Using a Portable Bath to Improve Calibration of Sanitary RTD's and Transmitters by Fluke Calibration

Fluke Calibration
Web Seminar Series
Principles and practical tips
about temperature, humidity, electrical,
flow, pressure, and RF calibration
How to Use a Portable Bath to
Improve Sanitary Temperature
Sensor and Transmitter
Calibration
© 2017 Fluke Corporation

How to Use a Portable Bath to Improve Sanitary Temperature
Sensor and Transmitter Calibration
May 10, 2017
Dry-block calibrators are easy to transport for on-site sensor calibration, but not as accurate as baths.
Compact calibration baths are more accurate than dry-blocks, but are limited to lab use due to size. Portable
baths give you the benefits of both -- dry-block portability plus bath accuracy.
Attend this free webinar where we’ll describe how the Fluke Calibration 6019A and 7109A Portable Calibration
Baths can improve the calibration throughput and accuracy of sanitary temperature sensors and transmitters.
Since production downtime can be costly, increasing sensor calibration throughput is critical.
Today’s Webinar

Fluke – American Fork, UT
Travis Porter
21 Years with Fluke Calibration (production, customer service, technical support)
Currently;
Inside Sales Account Manager
Travis.Porter@flukecal.com
Phone: 425-446-6351

Introduction
©2016 Fluke Calibration
There are several temperature source options
available for calibrating RTDs (resistance temperature
device) and transmitters on-site
 Calibration baths
 Best uncertainties
 Slow temperature transition
 Difficult to transport
 Fluids can be messy and difficult to cover entire
range
 Dry-block calibrators
 Fast, portable, clean (no fluids)
 Don’t accommodate many sensor sizes and shapes
 Larger uncertainties
 Portable calibration baths
 Excellent specifications
 Sensor size/shape compatibility
 Portable and fast temperature transition
 Can be equipped with process electronics features
 Fluids can be messy and difficult to cover entire
range

On-Site Temperature Calibration
• On-site – calibration work is done at the DUT (device under
test) location to minimize down time and to calibrate the
measurement loop
• Industrial temperature measurement systems
– DUT sensor (RTD, thermocouple) – resistance or voltage sensor that
measures the process temperature
– DUT transmitter head – measures and transmits sensor readings to
control room using 4-20 mA current loop
– Other – PLC (programmable logic controller) systems, ovens,
chambers, furnaces
• Calibrate the RTD and transmitter as a system (connected) or
separately
– RTDs can degrade and drift with use – don’t rely solely on simulation
– In most cases the sensor is placed in a temperature source to
calibrate a range of temperatures

Other On-Site Considerations
• Sanitary conditions – clean rooms,
medical device manufacturing,
pharmaceutical
• Explosive atmosphere – refineries,
oil/gas plants, intrinsically safe
equipment requirements
• Non-instrument friendly
environment – heat, cold, water,
vibration, chemical exposure
• Access – ladders, cat walks,
outdoors, transport in trucks

On-Site Sensor Shapes and Sizes

Sanitary Temperature Sensors
 Used in a number of process manufacturing industries
 Very common in pharmaceutical and biotechnology
clean room production
 They come in a variety of shapes and sizes
 Tri-clamp
 Short
 Odd geometries
 Integrated with transmitters
Examples of tri-clamp sanitary sensors
Examples of short, odd geometry sanitary sensors
and temperature sanitary transmitters

What is a Tri-Clamp Sensor?
• “Tri-clamp” refers to the mechanical housing of
a temperature sensor used in process
manufacturing where a liquid seal is required
• A tri-clamp sensor includes a stainless steel
(SST) flange ranging from ½-in to 3-in
diameter that clamps to a pipe ferrule creating
a seal
SST
Flange
Transmitter
housing

Tri-Clamp Sensor Photos
Tri-clamp sensor (side view) Tri-clamp sensor (bottom view)

Three Important Factors for
Good Sanitary Sensor Calibration
• Temperature source accuracy (bath or dry-block calibrator): Accuracy needs to
cover all sources of error including calibration uncertainty, stability, uniformity, and
repeatability. Use the most accurate source available to get the best calibration results.
• Immersion depth: Sanitary sensors need to be immersed to a proper depth in the
source to minimize the effects of temperature gradients and stem conduction.
• Calibration throughput: Calibrating more than one tri-clamp sensor or a batch of
sanitary RTDs and temperature transmitters at a time improves technician productivity.
That leads to shorter calibration time and getting production back on line quicker.
Short sensor can’t reach
full immersion in a dry-
block calibrator

Sanitary Sensor Immersion Depth
• Tri-clamp sensors vary in length and diameter
• The tank diameter of Fluke Micro-Baths (6102/7102/7103) or
a dry-block with liquid insert may not be large enough to
accommodate a tri-clamp sensor 51 mm (2 in) diameter or
bigger and a reference thermometer
• Best to immerse the tri-clamp sensor and flange in the bath
fluid during calibration
• For best results with a 6109A/7109A bath, position the
sensor tip 15 mm (0.6 in) above the bottom of the tank
Example Tri-Clamp Sensor
6109A/7109A baths with four tri-
clamp sensors and reference probe
mounted in Probe Holding Fixture

Temperature Sources for
Sanitary Sensor Calibration
• Dry-block calibrators: Block/insert size limits capacity to one tri-clamp sensor. May
not be able to get full insertion due to flange and short sensor length
• Circulating calibration baths: Sometimes used because of large working area – but
not designed for calibration. Stability/uniformity specs typically not provided and are
usually not very good.
• Fluke portable calibration baths:
– 6102/7102/7103 Micro-Baths: Good ± 0.25 °C accuracy. Working area limited to one tri-
clamp or small batch of sensors at a time.
– 6109A/7109A Portable Calibration Baths: Designed for calibrating sanitary sensors in
clean room production areas, capacity of four sensors

6109A / 7109A Portable Calibration Baths
Calibrate four tri-clamp sanitary
sensors at a time!
7109A6109A
Four times more calibration throughput
Much better accuracy than micro-baths and dry-block
calibrators
 Calibrate up to four tri-clamp sanitary sensors, or a batch of sanitary
RTDs and temperature transmitters, at the same time
 Wide temperature range covers most clean process applications:
6109A: 35 °C to 250 °C
7109A: –25 °C to 140 °C
 Excellent display accuracy of ±0.1 °C
[Accuracy covers all sources of error including calibration uncertainty, stability, uniformity, and repeatability]
 Excellent uniformity (0.02 °C) and stability (0.01 °C) to use with an
external reference
 Perfect for clean room use -- Stainless steel panels and tank
withstand harsh sterilizing chemicals and are rust proof; Made from
materials that don’t harbor bacteria

Two Methods for Calibrating Sanitary Sensors
1. Connected to the control system
 Unmount sensors from clamp and immerse in bath
 When sensors have stabilized, record the bath
temperature and the control room display temperature
 Advantages: Calibrates the whole system (loop).
Faster since sensors don’t need to be disconnected
from system.
 Disadvantages: May require two people to record data.
Errors with the sensors and/or transmitters may go
undetected.
2. Disconnected from the control system
 Place sensors in the bath and disconnect cable from
the transmitter
 Connect the sensors to a readout such as a 1586A
Super-DAQ (to calibrate multiple).
 When sensors have stabilized, record the bath
temperature and the sensor temperature displayed on
the 1586A Super-DAQ
 Calibrate the transmitter with the 4-20 mA
6109A/7109A 4-20 mA circuit
 Advantages: Requires only one person to record data.
Errors with sensors and transmitters are identified in
calibration.
 Disadvantages: Slower than leaving sensors
connected to the system. Not all data is in temperature
units

Example using a 7109A Portable Calibration
Bath to calibrate four tri-clamp sensors at a
time
The 7109 bath has a temperature range of
-25 to 140 °C
The tri-clamp sensors will be calibrated at
three temperature points: 0, 70, and 140 °C
Method 1: Calibrate Sanitary Sensors
Connected to the Control System (Loop)

Step 1: Immerse the
sensors in the bath fluid
Use the Adjustable Probe
Holding Fixture to hold up to four
tri-clamp temperature sensors
The fixture fits inside the tank
opening. The height of the
platform can be adjusted.
Immerse the tri-clamp sensors
with the flanges below the
surface of the bath fluid.
Adjustable Probe
Holding Fixture
Four tri-clamp
sensors mounted in
7109A bath tank

Step 2: Select the Setpoint
Temperatures
Push the “Program” button on the control
display.
In Program mode, you can define a
program with several setpoint
temperatures. See the Operators Manual
for details on programming setpoints.
For this example, we’ll assume a
“Program 1” with three setpoint
temperatures (0, 70, and 140 °C) and a
dwell time of 20 minutes at each setpoint.
7109A Display

Step 3: Run the Program
To run a program, push the
“Program” key, select “Program 1”,
and run. The bath will begin cooling
from room temperature to 0 °C
which is the first setpoint.
The display shows bath and
setpoint temperatures.
The upper right corner of the display
includes a Control Indicator and
Heating or Cooling Status.
7109A Display

Step 3. Run the Program
Continued
To view the bath temperature over
time, select the “Monitor” button and
F2 “View Graph”. The graph scales
automatically to best fit the data.
The Control Indicator will show
stable when the bath fluid is at the
setpoint and ready for temperature
measurement.
A Ready Indicator on the top of the
bath also changes from amber to
green when the bath is at setpoint.
Ready Indicator
Control Indicator

Step 4. Record the Data
When the bath is at setpoint, record the
bath temperature value and the sensor
readings in the control room.
Depending on the distance between the
bath and the control room, you may
need another person to help record data.
Then the bath will ramp to the next two
setpoints, 70 and 140 °C.
Complete the same steps at the other
two temperatures

Steps:
1. Connect the 1586A Super-DAQ to the
7109A bath with the data cable
2. Insert a reference probe and the tri-
clamp sensors to be tested into the 7109A
bath.
3. Connect the reference probe and
sensors to the 1586A. Enable the
channels they are connected to.
Disconnected from the Control System
Reference
Probe
Tri-clamp
Sensors
1586A Super-DAQ Precision
Temperature Scanner
7109A Portable
Calibration Bath

Steps Continued:
4. All setup is done from the
1586A. Setup measurements
and test points.
– Configurations can be named
and stored in memory for quick
recall and consistency
5. Start the test
– Several options to monitor
progress
Disconnected from the Control System

Steps Continued:
6. Collect and analyze data
• Files stored in CSV format,
easily read by Excel or other
analysis or reporting tools
• Two files stored with each test
– Setup.csv – records all
configuration details
– Data.csv – all measurement
data with time tag
Isolated from the Control System

Method 2: Calibrate Temperature Transmitter
 Temperature transmitters have a sensing
device such as an RTD or thermocouple
and a transmitter to read and relay the
signal to the control system
 All sensors, including RTDs, drift with time
 Testing the transmitter with the sensing
device is a good practice to ensure the
overall effectiveness of the temperature
transmitter in a process system
Example of Temperature
Transmitter

 Let’s demonstrate how to do a loop calibration of a
temperature transmitter with a 7109A-P Portable
Calibration Bath
 The 7109A-P model with Process Electronics includes
a panel for connecting a Reference Probe and
terminals for measuring and powering a 4-20 mA
transmitter
7109A-P Portable Bath
-25 to 140 °C
7109A-P Process Input Module
1. Current fuse
2. RTD terminals
3. Reference PRT connector
4. Thermocouple input
5. Transmitter terminals

Steps:
1. Isolate the temperature transmitter
from the process.
2. Immerse a Reference Probe into
the 7109A bath so tip is 15 mm
from bottom of bath.
3. Immerse the transmitter sensor in
the bath allowing fluid to cover the
flange.
Immerse Reference Probe and
Temperature Transmitter
Tip: a rule of thumb for reference probe immersion depth
is 20 times the diameter of the sheath, plus length of the
sensor

7109A-P Process Input Module
Steps Continued:
4. Connect the Reference
Probe to the Reference PRT
connector of the Process Input
Module.
5. Connect the 4-20 mA circuit
of the transmitter to the
Transmitter Terminals of the
Process Input Module.
Reference
Probe
Temperature
Transmitter

Steps Continued:
6. Turn on loop power from the
7109A bath.
7. Adjust the bath temperature to
each of the test points.
8. At each test point, record the
reading of the Reference Probe and
the transmitter output to determine if
adjustment is required.

Other Applications for 6109A/7109A
• Ideal calibration bath for a lab to get started with
– Great specs, 17025 / NVLAP accredited calibration
– Small size
– Flexible (in lab use, on-site use, etc.)
• Calibrate PRTs, thermistors, thermocouples in the laboratory or
calibration shop
• Calibrate digital thermometer systems (readout and probe connected)
• Interface with 1586A readout system and high-quality PRT for improved
uncertainties and process throughput

6109A and 7109A Specifications

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Questions?

Proprietary - Company Confidential ©2018 FLIR Systems Inc. Information and equipment described herein
may require US Government authorization for export purposes. Diversion contrary to US law is prohibited.
Questions or Comments?
Email Christina Spearman cspearman@transcat.com
Transcat: 800-828-1470
www.transcat.com
For related product information, go to:
https://www.transcat.com/brand/fluke-calibration

Using a Portable Bath to Improve Calibration of Sanitary RTD's and Transmitters by Fluke Calibration

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Using a Portable Bath to Improve Calibration of Sanitary RTD's and Transmitters by Fluke Calibration