Operating Instructions

42/10-20-EN

Thermocouples and
Resistance Thermometers











Blinder Text
2 42/10-20-EN



Thermocouples and Resistance Thermometers


Operating Instructions
42/10-20-EN

06.2006
Rev. 03


Manufacturer:
ABB Automation Products GmbH
Borsigstrae 2
63755 Alzenau
Germany
Tel.: +49 551 905-534
Fax: +49 551 905-555
[email protected]



Copyright 2006 by ABB Automation Products GmbH
Subject to change without notice
This document is protected by copyright. It assists the user with the safe and efficient operation of the
device. The contents may not be copied or reproduced in whole or in excerpts without prior approval of
the copyright holder.

Contents

Contents
42/10-20-EN 3

1 Safety....................................................................................................................................................................4
1.1 General Safety Information ............................................................................................................................4
1.2 Use in accordance with regulations ...............................................................................................................4
1.3 Technical limits...............................................................................................................................................5
1.4 Warranty provision .........................................................................................................................................5
1.5 Labels and symbols........................................................................................................................................5
1.5.1 Symbols and warnings............................................................................................................................5
1.6 Operator liability .............................................................................................................................................6
1.7 Personnel qualification ...................................................................................................................................6
1.8 Transport safety information ..........................................................................................................................6
1.9 Electrical installation safety information .........................................................................................................6
2 Design and function............................................................................................................................................7
2.1 General...........................................................................................................................................................7
2.2 Thermocouples...............................................................................................................................................7
2.3 Resistance Thermometers .............................................................................................................................7
2.4 Thermometer with head-mounted transmitter ................................................................................................7
3 Use in areas requiring ignition protection........................................................................................................8
4 Installation............................................................................................................................................................9
4.1 Installation ......................................................................................................................................................9
4.2 Connecting wires............................................................................................................................................9
4.3 Thermowells...................................................................................................................................................9
5 Maintenance / Repair.........................................................................................................................................10
6 Error messages .................................................................................................................................................11
6.1 Quick test .....................................................................................................................................................11
6.2 Error table.....................................................................................................................................................12
6.3 Specific errors with thermocouples: .............................................................................................................14
6.4 Specific errors with resistance thermometers: .............................................................................................14
7 Electrical connection ........................................................................................................................................15
7.1 Resistance thermometers ............................................................................................................................15
7.2 Thermoelements ..........................................................................................................................................15


Safety
4 42/10-20-EN

1 Safety


Our information regarding our products, equipment, plants and processes is based on extensive
research and experience in the field of applied engineering. We are making such information
available, to the best of our knowledge and in written form, without assuming any liabilty over
and above the terms of this contract but reserving the right to make technical changes of our
products at any time without prior notification.
In addition, our applications engineers are available on request to provide further consultation
and cooperation in solving production and application-related problems.
This however does not relieve the user from the obligation to verify the suitability of our
information and recommendations before putting our products to use.
This applies particularly to deliveries destined for customers in foreign countries, especially in
their obligation to ensure that no patent rights of third parties are infringed upon, including
applications and processing methods which we have not expressly spelled out in writing.
In case of damage or quality deficiencies, our liabilities and indemnities are limited to the same
volumes as stipulated in our General Terms of Supply and Delivery.

1.1 General Safety Information

The Safety chapter provides an overview of the safety aspects to be observed for the
operation of the device.
The device is built based on state-of-the-art technology and is operationally safe. It was tested
and left the factory in a proper state. The requirements in the manual as well as the
documentation and certificates must be observed and followed in order to maintain this state for
the period of operation.
The general safety requirements must be complied with completely during operation of the
device. In addition to the general information, the individual chapters of the manual contain
descriptions about processes or procedural instructions with specific safety information.
Only the observance of all safety information enables the optimal protection of personnel as well
as the environment from hazards and the safe and trouble-free operation of the device.

1.2 Use in accordance with regulations

The temperature sensors are for temperature measurement in the most diverse process
applications. The resistance thermometer or thermocouples can be used with and without
thermowell.

Safety
42/10-20-EN 5

1.3 Technical limits

The device is designed for use exclusively within the stated values on the name plate and in the
technical specifications (see "Technical Specifications chapter and/or data sheet). These must
be complied with accordingly, e.g.:
The maximum operating temperature may not be exceeded.
The permitted operating temperature may not be exceeded.
The housing protection system must be observed.

1.4 Warranty provision

A use contrary to the devices stipulated use, disregarding of this manual, the use of under-
qualified personnel as well as unauthorized alterations excludes the manufacturer of liability
from any resulting damages. The manufacturers warranty expires.

1.5 Labels and symbols

1.5.1 Symbols and warnings




Danger <Serious damage to health / risk to life>
One of these symbols in conjuction with the Danger warning indicates an imminent danger. If
it is not avoided, death or serious injury will result.


Warning <Bodily injury>
The symbol in conjunction with the Warning message indicates a possibly dangerous
situation. If it is not avoided, death or serious injury could result.


Caution <Slight injuries>
The symbol in conjuction with the Caution message indicates a possibly dangerous situation.
If it is not avoided, slight or minor injury can result. May also be used for property damage
warnings.


Attention <Property damage>!
The symbol indicates a possibly damaging situation. If it is not avoided, the product or
something in its area can be damaged.



Important!
The symbol indicates operator tips or especially useful information. This is not a message for a
dangerous or damaging situation.

Safety
6 42/10-20-EN

1.6 Operator liability

Before the use of corrosive and abrasive materials to be measured, the operator must clarify
the resistance of all parts that come into contact with the materials to be measured. ABB will
gladly support you with the selection, however, cannot accept any liability.
The operators must strictly observe the applicable national regulations in their countries with
regards to installation, function tests, repairs, and maintenance of electrical devices.

1.7 Personnel qualification

The installation, commissioning and maintenance of the device may only be carried out through
trained specialist personell authorized by the plant operator. The specialist personnel must have
read and understood the manual and comply with its instructions.

1.8 Transport safety information

Observe the following information:
Do not expose the device to moisture during transport. Pack the device accordingly.
Pack the device so that it is protected from vibration during transport, e.g. through air-
cushioned packaging.

Check the devices for possible damage that may have occurred from improper transport.
Damages in transit must be recorded on the transport documents. All claims for damages must
be claimed without delay against the shipper and before the installation.

1.9 Electrical installation safety information

The electrical connection may only be performed by authorized specialist personnel according
to the electrical plans.
Observe the electrical connection information in the manual, otherwise the electrical protection
can be affected.
The secure isolation of contact-dangerous electrical circuits is only guaranteed when the
connected devices fulfil the requirements of the DIN VDE 0106 T.101 (basic requirements for
secure isolation).
For secure isolation, run the supply lines separated from contact-dangerous electrical circuits or
additionally isolate them.

Design and function
42/10-20-EN 7

2 Design and function

2.1 General

We are capable of supplying complete thermometer assemblies ready for immediate use.
These thermocouples or resistance thermometers are sensitive devices which contain either
glass or ceramic parts. They must therefore be handled with due care.
On receiving the thermometer assembly, please make sure to unpack all supplied articles,
including those that may be delivered in dismantled form.
Long thermometers must be supported at various points, and lifted up or transported in
appropriate manner. The same care must be taken during the actual installation of the device.
Prior to installation, please check the thermometers (see 5.1) to ensure that the device has
suffered no transportation damages.

2.2 Thermocouples

Thermocouple assemblies are delivered with 1, 2, or sometimes 3 thermocouple elements. The
measuring point is usually insulated but can still be connected to the protecting tube.
The connection of the thermocouple to the measuring instrument is established with a
compensation lead (CL). Only the right type of compensation leads suiting the thermocouple
and possessing the right polarity should be used for the connection. The leads should be at
least 0.5 m away from the power cables, preferably laid in their own cable trays. Twisted and
shielded cables suppress magnetic and electrical parasitical interferences.

2.3 Resistance Thermometers

Resistance thermometers are supplied with 1, 2, or sometimes with 3 measuring resistors.
The measuring point is isolated. The connection between resistance thermometer and
measuring instrument is mostly of the 2wire type (the sum and compensation of line resistance
become part of the measurement). To obtain accurate measurements, the 3-wire technique is
used. If highly accurate measurements are desired, the 4-wire technique with constant current
and high resistance voltage pick-up are used.
Conventional copper cables usually found on the market, preferably with 1.5 mm
2
cross-section
should be laid, possibly at about 0.5 m away from the power cables, at best on their own cable
trays. Twisted and shielded cables suppress magnetic and electrical parasitical interferences.
Depending on the type, care must be taken not to exceed the measuring currents of 0.1 ... 10
mA, recommended by the manufacturer (errors may result from inherent heating).

2.4 Thermometer with head-mounted transmitter

The afore mentioned problems which could eventually be caused by transfer resistances in the
cable and EMC can be prevented by installing a 2-wire transmitter (output signal 4 ... 20 mA) in
the sensor head. Required is only a 2-core copper cable. Multiple wire circuits for resistance
thermometers and compensation cables for thermocouples are not necessary.
When using the transmitter, please take notice of the following:
the contents of these instructions or the operating manual provided with the transmitter
the relevant rules involving the installation and operation of electrical systems, in some
cases the regulations and directives for explosion protection.

Use in areas requiring ignition protection
8 42/10-20-EN

3 Use in areas requiring ignition protection

1. In accordance with of ElexV, maintenance work (repairs) may be conducted only under
the following conditions stated below:
1.1 If a part of an electrical device which is important for explosion protection is repaired, this
may be put into operation only after a technical expert has determined that the main
explosion protection characteristics still correspond to the required standard and after
issuing a certificate or awarding a test mark.
1.2 Item 1.1 shall not be valid if the component has been individually tested by the
manufacturer and it is conrmed that the main characteristics for application in hazardous
areas comply with the stipulated technical requirements.
2. The ElexV is only valid within the Federal Republic of Germany. In foreign countries, the
relevant binding regulation corresponding to ElexV must be adhered to.
3. Repair work may only be carried out using original components of the original
manufacturer, otherwise the standards stipulated in the certificate of conformity shall not
be fulfilled.
4. When ordering spare parts, exact information on previous delivery such as type of
protection (Exd, Exi), No. of the certificate of conformity, serial and item No.s must be
supplied.
5. Ex-protected thermometers only fulfil the required safety requirements as a unit
component, as determined by the certificate of conformity. Measuring insets or
connecting heads alone do not satisfy the explosion-protection requirements.
6. If ABB supplies thermometers destined for operation in hazardous areas without
protecting tubes, it will be the responsibility of the owner to see to it that
these thermometers are deployed only in zones which are permissible in accordance
with the certificate of conformity or with the manufacturers declaration (e.g. zones
1or2),
a protecting tube is provided for an eventually necessary separation of a zone (e.g.
zone 0 from zone 1). Such a tube must correspond fully to the special conditions
spelled out in the respective certificate of conformity.
ABB shall inform the plant owner of the above subject matter in appropriate form, e.g.
by drawing attention to this leaet of instructions.

Installation
42/10-20-EN 9

4 Installation

4.1 Installation

The thermometer (thermocouple, resistance thermometer) must be brought into contact with the
medium to be measured in the best possible manner.
To avoid thermal conduction errors, the immersion depth should be:
in uids 6 ... 8 times greater than the protective tube diameter.
in gases 10 ... 15 times greater than the protective tube diameter.
If only very short insertion lengths are possible, special designs should be applied. It is of-ten
helpful to install in a pipe bend, whereby the protective tube must be positioned against the ow
of the medium.

4.2 Connecting wires

For all connecting wires it is important to ensure that proper contact has been established and
that corrosion, humidity, pollution, electrical parasitic interferences of power cables etc. are
avoided.
The cables should be insulated to counter the ambient inuences (dry, humid, chemically
aggressive, hot), whereby the ambient temperature of both the cable and the connection head
may not exceed 100 C.
Please pay attention to the valid standards and regulations when selecting the types of cables
to be used.
If possible, all measuring systems should be operated in ungrounded condition, or only
grounded at one point.
When using thermocouples connected to protective tubes, these should be the only
ground/mass connection

4.3 Thermowells

Thermometers can be installed in any mounting position, preferably hanging vertically, up to
temperatures reaching about 500 C.
Ceramic thermowells must be protected from mechanical stress (bumps, bends), including
temperature shocks e.g. through direct ame contact.
If they are applied to hot processes (e.g. when changing the thermocouple), they must be either
prewarmed or inserted very slowly (1 ... 2 cm/min at 1600 C, 10 ... 20 cm/min at 1200 C). This
also applies when removing the hot protecting tube.
Care must be taken to avoid suspending lengths > 500 mm for temperatures > 1200 C.

Maintenance / Repair
10 42/10-20-EN

5 Maintenance / Repair


The thermometer and the entire temperature measuring circuit must be checked at regular
intervals for
wear and tear of protecting tube or chemical activity,
drifts of the measuring element caused by ageing,
reduction of insulation resistance through humidity and pollution
improper contact of the wire connections and
mechanical and chemical damage of the thermometer and wires.
Resistance thermocouple circuits can be checked by replacing the measuring element with a
known defined resistance, thereby simulating a specific temperature.
Thermoelement measuring circuits can be checked by connecting a mV voltage of a known
variable to the measuring circuit, instead of the thermocouple.
In both cases, substantial deviations from the set point can be determined, also if the
thermometer or the instrumentation is the cause off function errors.
The insulation resistance of the entire ungrounded measuring circuit (wires and thermometer)
against ground should be > 1 M (measured with 100 V DC).

Error messages
42/10-20-EN 11

6 Error messages

6.1 Quick test

Perform quick tests of thermocouples and resistance thermometers as well as the associated
measuring circuits in the uninstalled state.
Instruments required:
Millivolt meter
Resistance meter or resistance bridge
Isolation meter with 60 100 V voltage (all measurements at room temperature)
The following tests can be performed:
Check opening and isolation at room temperature.
Locate wire breaks by knocking.
A thermocouple is regarded as functioning correctly when R < 20 (wire > 0.5 mm ). The
value depends on the wire cross section and the length. R
isol
= 100 M (with isolated
thermocouple).
A resistance thermometer is regarded as functioning correctly when R >> 110 (for Pt100),
R
isol
> 100 M.
The heating of the thermocouples or resistance thermometers to approx. 200 C to 400 C
(without temperature controls) allows for further conclusions to be drawn about interruptions,
reversed polarity (with thermocouples), too little isolation resistance, etc.


Note
The accuracy of temperature sensors according to the ISO 9000 requirements can only be
checked by comparison with a reference element. In most cases, the deinstallation and test in
a test oven are necessary.

Error messages
12 42/10-20-EN
6.2 Error table

The complete temperature measurement circuit should be routinely tested. The following tables
contain the most important errors with the possible causes and suggestions for their remedy.

Error Error cause Error remedy
Electrical/magnetic
interspersion
Keep at least 0.5 m distance between the
measurement wires with parallel running.
Electrostatic shielding via on a point grounded
foil/netting.
Twisting of the wires (pairs) against magnetic
interspersion.
Right angle intersecting of measurment wires
with interfering leading wires.
Use of transmitters.
Ground loops Only one grounding point in measurement
circuit or measurement system floating (not
grounded).
Measurement
signal fault
Removal of the
isolation resistance

Moisture has possibly penetrated into the
thermometer or the measuring inset; dry if
necessary and seal again.
Replace measuring inset.
Check whether the thermometer is thermally
overloaded.

Error messages
42/10-20-EN 13

Error Error cause Error remedy
Incorrect installation
location:
In the flow shadow
In the influence of
a heat source
Select installation location so that the
medium can transfer its temperature
undisturbed.
Incorrect installation-
method:
Insufficient
installation depth
Too much heat
dissipation
Installation depth approx. temperature
sensitive length + 6 x d (fluids) to 10 x
(gases) d (d = outer thermowell diameter).
Ensure thermal contacts, above all with
surface measurements, through appropriate
contact surfaces and/or thermal conducting
material.
Thermowell too thick
Thermowell hole too
large

Select the smallest thermowell possible for
the process.
Response time as a first approximation
proportional to the cross section or volume
of the thermometer, depending on the
thermal transition values and air gaps in the
installation.
The latter with contact agent.
Response times
too long, faulty
signals
Deposits on the
thermowell

Remove during inspections.
If possible, select a different thermowell or
another installation location.
Interruptions in
the thermometer

Vibration

Enforced springs on the measuring inset.
Shortening of the installation length.
Relocation of the measuring location (if
possible).
Special construction of measuring inset and
thermowell.
Heavily corroded
thermowell

Composition of the
medium not as
assumed or has
changed
Improper thermowell
material selected
Check medium
Possibly analyze the defective thermowell
and then select a more suitable material.
Use an additional surface protectant.
Under certain circumstances, the thermowell
may have to be replaced regularly as a wear
part.

Error messages
14 42/10-20-EN
6.3 Specific errors with thermocouples:

Error description Error cause Error remedy
Fluctuating temperature
indication with otherwise
trouble-free measurement
circuit assembly of the
thermocouple

Reference junctions -
temperature or voltage
not constant

Temperature or supply voltage
must remain constant.
< 0.1 % (check instruments).
With non-stainless steel
thermocouples, taken with the
entire value into the
measurement, with stainless
steel thermocouples with only
approx. half of the value.
Strong deviations of the
temperature indicator from
table values for
thermocouples

Incorrect material
combinations:
Poor electrical contacts
Parasitic voltages
(thermovoltages,
galvanic voltages)
Incorrect compensating
line
Check thermocouples and lines
for:
Correct pairing.
Correct compensating line.
Correct polarity.
Approved ambient temperature
at connection head.

6.4 Specific errors with resistance thermometers:

Error description Error cause Error remedy
Too high or fluctuating
temperature indicator
despite known cross
section and measurement
resistance of the
resistance thermometer
Line resistances too high,
not compensated
Temperature-related
resistance change of the
supply line
If still possible:
Running of 2 lines or larger
cross section possibly only
after a more accessible
location.
Shorten the supply line.
Line compensation.
Switching to 3- or 4-wire
circuits.
Use of head-mounted
transmitters.
Fluctuating temperature
indication with otherwise
trouble-free measurement
circuit assembly of the
resistance thermometer
Voltage or power supply
not constant
Must be held constant to < 0.1
%. With out-of-tune bridges and
power/voltage measurements
(4-wire circuit), measured with
the entire value.

Electrical connection
42/10-20-EN 15

7 Electrical connection
Resistance
7.1 Resistance thermometers

In accordance with EN 60751 (IEC 60751)
Single
2-wire circuit 3-wire circuit 4-wire circuit
Fig. 1
R red

In accordance with EN 60751 (IEC 60751)
Dual
2-wire circuit 3-wire circuit 4-wire circuit
Fig. 2
Y yellow
B black
R red
W white



7.2 Thermoelements

In accordance with EN 60584
Single Dual

Fig. 3







ABB provides expert and comprehensive consulting services
in more than 100 countries worldwide.

www.abb.com/temperature

ABB is continually improving its products. As a
result, technical information in this document is
subject to change.
Printed in the Fed. Rep. of Germany (06.2006)
ABB 2006





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ABB Limited
Salterbeck Trading Estate
Workington, Cumbria
CA14 5DS
UK
Tel: +44 (0)1946 830 611
Fax: +44 (0)1946 832 661

ABB Inc.
125 E. County Line Road
Warminster, PA 18974
USA
Tel: +1 215 674 6000
Fax: +1 215 674 7183

ABB Automation Products GmbH
Borsigstr. 2
63755 Alzenau
Germany
Tel: +49 551 905-534
Fax: +49 551 905-555
[email protected]