Transcat Webinar: How to Calibrate Sanitary Sensors

Fluke Calibration

Web Seminar Series

Principles and practical tips

about temperature, humidity, electrical,

flow, pressure, and RF calibration

How to Calibrate Sanitary

Temperature Sensors and

Transmitters

© 2017 Fluke Corporation

How to Calibrate Sanitary Temperature Sensors and Transmitters

Pharmaceutical, biotechnology, and food processing companies utilize many tri-clamp and sanitary sensors in

their process manufacturing. These sensors require periodic calibration which halts production. The new Fluke

Calibration 6109A and 7109A Portable Calibration Baths are clean room compatible and calibrate four times

more sanitary sensors per batch with twice the accuracy of other baths in their class, speeding the calibration

process to get plants back on line quickly.

Attend this free webinar where we’ll describe how these new portable calibration baths improve calibration

throughput of tri-clamp, sanitary sensors and temperature transmitters.

Today’s Webinar

Your Presenter

• Fluke Calibration

– Electrical (Everett, WA)

– RF (Norwich, UK)

– Temperature (American Fork, UT)

– Pressure/Flow (Phoenix, AZ)

Fluke Calibration, Temperature, American Fork, UT

• Presenter: Michael Coleman

– Fluke Corporate Temperature Metrologist

• With Fluke/Hart Scientific 19 years

– Primary Temperature Calibration Lab

– TCAL Service Department

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)

Four 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.

• Calibration traceability: Calibrating the transmitter only, while not calibrating the sensor,

breaks the path of traceability. Sensor drift can account for as much as 70% of system

tolerance

Temperature Sources for

Sanitary Sensor Calibration

• Dry-block calibrators: Typically use a special kit or liquid bath mode to improve

stability/uniformity for sanitary sensor calibration. Limited to one tri-clamp or small

batch of sensors at a time.

• Circulating 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 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.

– NEW 6109A/7109A Portable Calibration Baths: Designed for calibrating sanitary

sensors in clean room production areas.

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]

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

Easy to transport up stairs and across catwalks

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

1. Sensor connected to the control system display

(loop/system)

Insert sensors into a calibration bath

Calibrate the control system display and sensor

together

Advantages:

Calibrates the whole system (loop) display and

sensor

Faster since sensors don’t need to be disconnected

from system and calibrated separately

Maintains full traceability

Disadvantages:

Errors with the sensor and/or transmitter may go

undetected

2. Sensor separated from control system display

Disconnect sensor and transmitter from the control

system

Calibrate in a calibration bath - measure sensor with a

readout and measure transmitter with 4-20 mA

calibrator

Advantages:

Errors with the sensor and transmitter are identified

in calibration

Maintains full traceability

Disadvantages:

Slower than leaving sensor/transmitter connected to

the system

No “system” verification

Two Methods for Calibrating

Sanitary Sensors

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 automatically ramp to the next two setpoints, 70 and 140 °C.

Complete the same steps at the other two temperatures

Step 5. Analyze the results.

Adjust the controller and repeat these steps if necessary



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.

Note: The 6109A/7109A –P option can measure one DUT sensor at a time. For multiple DUT sensors use the 1586A as described here

Reference

Probe

Tri-clamp

sensor with

transmitter

1586A Super-DAQ Precision

Temperature Scanner

7109A Portable

Calibration Bath


Separated from the Control System

7109A-P Portable BathWith –P (process electronics)

option

7109A-P Process Input Module1. Current fuse

2. RTD terminals

3. Reference PRT connector

4. Thermocouple input

5. Transmitter terminals

Steps Continued:

4. Connect the transmitter to the

7109A –P option 4-20 mA

circuit



Steps Continued:

5. Configure the setpoints in the 1586A.

– Configurations can be named and stored in memory for quick recall and consistency

6. Turn on 4-20 mA loop power in the 7109A

7. Start the test

– The 1586A controls the 6109A/7109A to move through the setpoints



Steps Continued:

8. Collect and analyze sensor 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 date/time stamp

9. Collect the transmitter data and compare with the reference readings



Other Applications

• The large tank space and excellent specifications make the

6109A/7109A a useful multi-purpose calibration solution

– Thermocouple wire testing

– Temperature sensor validation

– PRT characterization heat source (system uncertainty as good

as ≈ 0.03 °C including readout, reference probe, and bath

uncertainties)

– Integrated (sensor and readout attached) thermometer

calibration

– Tank size accommodates other sensor styles with a large

measurement head or odd sensor shape

©2016 Fluke Calibration

Other Recommendations

• Will work with many conventional bath fluids but Fluke calibration

recommends 200.10 silicone oil for the 7109A and 200.50 oil for the

6109A

• When working at freezing temperature setpoints (<0 °C), use the access

cover to prevent ice build-up

• Specifications are applicable with the tank access cover removed (see

spec tables for details) but performance in general can be improved with

the lid installed

• The unit can be transported with the fluid installed. Ensure the transport

cover is installed and overflow port plug is installed


Questions or Comments?

Email Nicole VanWert-Quinzi

[email protected]

Transcat: 800-800-5001

www.Transcat.com

For related product information, go to:

www.Transcat.com/Fluke

mailto:[email protected]

http://www.transcat.com/

http://www.transcat.com/Fluke

2017 Temperature Calibration Classes

Instructor-led Training

• Advanced Topics in Temperature Metrology, Sep 18-20

• Infrared Calibration, Sep 21-22

• Practical Temperature Calibration, Nov 7-9

• Installation and Training Supplemental Services

(courses scheduled on-demand)

Additional Resources

Free for download from Flukecal.com

• “6109A/7109A Portable Calibration Baths Operators Manual”

• “Automated Temperature Sensor Calibration with the 1586A Super-

DAQ” Application Note, 6002875A

• “Temperature Calibration Applications and Solutions” Brochure,

6005929A

Models and Accessories

7109A-P6109A-P6109A 7109A

7109-2080

Fluid Expansion

Overflow Tank

7109-2051

Single Probe

Clamp Kit

7109-2027

Adjustable Probe

Holding Fixture

7109-2013-1

Transport Cover

7109-2013-2

Probe Access Cover

7109-CASE

Carrying Case

6109A or 7109A Portable Calibration Bath

Mains power cord

USB cable

Probe access cover

Transport tank cover

Printed safety information

Product CD

Report of calibration with label

Clamp-on ferrite (-P models)

DIN connector (-P models)

Test lead kit (-P models)

What’s in the 6109A/7109A Box

Ordering Information

6109A / 7109A Features

6109A / 7109A Specifications

• Measures – Thermocouples

– RTDs/PRTs

– Thermistors

– DCV

– DCI

– Resistance

• Scan speed of up to 10 channels per second

• Best-in-class temperature measurement accuracy:– PRTs: ± 0.005 ºC

– Thermistors: ± 0.002 ºC

– Thermocouples: ± 0.3 ºC (internal CJC)

1586A Super-DAQ

Precision Temperature Scanner

1586A Super-DAQ (overview cont.)

Up to a total of 45 isolated inputs

o One 4-wire front panel reference input

o Up to two internal “High-Capacity” modules (20

channels +2 DCI channels)

o Optional external “DAQ-STAQ” module with 10

four-wire mini-DWF connectors and 20 mini-jack

thermocouple connectors

Records up to 20 MB of data to internal memory or

directly to a USB flash drive

Controls Fluke drywells/baths for automated

calibration routines

20 on-board math channels

Real-time color trending—chart up to four channels

simultaneously

Built-in data security levels for regulated industries

Internal High-Capacity

Module

External DAQ-STAQ

Multiplexer

1586A Super-DAQ

Transcat Webinar: How to Calibrate Sanitary Sensors

Engineering

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