Mini RTD Pt100 Three Wire Transmitter

These are the circuits and boards of a Mini Temperature Transmitter for a Platinum hundred ohms temperature Sensor.

Transmitter RTD

The customer wanted a two wire system, this needs low power opamps which were ten times the price. If this transmitter works at 3mA it could have been two wire. Those parts were in short supply and the budget of customer was low. So i made it with regular opamps but three wire. The customer was satisfied as he got a cost effective solution. But now the situation of markets and products are different.

RTD  Three Wire Transmitter

If you need to transmit the temperature from a high voltage area or toxic environment. You will need to hermetically seal the transmitters, convert the Voltage to frequency, frequency to IR LED flashes or RF. This can be then remotely monitored. Then the transmitter has to be battery-solar operated, low power too. ICL7135 is a simple solution. It has a serial output that can be used to Drive IR Leds. Remotely sense these flashes in a Micro-controller and you have a reading. You may be able to use optic-fibers too. Where volatile liquids are present so that the risks of sparks can be eliminated.

3 Wire Transmitter RTD

More at Process Control Circuits

This is the same Mini RTD Pt-100 Transmitter but in its case. Encapsulated in epoxy, hermetically sealed against harsh industrial environment. This will work well even near fumes of Ammonia with no corrosion. But not near vapors which can be ignited by sparking as terminals are still open. The side view shows zero and full scale ten turn bourns trimpots heads, for calibration. After cal it can be sealed with RTV compound.

RTD PT100 Transmitter

This is a RTD Pt-100 Transmitter, It can Convert Thermocouple mV or RTD mV to 4-20 mA Current Transmitter. The part numbers on Circuit and silk screen may not match. But the PCB may be usable. The output is a current source and not a current sink. It goes to a 4-20mA Mux with a common ground. The Circuit RTD-Pt-100-Transmitter Circuit.

RTD Transmitter 4-20 mA

This low-cost transmitter was made to send RTD information in a 4-20mA over long distance. The 4-20mA was the input to a Analog-Mux which interfaced to a GE-Fanuc PLC system and a 486 Computer. The Analog Multiplexer Built around CD4051 was was controlled by PLC to get data from numerous channels. This reduced the cost of the System. This is ok when Real-Time Acquisition is not required. The Analog 4-20 to 4-20 Mux-Buffer circuit can be seen at Industrial Process Control Circuits.

This was done as customer budget could not afford dedicated analog input modules for every channel. There were more than 50 Inputs. The thermal inertia of system did not need a real time or fast correction.

The PNGs of PCB is 600dpi 16 color. It is to be scaled appropriately.

LM335 Cold Junction Compensation

Temperature Sensors like Thermocouples need cold junction compensation as a part of front end signal conditioning, this is done at the terminal block where the Thermocouple wires are terminated. This design has to be more accurate and broad, if the design we make has to work well in both Tropical and Temperate Climate Zones.

LM335 Cold Junction Compensation

Another Method using a Copper Resistor

If wires of two dissimilar metals are joined at both the ends and the junction formed at one of the ends, is heated more than the other junction, a current flows in the circuit due to Seebeck thermal emf. This effect is used in thermocouple temperature sensors.

The Peltier effect is the converse of above Seebeck effect, which means that if a current is forced through junctions of dissimilar metals, the junction will generate heat or absorb heat (cooling) depending on direction of the applied emf. This effect is used to make portable and small refrigerators. Thermocouple Temperature DPM - DMM

Thermocouple Temperature DPM – DMM

Temperatur Control Simulation – ITC Leipzig

At Institute of Technical Chemistry Leipzig. you can try out a Java based control systems simulation.

Temperatur Control Simulation – ITC Leipzig

  • The Plant, parameter determination
  • The Controller, control functions, estimation methods.

Related

Millivolt Source with Digital Potentiometer

Here is a Millivolt Source i built for Calibration in the early days. It uses only CMOS Digital and Mixed Chips from Intersil and CD40xx Series.

Millivolt Source

Later i tried a unit with 8748 part of the code in my uC section. This is with Ramp-up and Ramp-down using only two buttons. This works even now, The support below is an HRC Fuse Holder made of Phenolic or Epoxy Resin. The mV Terminations are on Top.

Process Control Instrumentation

Process Control Instrumentation Section Updated

This is a generic or standard controller for any type of process. Shown here is a temperature controller.Temperature Controller

The STC1000 could be used for Ovens or furnaces, liquid baths, heating or environment chambers. It has a single analog input and an analog or relay output.

Analog inputs could be like 4-20 mA, thermocouple or RTD. Analog outputs can be 0-10 V for a thyristor drive, SSR drive output or potential free contacts of a relay to operate external 3 phase contacters.

The closed loop control could be On-Off or Time-Proportional. It was known as digital temperature indicating controller. Sometimes it would be used just as a Alarm or in a Trip circuit for protecting a system, when a uP or uC based PID controller fails.

This is used in the processing of plastics, rubber, metals and in chemical plants too. Here is a checklist that was made for helping its fabrication. You can see the limitations in which we manufactured these products. An optimum quality was evolved, defined by a user’s affordability of the product.

Thermocouple and Pt-100 RTD

The easiest way to measure temperature is with a glass diode like 1N4148 or a metal Transistor like 2N2222. These have a small temperature range, probably -5 to +120 is possible, but non-linear. A copper coil or any metal wire or even a wirewound resistor can work as temperature sensor but the thermal inertia makes it sluggish. IC semiconductor based sensors like LM335 and AD590 are easy to work with and pretty accurate. In industrial environment many types of Thermocouples, Pt-100 RTD and Optical Infra-Red Temperature measurements are used.

Thermocouple-RTD-Chart.png

Input Levels for Thermocouples and RTD Pt-100. And the ways it can be used. Thermocouples are selected on the basis on how they are mounted or fixed, the environment, the temperature range that is measured and finally the price you can afford for a particular application. Sometimes mechanical wear or chemical environments may eat away the sensors, so a cost-effective solution has to be evolved.

One customer wanted a special Pt-PtRh very high temperature sensor for molten aluminum. It was very difficult and costly to even arrive at a solution. So a non-contact infra-red sensor may save a lot of time-money and even reduce risk of injury.

For J, K, and T Thermocouple Read “Temperature” + Room Temperature for mV shown applied to equipment, eg…. If Room Temperature is 25 Deg C and mv applied is 10.777 for J Type STC1000 then reading should be 200 + RT = 225 deg C. The mV shown are for Reference Junction at 0 Deg C. It would be better if you refer links below, The above table i made long ago, then a Scan with OCR later formatting. It could have errors.

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