simplified thermocouple analog...

2002-2020 Microchip Technology Inc. DS0000844B-page 1

AN844

INTRODUCTIONThermocouples are the simplest form of temperaturesensors. Thermocouples are normally:• Very inexpensive• Easily manufactured• Effective over a wide range of temperaturesThermocouples come in many different types to covernearly every possible temperature application.

In Application Note AN684, thermocouple basics arecovered along with some circuits to measure them.This Application Note begins where AN684 leaves offand describes methods of obtaining good accuracywith minimal analog circuitry. Also covered in thisApplication Note are:• Different linearization techniques• Cold junction compensation• Diagnostics

FIGURE 1: THERMOCOUPLE CIRCUITS

All thermocouple systems share the basic characteris-tic components shown in Figure 1. The thermocouplemust pass through an isothermal barrier so the abso-lute temperature of the cold junction can be deter-mined. Ideally, the amplifier should be placed as closeas possible to this barrier so there is no drop in tem-perature across the traces that connect the thermocou-ple to the amplifier. The amplifier should have enoughgain to cover the required temperature range of thethermocouple. When the thermocouple will be measur-ing colder temperatures than ambient temperatures,there are three options: 1. Use an Op Amp that operates below the nega-

tive supply.2. Bias the thermocouple to operate within the Op

Amp's supply.3. Provide a negative supply.

Some thermocouples are electrically connected to thedevice they are measuring. When this is the case,make sure that the voltage of the device is within theCommon mode range of the Op Amp. The most com-mon case is found in thermocouples that are grounded.In this case, option 2 is not appropriate because it willforce a short circuit across the thermocouple to ground.

LinearizationLinearization is the task of conversion that produces alinear output, or result, corresponding to a linearchange in the input. Thermocouples are not inherentlylinear devices, but there are two cases when linearitycan be assumed:1. When the active range is very small.2. When the required accuracy is low.

Author: Joseph JulicherMicrochip Technology Inc.

Note: Consider the MCP9600 and MCP9601family of Thermocouple ICs which providea factory trimmed plug-and-play solutionfor various thermocouples.

Linearization

Scaling

ResultGain

AbsoluteTemperatureReference

Thermocouple Isothermal Barrier

Simplified Thermocouple Analog Solutions

DS0000844B-page 2 2002-2020 Microchip Technology Inc.

Pilot lights in water heaters, for example, are typicallymonitored by thermocouples. No special electronics isrequired for this application because the only accuracyrequired is the ability to detect a 600-degree increasein temperature when the fire is lit. A fever thermometer,on the other hand, is an application where the activerange is very small (90 F – 105 F). If the temperaturegets higher than the effective range, either the ther-mometer is not being used correctly or the patientneeds to be in the hospital.There are many ways to linearize the thermocoupleresults. Figure 1 shows linearization following the gainstage. Sometimes, the linearization follows the additionof the absolute temperature reference. No matterwhere it occurs, or to what degree, linearization iscritical to the application.

Absolute Temperature ScalingThermocouples are relative measuring devices. Inother words, they measure the temperature differencebetween two thermal regions. Some applications are

only interested in this thermal difference, but mostapplications require the absolute temperature of thedevice under test. The absolute temperature can beeasily found by adding the thermocouple temperatureto the absolute temperature of one end of the thermo-couple. This can be done at any point in the thermocou-ple circuit. Figure 1 shows the scaling occurring afterthe linearization.

ResultsThe result of the thermocouple circuit is a usable indi-cation of the temperature. Some applications simplydisplay the temperature on a meter. Other applicationsperform some control or warning function. When theresults are determined, the work of the thermocouplecircuit is finished.

Pure Analog CircuitA pure analog solution to measuring temperatures witha thermocouple is shown in Figure 2.

FIGURE 2: PURE ANALOG SOLUTIONIsothermalBlock

NTCThermistor

VDD

100

2.5 K

Output+

-

10 K 10 K

10 K

RG

+

-

-

+

10 K10 K

1 K

19.1 K

VREF2.5V

LM136-2.5

VREF

10 K9.76 K

+

-

Thermocouple

Offset Adjust


In the analog solution, the thermocouple is biased up to2.5V. This allows the thermocouple to be used to mea-sure temperatures hotter and colder than the isother-mal block. This implementation cannot be used with agrounded thermocouple. The bias network that biasesthe thermocouple to 2.5V contains a thermistor. Thethermistor adjusts the bias voltage making the thermo-couple voltage track the absolute voltage. Both thethermistor and the thermocouple are non-lineardevices, so a linearization system would have to becreated that takes both curves into account.

Simplified DigitalMost analog problems can be converted to a digitalproblem and thermocouples are no exception. If anAnalog-to-Digital Converter (ADC) were placed at theend of the analog solution shown in Figure 2, the resultwould be a simple digital thermometer (at least the soft-ware would be simple). However, the analog/linear cir-cuitry could be made less expensive to build andcalibrate by adding a microcontroller.As Figure 3 shows, the circuit got a lot simpler. Thissystem still uses a thermistor for the absolute tempera-ture reference, but the thermistor does not affect thethermocouple circuit. This makes the thermocouplecircuit much simpler.

FIGURE 3: SIMPLIFIED DIGITAL CIRCUIT

-

+

+

-

+5 V

10 KVDD

AN0

AN1

PICmicro MICROCONTROLLER

VSS


Hot Only or Cold Only MeasurementIf the application can only measure hot or cold objects,the circuit gets even simpler (see Figure 4). If only onedirection is going to be used in an application, a simpledifference amplifier can be used. The minimum tem-perature that can be measured depends on the qualityof the Op Amp. If a good single supply, rail-rail Op Ampis used, the input voltage can approach 0V and tem-perature differences of nearly 0 degrees can be mea-sured. To switch from hot to cold measurement, thepolarity of the thermocouple wires could be switched.

FIGURE 4: HOT OR COLD ONLY MEASUREMENT

FAULT DetectionWhen thermocouples are used in automotive or aero-space applications, some sort of FAULT detection isrequired since a life may be depending on the correctperformance of the thermocouple. Thermocoupleshave a few possible failure modes that must beconsidered when the design is developed:1. Thermocouple wire is brittle and easily broken in

high vibration environments.2. A short circuit in a thermocouple wire looks like

a new thermocouple and will report thetemperature of the short.

3. A short to power or ground can saturate the highgain amplifiers and cause an erroneous hot orcold reading.

Solutions for these problems depend on theapplication.

Measuring the Resistance of the ThermocoupleThe most comprehensive thermocouple diagnostic isto measure the resistance. Thermocouple resistanceper unit length is published and available. If the circuitcan inject some current and measure the voltageacross the thermocouple, the length of the thermocou-ple can be determined. If no current flows, there is anopen circuit. If the length changed, then the thermocou-ple is shorted. This type of diagnostic is best performedunder the control of a microcontroller.

-

++

-

+5V

ADC

ADC


DIGITAL COLD COMPENSATIONDigital cold compensation requires an absolute tem-perature reference. The absolute temperature refer-ence can be from any source, but it must accuratelyrepresent the temperature of the measured end of thethermocouple. The previous examples used a thermis-tor in the isothermal block to measure the temperature.The analog example used the thermistor to directlyaffect the offset voltage of the thermocouple. The digitalexample uses a second ADC channel to measure thethermocouple voltage separately.

The formula for calculating the actual temperaturewhen the reference temperature and thermocoupletemperature are known is:

Linearization TechniquesThermocouple applications must convert the voltageoutput from a thermocouple into the temperatureacross the thermocouple. This voltage response is notlinear and it is not the same for each type of thermocou-ple. Figure 5 shows a rough approximation of the familyof thermocouple transfer functions.

FIGURE 5: THERMOCOUPLE TRANSFER FUNCTIONS

Linear ApproximationThe simplest method of converting the thermocouplevoltage to a temperature is by linear approximation.This is simply picking a line that best approximates thevoltage-temperature curve for the appropriate tem-perature range. For some thermocouples, this range isquite large. For others, this is very small. The range canbe extended if the accuracy requirement is low. J andK thermocouples can be linearly approximated overtheir positive temperature range with a 30-degree error.This is acceptable for many applications, but to achievea better response, other techniques are required.

PolynomialsCoefficients are published to generate high order poly-nomials that describe the temperature-voltage curvefor each type of thermocouple. These calculations arebest performed with floating point math because thereare many significant figures involved. If the PICmicroMCU has the program space for the libraries, then thisis the most general solution.

Actual temperature = reference temperature +thermocouple temperature

1000 2000 3000 4000 5000

10

20

30

40

50

60

70

80

Temperature (Farenheit)

Milli

volts

BSR

C

G

N

K

T

J

E


Look-up Table (LUT)The easiest method of linearizing the data is to build aLook-up Table (LUT). The LUT should be sized to fit theavailable space and required accuracy. A spreadsheetcan be used to convert the coefficients into the correctdata table. A table will be required for each type of ther-mocouple used. If high accuracy (large tables) areused, it may be a good idea to minimize the number ofthermocouple types.To minimize the table size, a combination of techniquesmay be used. A combination of tables and linearapproximation could reduce the J or K error to just afew degrees.

BUILDING AN ENGINE TEMPERATURE MONITOR

BackgroundOne application of thermocouples is measuring engineparameters. Air-cooled engines, such as those used inaircraft, require good control of cylinder head tempera-ture (CHT) and exhaust gas temperature (EGT). Thecontrol is typically performed by the pilot by adjusting:• Fuel mixture• Power settings• Climb/descent rateBecause mixture is used to control temperature, fueleconomy is directly impacted by the ability to accu-rately measure the EGT. CHT is critical in an air-cooledengines because of the mechanical limits of the cylin-der materials. If the cylinder is cooled too fast (shockcooled), the cylinders or rings could crack, or the valvescould warp. Typically, shock cooling results from a rapiddescent at a low-throttle setting.

DeviceA good device for measuring these engine parametersshould have a range of 300-900 F for EGT and 300-600F for CHT. Additionally, diagnostics for short/opencircuits are required to alert the pilot that maintenanceis needed. The electronics should be placed in a suit-able location that has a total temperature range of -40to +185. This will allow the thermocouple circuitry to besimplified. The data will be displayed on a terminalprogram on a PC through an RS-232 interface.

AmplifierThe amplifier circuit is in two stages. First is a differen-tial amplifier that provides a gain of 10 and a highimpedance to the thermocouple. This is followed by asingle-ended output stage that provides a gain of 25 forK thermocouples and 17 for J thermocouples. Theamplifier selected is the MCP619. This device wasselected for its rail-rail output and very low VOS. Thethermocouple is located in a high-frequency/radio-fre-quency environment so small capacitors are used atthe input and between the stages to filter out the noise.As with most RF sources, these are normally very well-shielded. Since the temperatures don't change quickly,heavily filtering the signal to eliminate the noise doesnot affect the temperature measurement.

TABLE 1: J THERMOCOUPLE DATA TABLE – TEMPERATURE TO VOLTSCoefficient Temperature -210C to 760C Temperature 760C to 1200C

C0 0.0000000000E+00 2.9645625681E+05C1 5.0381187815E+01 -1.4976127786E+03C2 3.0475836930E-02 3.1787103924E+00C3 -8.5681065720E-05 -3.1847686701E-03C4 1.3228195295E-07 1.5720819004E-06C5 -1.7052958337E-10 -3.0691369056E-10C6 2.0948090697E-13 0.0000000000E+00C7 -1.2538395336E-16 0.0000000000E+00C8 1.5631725697E-20 0.0000000000E+00Note: v = c0 * t + c1 * t^1 + c2 * t^2 + c3 * t^3 + c4 * t^4 + c5 * t^5 + c6 * t^6 + c7 * t^7 + c8 * t^8v = voltst = temperature in C if the above table is used.


Digital Conversion and Cold CompensationThe signal is converted to digital with a MCP3004 A/Dconverter chip. The absolute temperature is measuredwith a TC1046 on the third channel of the MCP3004.The data is received by a PIC16F628 and converted toa regular temperature report over an RS-232 interface.To convert from volts to temperature, the Most Signifi-cant 8 bits of the conversion are used to index into a256-entry Look-up Table (LUT). The remaining 2 bitsare used to perform linear interpolation on the databetween two adjacent points in the LUT. Three tablesare stored in the memory of the PIC16F628. Thesetables are for:• J - type thermocouple• K - type thermocouple• TC1046AThe TC1046A has linear output, but we could easilysubstitute a non-linear thermistor for the same task.

Look-up Table (LUT) GenerationEight-bit Look-up Tables are generated using a spread-sheet. The polynomial values of the voltage-to-tem-perature curve are used to generate a voltage-to-temperature conversion spreadsheet. The voltages arethe predicted values from the Analog-to-Digital Con-verter (ADC). A 256-entry table was constructed ofADC counts to temperatures. The temperatures rangedfrom zero degrees Cto 535C. Because the table canonly store 8-bit values of temperature, two points wereselected as pivot points. At the first point, the tempera-ture was reduced by 255C. At the second point, thetemperature was reduced by 510C. The final tem-perature can be easily reconstructed by adding the twoconstants back in as appropriate. Additional resolutionis obtained by interpolating between two points in the 8-bit table using the extra 2 bits from the 10-bit conver-sion. This will result in four times as many data pointsby assuming a linear response between the points inthe LUT.

CONCLUSIONSThermocouples can be tricky devices, but when theproblem is shifted from the hardware analog compo-nents into the software, they can become a lot moremanageable. The only real requirement when usingthermocouples is to provide a high-quality amplifier tosense and scale the signal before converting it to digitalform.

MEMORY USAGETABLE 2: SOFTWARE MEMORY USAGE

Program Memory File Registers Data EEPROM

1399 Words 28 Bytes 0 Bytes


APPENDIX A: SCHEMATIC OF EXHAUST GAS AND CYLINDER HEAD TEMPERATURE MONITORING DEVICE

R3

R2

R1

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R12R8

R13

R9

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D2

Out

3Vs

sU

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1P1

3P3

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1 2 3 4 65

J3

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+5V

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R18

Gai

n =

160

J Th

erm

ocou

ple

Cha

nnel

Gai

n =

240

K Th

erm

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ple

Cha

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R19

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R17

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1 3 2

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1-

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RA5

/MC

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RA0

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RA1

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11

RA2

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22

RA3

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RA4

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J2

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R6

C1

C2

R10

C3

R11

R7

C4

C6C11

GndGnd

24

3

C12

C13

C14

C15

C18

C16

C17

C10

C8C9

C7

R14

C5

R15

U1:

MC

P619

U2:

TC

1046

Tem

pera

ture

Sen

sor

U3:

PIC

16F6

28U

4: M

AX23

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5: L

M29

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6: M

CP3

004

C11

= 4

7 F

C12

= 1

F

C16

, C17

= 1

00 p

FC

7, C

8, C

9, C

10, C

13, C

14, C

15, C

16 =

0.1

F

C1,

C2,

C3,

C4,

C5

= 0.

01

FR

1, R

2, R

3, R

4 =

10 k

R5,

R6,

R7,

R16

= 1

00 k

R8,

R11

, R12

, R15

, R19

= 1

kR

9, R

10 =

24

kR

13, R

14 =

16

kR

17, R

18 =

470

U6

PAR

TS L

IST:

Isot

herm

alAr

ea

J1: S

crew

Ter

min

al B

lock

J2: D

B9 F

emal

eJ3

: RJ1

1 6

Pin

Jack

J4: 5

mm

Coa

xial

Jac

kY

1 =

6 M

Hz

Res

onat

or w

/cap

s


REFERENCESApplication Note AN684Omega Temperature Sensing Handbook


APPENDIX B: REVISION HISTORY

Revision B (December 2020)Added the MCP9600 and MCP9601 family on page 1;applied editorial updates throughout the document.

Revision A (2002)Initial release of this document.


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