CONSTRUCTION AND CALIBRATION OF A THERMOCOUPLE

BY
N. N. Garba,* N.Rabi’u,* A. M. Yusuf,* A. Isma’il,* A. K. Abubakar,* I.
Abdullahi**
* Department of Physics, Ahmadu Bello University, Zaria
**School of Basics and Remedial Studies (A.B.U Zaria), Funtua.
Corresponding author’s address nurangetso@yahoo.com.+2348034298444

ABSTRACT

Temperature, being one of the factors that affect man and his environment, requires a

sensitive device for its measurement over a wide range with a relatively high degree of

accuracy. In an effort to determine temperature value using various laboratory thermometers,

one hardly gets accurate results, or wide range of values, therefore, there is the need to come

up with an instrument to solve this problem. In this work a type k thermocouple was

constructed and calibrated and the values obtained are in good agreement with the standard

of type k thermocouple, the values are E = 10.20mV, a = 0.055mV/°C and b = 0.001mV/°C

both at t0 = 275°C which, within the experimental limit, will take care of most of the

aforementioned problems. A thermocouple is an instrument whose principle of operation is

based on the theory of thermoelectricity. Furthermore, the components used in the

construction are cheap and available in our market today.

INTRODUCTION potential difference into electric potential

It turns out nowadays that, in electronics difference(2).

and electrical engineering, thermocouples They are relatively cheap (3) in our

are a widely used type for temperature markets and interchangeable have standard
(1)
sensing/measurement and can also be connectors and can measure a wide range

used as a means to convert thermal of temperature. The main limitation is

accuracy; a research by Kieran Thomas

1
shows that system errors of less than one
Thermocouple used principle of
thermoelectricity in its operation
thermoelectricity is the electricity
generated by application of heat to the
junction of two dissimilar metals arranges
so that two junctions are formed (4)
In 1821, the German –Estonian physicist
Thomas Johann see beck discovered that
when any conductor (such as a metal) is
subjected to a thermal any conductor, it
will generate a voltage. This is known as
thermoelectric effect or sees beck effect.
Any attempt to measure this voltage
necessarily involves connecting another
conductor to the “hot” ends. This
additional conductor will then also
experience the temperature gradient, and
develop a voltage of its own which will
oppose the original. Fortunately , the
magnitude of the effect depends on the
metal in use, using a dissimilar metal on
2
degree Celsius (1oc) can be difficult to
achieve.
the complete the circuit creates a circuit
in which the two ends legs generate
different voltages, leaving a small
difference in voltage available for
measurement that difference incrassates
with temperature, and can typically be
between 1 and 70 (µV/oc) for the modern
range of available metal combinations
A thermocouple can produce
current, which means it can be used to
drive some processes directly without the
need for extra circuiting and power
sources
For example, the power from a
thermocouple can active a value when a
temperature difference arises. The electric
power generated by a thermocouple is a
conversion of the heat energy that one
must couple to maintain the electric
cause the current flowing through the
thermocouple tends to heat up this is touches the probes2. As both conductors

known as Peltier effect(5) are non-magnetic type T thermocouples

are a popular choice for application such

TYPES OF THERMOCOUPLE as a electrical generators which contain

A variety of thermocouples are strong magnetic fields-its sensitivity is

available, suitable for different about 43µV/0C (tungsten 5% rhenium –

measurements. They are usually selected tungsten 26% rhenium) thermocouple are

based on the temperature range and suited for measurement in the range O0C

sensitivity needed. Thermocouple with to 23200c. This thermocouple is well-

low sensitivities (B, R and S types) criteria suited for vacuum furnace at extremely

include the inertness of the thermocouple high temperatures and must never be used

material, and whether or not is magnetic. in the presence of oxygen at temp .above

In this research we focused on 2600c6.

constructing and calibrating type T Materials and method

thermocouple because its construction The materials needed for this construction

does not require any hardship, the are

construction is simple and direct. It gives - 2 pieces of 32SWG. 1m length

larger E.M.F for a small temperature insulated copper wire

difference which is not so to other type1. - 32 SWG, IM length insulated

Type T thermocouple is made of constantan wire

copper – constantan and this is suitable for - 6cm Tinmans solder

temperature ranges between (-200 – 350) - 100w, 240V soldering iron with
0
C often used as a differential soldering bit

measurement since only copper wire Method

3
 The construction was done as TESTING

follows. After the construction, the thermocouple

- the insulation was carefully removed at was tested and a highly impressive result

one end of the copper wire and also at was obtain

both ends of the constantan wire procedure: First the insulation of the

- One end of the constantan was then ends of the copper wires of the

soldered carefully with bare end of the thermocouple were removed and the bare

copper wires. The other end of the ends were connected to a galvanometer

constantan wire was again soldered (G) one copper-constantan junction was

carefully with the bare end of the other maintained at room temperature and the

piece of copper wire and the other junction was taken of a furnace as:

thermocouple was then formed.

Cu G Cu

Constantan Furnace

Fig(1) Testing of Thermocouple

The furnace was then switched on and the the furnace reaches 300C. The

galvanometer deflects when the temp of galvanometer keeps deflecting with

4
 increasing temperature of the furnace. repeated but the reference junction inside a

Maximum deflection was obtained at a melting the in a beaker of the

temperature around 2400C beyond which galvanometer happened with maximum

the deflection reduces until it finally deflection of the galvanometer now at

became zero at temperature around 6850C temp around 3000c and the reversal takes

and the deflection increases in the reverse place at about 7100C6.

direction. The same procedure was

Test Result

Reference junction Furnace Galvanometer

Temperature ( 0c ) Temperature ( 0c ) Deflection

25 25 No deflection
25 30 Very small deflection
25 40 Deflection increase
25 100 Significant increase
25 200 Continue increases
25 250 Steady deflection
25 300 Fall in deflection
25 600 Significant fall
25 690 Almost zero def
0 25 Start deflection
0 30 Increase to deflection
0 40 Continue to deflect
0 100 Some significant increases
0 200 Significant deflection
0 300 Steady deflection
0 400 Fall in deflection
0 500 Significance fall
0 700 Almost zero deflection

Thermal EMF measurement

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After test result was obtained then the melting ice in a beaker was joined to

EMF (thermal) was found by connecting A, to which the positive terminal of X

the thermocouple to a potentiometer is connected. The other junction in was

whose resistances was measured by an warmed in fingers and a balance point

ohmmeter. was obtained closed to A, this hot

Apparatus junction switched on

- 2v accumulator X As temperature rises, approximate

- Variable resistor (Resistance box R) balance points were then located until

- Potentiometer of length AB the balance point L reached a

- Sensitive galvanometer G with maximum near temperature of about

protective resists P=13Ω 3000c. this temp was then fairly

- Jockey, 2 block of ice and a 500ml maintained steady and the value of R

beaker from the resistance box final value of

- Furnace and ohmmeter R was noted and not been altered

- Voltmeter again, the furnace was heated up to

Method about 5000c and then allowed to cool

The potentiometer was connected to slowly to room temp and carefully the

the thermocouple as can be seen in fig balance point was taken at 500c

2.0 with R set temporarily at about 500 interval after the protective resistive

Ω. It should be noted that the cold was removed.

junction C, to which surrounded by

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 R
x

A L C
B
G

o c o
o o
- o o

Furnace

Fig (2) Measurement of thermal EMF

The values measured are as follows:

Resistance of wire AB (S) = 3.6Ω

EMF of the accumulator X = 2.0V

Resistance R = 682Ω

Cold junction temperature. = 00C.

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Hot Junction temp.(oC) Balance length(cm) E.M.F of the couple(mV)
0 0 0.00
50 19 2.00
100 39 4.10
150 65.7 6.90
200 84.7 8.90
250 96.2 10.10
300 96.2 10.10
350 78.1 8.20
400 57.1 6.00
450 39 4.10
500 22.9 2.40

The P.d across the wire AB was found by the relation

P.d. = 1000E ×S
(R+S)

= 3.6 x 1000 × 2
682 +3.6

= 10.5 mV

Then the thermal E.M.F was found using the relation

Ethermal = L x P.d across AB

100
= L x 10.5
100

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 The EMF thermal was found at all other balance points and the result was tabulated

as follows.

T(0C) L(cm) EMF thermal (mV)

0 0.0 0.00
50 19.0 2.00
100 39.0 4.10
150 65.7 7.00
200 84.7 9.00
250 96.2 10.10
300 96.2 10.10
350 78.1 8.20
400 57.1 6.00
450 39.0 4.10
500 22.9 2.40

origin which is given by all values

Calibration chosen from the graph i.e. a =

Calibrating a thermocouple means 0.055mV/0C Also as can be seen from

finding the numerical values of a and the graph temp. At which the

b in the equation E = at1 +bt22 maximum EMF was obtained is known

(1) as neutral temp. Which is 2750C from

in which one of the temp is known graph denoted by to with a =

and the corresponding E thermal is 0.55mV/0c equal thus become

known as well the constants can be E = 0.055t1 +bt22 (2)

from the calibration growth plotted But rate of change of E with temp

(fig 3.0) which is the graph of E is zero at stationing point

thermal against temp for this couple A +2bt = 0

the calibration graph was plotted and Gy (2) becomes

the constants of the graph at the dE = 0.055 +2bt

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 dt 2b (275) = -0.055
0.055+2bt = 0

2bt = - 0.055 (3) 550b = 0.055/550

b = -0.0001

‫ ؞‬E= 0.55t – 0.0001t2 (4)

But stationing point the graph was

By the above equationn a given
neutral temp t = 2750c
temp will lead to the determination of
Eqn. 3 becomes
E and vice versa.

Graph of thermal EMF against Temperature

12
10
EMF (mV)

8
6
4
2
0
0 200 400 600
Temperature (0C)

Figure (3) calibration graph of constructed type T thermocouple

CONCLUSION At the end of the research we

were able to find out the

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 maximum EMF to be 10.20mV, thermoelectric effects: Department

neutral temperature to = 2750C, a of physics and mathematics Zwitch

=0.055mV/0C and, University of applied sciences 8401

b = - 0.001mV/0C which is in Winterthur Switzerland.

good agreement with the 4. M. NELKON, PARKER.

standard value of type T (1984); Advance level physics:

thermocouple. Heinemann educational books

London.

REFERENCES 5. A. KEY (1990); Fundamental

1.(http://www.temperatures.co physics laboratory pp34:

m/tcs.html); Thermocouple Macmillan publishing company.

temperature sensors: Retrieved on 6. RICHARD PARK (2000);

11/04/2007. Thermocouple gradient theory:

2.(http://www.omega.com/thermoc Thermocouple works marlin

ouples.html); Thermocouple – an manufacturing company.

introduction: Omega engineering

retrieved 11/04/2007

3. HANS U.F. (2002); a simple

continuum model leading to the

reciprocity relation for

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