junction. f. Repeat step c once more, this time submerging both junctions into the ice bath. 2-8

9 end junction splice digital thermometer ice bath Figure 2.7. Experiment setup for Part B. Part C. Effect of Junction Temperatures on Voltage Output Equipment: Digital voltmeter (set to mv) and test leads Two beakers (one filled with boiling water, one with room-temperature water) Ice bath Hot plate Glass thermometer Red and purple wire thermocouple pair (one of the thermocouple pairs you used in Part A) Procedure In this experiment, you will examine more closely the effect of junction temperatures on the thermocouple voltage using water at three known temperatures: tap, boiling, and ice water temperature. 1. Connect the red/purple thermocouple you used in Part A to the digital voltmeter (DVM) and set the voltmeter to read the lowest range of voltage. To do this, set the upper knob on the meter to 200 mv and the lower knob to DCV. The resolution of the device will be 0.1 mv. 2. Fill two beakers with tap water. Heat one of the beakers of water to boiling. Use the ice bath from Part A for the third bath of water. 3. Record the voltage for each combination of junction temperatures using the three baths: (a) Boiling water and ice water, (b) ice water and tap water, and (c) boiling water and tap water. The experimental setup is shown on the next page in Figure 2.8. You will use the same thermocouple for all three measurements. Be careful to keep the polarity of the thermocouple constant, as indicated in the figure. (For example, when measuring V 1, the junction leading from the negative port on the DAQ system is placed in the boiling water. The other junction is placed in the ice bath. For V 2, the junction leading from the negative port on the DAQ system is placed in the ice bath.) At the same time, record the temperatures of the three baths using the glass thermometer. 4. Finally, place both junctions into the tap water, and record the indicated voltage. Repeat for the ice water and the boiling water. 2-9

10 a. Boiling water - + V 1 Ice bath b. Ice bath Tap water - + V 2 c. Boiling water - + V 3 Tap water Figure 2.8. Thermocouple configurations for Part C. 2-10

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