Hukseflux

Thermal Sensors

USER MANUAL
RHF SERIES
Ring heat flux sensors

Copyright by Hukseflux | manual v1623 | www.hukseflux.com | [email protected]

Warning statements

Follow the installation instructions of this user

manual.

The sensor and sensor-to-cable transition should not

be exposed to significant force.

Putting more than 12 Volt across the sensor wiring

can lead to permanent damage to the sensor.

Do not use “open circuit detection” when measuring

the sensor output.

RHF is usually cooled using air or water. The user

must keep the RHF temperature within its rated
operating range.

RHF series manual v1623 2/21

Contents
Warning statements 2
Contents 3
List of symbols 4
Introduction 5
1 Ordering and checking at delivery 8
1.1 Ordering RHF 8
1.2 Included items 8
1.3 Quick instrument check 8
2 Instrument principle and theory 9
3 Specifications of RHF-series 11
3.2 Dimensions of RHF 13
4 Standards and recommended practices for use 14
5 Installation of RHF 15
5.1 installation 15
5.2 Electrical connection 15
5.3 Requirements for data acquisition / amplification 16
6 Maintenance and trouble shooting 17
6.1 Trouble shooting 17
7 Appendices 19
7.1 Appendix on cable extension / replacement 19
7.2 EU declaration of conformity 20

RHF series manual v1623 3/21

List of symbols
Quantities Symbol Unit

Heat flux Φ W/m²

Voltage output U V
Sensitivity S V/(W/m2)
Temperature T °C
Resistance R Ω
Temperature dependence TD %/K
Thermal conductivity λ W/(m·K)

Subscripts

property of thermopile sensor sensor

calibration reference condition reference

RHF series manual v1623 4/21

Introduction
The RHF series consists of customer-specific heat flux sensors incorporated in a stainless
steel ring. They are used as building blocks in larger measuring systems, for example to
study fouling and slagging in combustion processes. Many RHF’s are eventually part of
so-called “deposition probes” or “fouling sensors” designed by the customer. It is
particularly suitable for trend monitoring that is necessary for this application. A typical
sensor contains 4 separate heat flux and 4 temperature sensors, so that fouling
behaviour can be studied at different locations on the sensor at different angles relative
to the local gas flow.

Sensors of the RHF series are used in scientific as well as operational experiments to
study fouling and slagging behaviour. RHF design is user-specific; geometry and cabling
are designed in cooperation with the user for the specific application.

RHF may be employed as a building block, when designing a deposition probe or a

fouling sensor. Many RHF sensors are part of multi-purpose probes that also measure
local gas temperature and take gas samples (so-called suction probes). RHF’s can be
manufactured in many different geometries and dimensions. RHF01 is a version
incorporating 4 heat flux / temperature sensors. Usually the RHF is cooled by
compressed air or water.

RHF measures heat flux, in W/m2, as well as its body temperature in °C. The sensors in
RHF are a thermopile and a type K thermocouple. The thermopile measures the
temperature difference across the body of RHF, creating an output that is representative
of the local heat flux. The thermocouple measures the approximate sensor body
temperature. A thermopile and a thermocouple are passive sensors; they do not require
power.

The part of the cabling closest to the sensor is a special high-temperature metal
sheathed cable. The sensor as well as the high temperature cable and armour withstand
temperatures up to 800 °C. The low-temperature extension cable has wire insulation and
a jacket of PTFE type plastic.

Using RHF is easy. Its sensors can be connected directly to commonly used data logging
systems. The heat flux, Φ, in W/m2, is calculated by dividing the RHF sensor output, a
small voltage U, by the sensitivity S, possibly applying user–determined corrections
based on the temperature or flow rate measurement.

A typical measurement function of RHF, involving the temperature dependence TD, is:

Ф = U/(S∙(1 + TD∙(T - Treference))) (Formula 0.1)

The sensitivity at around 30 °C is provided with RHF on its product certificate for all
sensors in the RHF.

RHF series manual v1623 5/21

Figure 0.1 Example of a customer-specific RHF ring heat flux sensor with 2 x heat flux
and temperature sensor, also showing high temperature cables

RHF is most suitable for relative measurements using one sensor, i.e. monitoring of
trends relative to a certain reference point in time or comparing heat flux at one location
to the heat flux at another location. The heat flux sensor calibration depends on the way
the sensors are built-in and may also depend on the flow rate of the gas or liquid used
for cooling. RHF01 is provided with a factory calibration of every sensor which is suitable
for relative measurements. If you want to perform accurate absolute measurements with
RHF, as opposed to relative measurements, it is necessary to calibrate the RHF
incorporated in the final design under operating conditions, possibly as a function of
water or air flow. Hukseflux can provide dedicated heaters to perform such calibration.

Hukseflux can provide dedicated heaters to perform such calibration.

Suggested use of RHF:

• building block for customer-specific sensors
• deposition sensors
• fouling sensors
• heat flux sensors

See also:
• SBG01 for high accuracy radiative flux measurements
• HF03 for study of flares / mobile measurements
• HF02 for flare measurement
• view our complete product range of heat flux sensors

RHF series manual v1623 6/21

Figure 0.2 Example of a customer-specific RHF01 ring heat flux sensor with 4 x heat flux
and temperature sensor

Figure 0.3 Example of a customer-specific RHF ring heat flux sensor; the entire sensor,
high temperature cable and low temperature extension cable

RHF series manual v1623 7/21

1 Ordering and checking at delivery
1.1 Ordering RHF

RHF design is user-specific; geometry and cabling are designed in cooperation with the
user for the specific application. Common options are:

• longer cable (specify total cable length for both cable types in m)
• connector at RHF cable end
• low temperature extension cable with 2 connectors, matching cable connector and
chassis connector
• chassis connector with internal wiring
(colour code of wiring identical to cable colour code)

1.2 Included items

Arriving at the customer, the delivery should include:

• heat flux sensor RHF according to customer-specific drawing

• cable of the lengths as ordered
• product certificate matching the instrument serial number

1.3 Quick instrument check

A quick test of the instrument can be done by connecting it to a multimeter.

1 Check the electrical resistance of the heat flux sensor between the black [-] and red
[+] wires and the thermocouple between the green [+] and white [-] wires. Use a
multimeter at the 100 Ω range. Measure the sensor resistance first with one polarity,
then reverse the polarity. Take the average value. Typical resistance should be the
nominal sensor resistance of 1 to 2 Ω for the thermopile sensor, plus for additional low
temperature extension cable 0.2 Ω/m (resistance per meter cable) for the total
resistance of two wires (back and forth added), for high temperature cable 13 Ω/m. For
the thermocouple work with 1 to 2 Ω , plus additional low temperature extension cable 3
Ω/m resistance per meter cable ), for high temperature cable 28 Ω/m. Infinite resistance
indicates a broken circuit; zero or a lower than 1 Ω resistance indicates a short circuit.
2. Check if the heat flux sensor reacts to heat: put the multimeter at its most sensitive
range of DC voltage measurement, typically the 100 x 10-3 VDC range or lower. Expose
the sensor to heat, for instance exposing the sensor to the flame of a lighter. The signal
should read > 0.1 x 10-3 V now. Also look at the reaction of the thermocouple to heat.
3. Inspect the instrument for any damage.
4. Check the sensor serial number engraved on the sensor or on the transition piece
between high temperature and low temperature cable, against the certificate provided
with the sensor.

RHF series manual v1623 8/21

2 Instrument principle and theory
A heat flux sensor measures the heat flux density through the sensor itself. This
quantity, expressed in W/m2, is usually called “heat flux”. RHF users typically assume
that the measured heat flux is representative of the undisturbed heat flux at the location
of the sensor though a pipe of the same temperature. Users may also apply corrections
based on scientific judgement.

The heat flux sensors in RHF are thermopiles. This thermopile measures the temperature
difference across the wall of the pipe. Working completely passive, the thermopile
generates a small voltage that is a linear function of this temperature difference. The
heat flux is proportional to the same temperature difference divided by the effective
thermal conductivity of the heat flux sensor body.

Using RHF is easy. For readout the user only needs an accurate voltmeter that works in
the millivolt range. To convert the measured voltage, U, to a heat flux Φ, the voltage
must be divided by the sensitivity S, a constant that is supplied with each individual
sensor, and correct for the temperature of the sensor.

The temperature sensor inside RHF is a type K thermocouple.

Heat flux sensors such as RHF, for use in industry at high heat flux levels, are typically
calibrated under the following reference conditions:

• conductive heat flux (as opposed to radiative or convective heat flux)

• homogeneous heat flux across the sensor
• 30 °C
• heat flux in the order of 3000 W/m2

RHF series manual v1623 9/21

Measuring with heat flux sensors, errors may be caused by differences between
calibration reference conditions and the conditions during use. The user should analyse
his own experiment and make his own uncertainty evaluation.

30
16
11

1 2 3 4 5 6 7

Figure 2.1 Example of RHF01 ring heat flux sensor with 4 x heat flux / temperature
sensors (1), in a stainless steel body (2), with either a flat connection for welding- (3) or
a threaded connection (4). High temperature cable (5) is usually extended with low
temperature extension cable (7). Cooling must be provided by air, oil or water. RHF
design is user-specific. Dimensions in the drawing serve as an example only. Dimensions
are in x 10-3 m.

RHF series manual v1623 10/21

3 Specifications of RHF-series
3.1 RHF specifications

RHF consists of sensors embedded in a ring-shaped tube wall. They measure the heat
flux density through the surface of the sensor. This quantity, expressed in W/m2, is
called heat flux. They also measure the absolute temperature of the wall. RHF design is
user-specific; geometry and cabling are designed in cooperation with the user for the
specific application. An RHF is passive, using thermopile and thermocouple sensors. The
thermopiles generate a small output voltage proportional to the heat flux. RHF can only
be used in combination with a suitable measurement system. The RHF is usually cooled
by air or water. RHF sensors are typically used for trend monitoring, which does not rely
on absolute calibration. For absolute measurements the user must calibrate the RHF
incorporated in the final design under operating conditions, possibly as a function of
water or air flow.

Table 3.1 Specifications of RHF (continued on next page)

RHF SPECIFICATIONS

Sensor type ring heat flux sensors

Sensor design RHF design is user-specific; geometry and cabling are
designed in cooperation with the user for the specific
application.
Sensor type according to ASTM heat flow sensor or heat flux transducer
Heat flux sensor thermopile
Measurand heat flux
Measurand in SI units heat flux density in W/m2
Measurement range 0 to 300 x 103 W/m2
Temperature sensor thermocouple type K
Temperature sensor specification ANSI MC96.1-1982 / EN 60584
Measurand temperature
Measurand in SI units temperature in °C
Measurement function / required Ф = U/(S∙(1 + TD∙(T - Treference)))
programming
Temperature dependence TD - 0.013 %/K
(constant value for all sensors, based on material and
thermocouple specifications)
Optional measurement function / user-specific measurement equation, determined by
required programming user calibration
Recommended number of sensors 2 to 4 per ring
Sensitivity (nominal) 4 x 10-9 V/(W/m2)
Response time (95 %) 180 s (depends on cooling)
Directional sensitivity see product certificate
Expected voltage output multiply the sensitivity by the maximum expected
heat flux
Required readout per heat flux and temperature sensor:
heat flux sensor: 1 x differential voltage channel or 1
x single ended voltage channel
temperature sensor: 1 x Type K differential
thermocouple channel or 1 x Type K single ended
thermocouple channel
both with input resistance > 106 Ω

RHF series manual v1623 11/21

Table 3.1 Specifications of RHF (started on previous page, continued on the next page)

Rated operating temperature ranges:

sensor and high temperature cable -30 to +800 °C
low temperature extension cable -30 to +240 °C
optional connectors -50 to +250 °C
IP protection class
Sensor and high temperature cable IP68
Low temperature extension cable IP67
Rated operating relative humidity range 0 to 100 %
Required sensor power zero (passive sensors)
Sensor diameter including guard 8 x 10-3 m (typical)
Sensor thickness 12 x 10-3 m (typical)
Sensor thermal conductivity λ = 13.2 + 0.015T W/(m·K)
for SS316
Standard cable lengths:
High temperature cable 1 m (see options)
Low temperature extension cable 3 m (see options)
Standard cable diameter:
High temperature cable 0.15 x 10-3 m
Low temperature extension cable 4 x 10-3 m
High temperature cable type metal sheathed mineral insulated signal cable
Low temperature extension cable type PTFE signal cable with shield
Heat flux sensor resistance range 1 to 2 Ω
Low temperature extension cable: heat 0.2 Ω/m (nominal)
flux sensor cable resistance
High temperature cable: heat flux sensor 13 Ω/m (nominal)
cable resistance
Temperature sensor resistance range 1 to 2 Ω
Low temperature extension cable: 3 Ω/m (nominal)
temperature sensor cable resistance
High temperature cable: temperature 28 Ω/m (nominal)
sensor cable resistance
Low temperature extension cable 4 x 10-3 m
diameter
Transition piece diameter 10 x 10-3 m
Marking see drawing
1 x sensor serial number engraved on connection
piece high temperature to low temperature cable or
on the sensor body
1 to 4 x individual sensors are marked by a number
engraved on the metal of the ring
1 x sensor serial number on sticker at the end of the
low temperature extension cable
Gross weight on request
Net weight on request
Packaging box of 300 x 320 x 60 mm (typical)

RHF series manual v1623 12/21

Table 3.1 Specifications of RHF (started on previous 2 pages)

INSTALLATION AND USE

Cooling by air, water or oil

(user responsibility)
Cooling requirements RHF is usually cooled using air or water. The user
must keep the RHF temperature within its rated
operating range.
Installation see recommendations in this user manual
avoid mechanical force on the sensor body and
sensor-to-cable transition.
Cable extension see options: longer cable, extension cable and
connectors
ACCESSORIES

Heater for calibration verify heater type for the user specific RHF
typical heater specifications:
heater resistance 100 Ω (nominal)
heater voltage 30 VDC
effective surface area 0.00407 m2
CALIBRATION

Calibration traceability to SI units

Product certificate included
(showing calibration result and traceability)
Calibration method CBW01 calibration method
Calibration hierarchy from SI through international standards and through
an internal mathematical procedure
Calibration uncertainty ± 20 % (k = 2)
Calibration reference conditions 30 °C, heat flux of 3 x 103 W/m2
Validity of calibration factory calibration may be used for trend monitoring.
For absolute measurements re-calibrate when the
sensor is built-in.
Temperature sensor tolerance class IEC Tolerance class EN60584-2: Type KX, class 2
Temperature sensor error limits ASTM E230-ANSI MC96.1: Type KX, standard limits
MEASUREMENT ACCURACY

Uncertainty of the measurement statements about the overall measurement

uncertainty can only be made on an individual basis.
see the chapter on uncertainty evaluation.
VERSIONS / OPTIONS

Order code RHF with reference to drawing

Longer cable longer cable (specify total cable length for both cable
types in m)
Connector connector at RHF cable ends
Extension cable low temperature extension cable with 2 connectors
with 2 connectors matching cable connector and
chassis connector (specify cable length in m)
Chassis connector chassis connector with internal wiring
(colour code of wiring identical to cable colour code)

3.2 Dimensions of RHF

RHF design is user-specific; geometry and cabling are designed in cooperation with the
user for the specific application.

RHF series manual v1623 13/21

4 Standards and recommended practices
for use
Use of RHF is not subject to standardised operating procedures.

RHF series manual v1623 14/21

5 Installation of RHF
5.1 Installation and cooling

Table 5.1.1 Recommendations for installation of RHF heat flux sensors

Location RHF sensors are often used as building blocks in larger measuring
systems for example to study fouling and slagging in combustion
processes. Many RHF’s are eventually part of so-called “deposition
probes” or “fouling sensors” designed by the customer.

Performing a A typical sensor contains 4 separate heat flux and 4 temperature sensors,
representative so that fouling behaviour can be studied at different locations on the
measurement sensor at different angles relative to the local gas flow.

Cooling requirements RHF is usually cooled using air or water. The user must keep the RHF
temperature within its rated operating range. We recommend making a
safety system by measuring the RHF temperature.

Mechanical mounting: RHF is usually mounted on a probe of the user. The connection may be
avoiding strain on the made by welding or screwing.
sensor to cable
transition In case of a welded connection, make sure that the sensor temperature
during welding remains below 800 °C.

The sensor-to-cable transition is vulnerable. During installation as well as

operation, the user should provide proper strain relief of the cable so that
transition is not exposed to significant force.

5.2 Electrical connection

A heat flux sensor should be connected to a measurement system, typically a so-called

datalogger. The thermopiles of an RHF are passive sensors that do not need any power,
neither for the heat flux sensor, nor for the temperature sensor. Cables may act as a
source of distortion, by picking up capacitive noise. We recommend keeping the distance
between a datalogger or amplifier and the sensor as short as possible. For cable
extension, see the appendix on this subject.

Table 5.2.1 The electrical connection of a single heat flux and temperature sensor of an
RHF. The shield is not connected to the stainless steel sensor body.

WIRE
Red heat flux signal [+]

Black heat flux signal [−]

Green thermocouple type K [+]

White thermocouple type K [−]

Blank shield

RHF series manual v1623 15/21

5.3 Requirements for data acquisition / amplification

The selection and programming of dataloggers is the responsibility of the user. Please
contact the supplier of the data acquisition and amplification equipment to see if
directions for use with the RHF are available.

Table 5.3.1 Requirements for data acquisition and amplification equipment for a single
sensor of RHF

Capability to measure small voltage preferably: < 5 x 10-6 V uncertainty

signals Minimum requirement: 20 x 10-6 V uncertainty
(valid for the entire expected temperature range of the
acquisition / amplification equipment)

Capability for the data logger or the to store data, and to perform division by the sensitivity to
software calculate the heat flux.
Ф = U/(S∙(1 + TD∙(T - Treference))) (Formula 0.1)

Capability to measure thermocouple preferably: measurement uncertainty within ± 3 °C

type K

Data acquisition input resistance > 1 x 106 Ω

Open circuit detection open-circuit detection should not be used, unless this is done
(WARNING) separately from the normal measurement by more than 5
times the sensor response time and with a small current
only. Thermopile and thermocouple sensors are sensitive to
the current that is used during open circuit detection. The
current will generate heat, which is measured and will
appear as a temporary offset.

RHF series manual v1623 16/21

6 Maintenance and trouble shooting
6.1 Trouble shooting

Table 6.2.1 Trouble shooting for RHF

General Inspect the sensor for any damage. Inspect the quality of mounting / installation.
Inspect if the wires are properly attached to the data logger.
Check the condition of the cable.
Inspect the connection of the shield (typically connected at the datalogger side).
Check the datalogger program in particular if the right sensitivity is entered. RHF’s
sensor serial number is engraved on the sensor or on the transition piece between
high temperature cable and low temperature extension cable. The sensitivity can
be found on the calibration certificate.

Check the electrical resistance of the heat flux sensor between the black [-] and
red [+] wires and the thermocouple between the green [+] and white [-] wires.
Use a multimeter at the 100 Ω range. Measure the sensor resistance first with one
polarity, then reverse the polarity. Take the average value. Typical resistance
should be the nominal sensor resistance of 1 to 2 Ω for the thermopile sensor, plus
for additional low temperature extension cable 0.2 Ω/m (resistance per meter
cable) for the total resistance of two wires (back and forth added), for high
temperature cable 13 Ω/m. For the thermocouple work with 1 to 2 Ω , plus
additional low temperature extension cable 3 Ω/m resistance per meter cable ), for
high temperature cable 28 Ω/m. Infinite resistance indicates a broken circuit; zero
or a lower than 1 Ω resistance indicates a short circuit.

The sensor Check if the heat flux sensor reacts to heat: put the multimeter at its most
does not give sensitive range of DC voltage measurement, typically the 100 x 10-3 VDC range or
any signal lower. Expose the sensor heat, for instance touching it with your hand. The signal
should read > 2 x 10-3 V now. Touching or exposing the red side should generate
a positive signal, doing the same at the opposite side, the sign of the output
voltage reverses.
Also look at the reaction of the thermocouple to heat.
Check the reaction of the thermocouple sensor to heat.
Check the data acquisition by replacing the sensor with a spare unit.

The sensor Check the cable condition looking for cable breaks.
signal is Check the data acquisition by applying a 1 x 10-6 V source to it in the
unrealistically 1 x 10-6 V range. Look at the measurement result. Check if it is as expected.
high or low Check the data acquisition by short circuiting the data acquisition input with a
10 Ω resistor. Look at the output. Check if the output is close to 0 W/m2.

The sensor Check the presence of strong sources of electromagnetic radiation (radar, radio).
signal shows Check the condition and connection of the shield.
unexpected Check the condition of the sensor cable.
variations Check if the cable is not moving during the measurement.

RHF series manual v1623 17/21

RHF series manual v1623 18/21
7 Appendices
7.1 Appendix on cable extension / replacement

A heat flux and temperature sensor in an RHF is equipped with one cable that consists of
a high temperature cable and a low temperature extension cable. Keep the distance
between data logger or amplifier and sensor as short as possible. Cables may act as a
source of distortion by picking up capacitive noise. In an electrically “quiet” environment
the RHF cables may be extended without problem to 50 metres. If done properly, the
sensor signal, although small, will not significantly degrade because the sensor resistance
is very low (which results in good immunity to external sources) and because there is no
current flowing (so no resistive losses). Cable and connection specifications are
summarised below.

Table 7.1.1 Preferred specifications for cable extension of a single sensor in RHF

Cable Hukseflux RHF high temperature cable (not extendable)

Hukseflux RHF low temperature extension cable

Extension use Hukseflux RHF extension cable with 2 connectors matching cable
connector and chassis connector (specify cable length in m)

use Hukseflux RHF cable connector at the end of the RHF low
temperature extension cable to a connector of the extension cable with 2
connectors

use Hukseflux RHF chassis connector

Outer diameter 4 x 10-3 m (low temperature extension cable)

Length cables should be kept as short as possible, in any case the total cable
length should be less than 50 m

RHF series manual v1623 19/21

7.2 EU declaration of conformity

We, Hukseflux Thermal Sensors B.V.

Delftechpark 31
2628 XJ Delft
The Netherlands

in accordance with the requirements of the following directive:

2014/30/EC The Electromagnetic Compatibility Directive

hereby declare under our sole responsibility that:

Product model: RHF

Product type: Ring heat flux sensor

has been designed to comply and is in conformity with the relevant sections and
applicable requirements of the following standards:

Emission: EN 61326-1 (2006)

Immunity: EN 61326-1 (2006)
Emission: EN 61000-3-2 (2006)
Emission: EN 61000-3-3 (1995) + A1 (2001) + A2 (2005)
Report: 08C01340RPT01, 06 January 2009

Eric HOEKSEMA
Director
Delft
September 08, 2015

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 © 2016, Hukseflux Thermal Sensors B.V.
www.hukseflux.com

Hukseflux Thermal Sensors B.V. reserves the right to change specifications without notice.