TEMPERATURE

48

June 1998 In Tech

Selecting the right infrared

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By Karen Ackland
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Infrared temperature sensors have been successfully used for years in process industries for
ongoing temperature monitoring and control.
Although the technology is proven, choosing
among units with different specifications is sometimes confusing, leaving the process engineer to
rely on more traditional temperature measurement
methods (e.g., those involving contact) or on vendor recommendations. Recent innovations in
infrared temperature sensor design have provided

equipment?

process engineers with enhanced functionality, and

more questions about how to integrate and use
infrared temperature sensors in their process.
Infrared technology explained
An infrared temperature sensor collects radiation from a target in the field of view defined by
the instruments optics and location. The
infrared energy is isolated and measured using
photosensitive detectors. The detectors convert

TEMPERATURE

In Tech June 1998 49

the infrared energy to an electrical signal, which

is then converted into a temperature value based
on the instruments internal algorithms and the
targets emissivity (a term referring to the emitting qualities of the targets surface). Infrared or
noncontact temperature sensors are very successful in measuring hot, moving, or difficult-toreach objects, or where contact temperature
sensors would damage the target. A block diagram of an infrared temperature sensor is shown
in Figure 1.
Understanding the process application helps
determine which type of infrared temperature
sensor to use. What is the temperature range of
the target? How big is the measurement spot?
How far away is that spot from the sensor? These
are the first of several questions to ask to help find
the right temperature sensor for your application.
Environmental and operating conditions determine other sensor specifications (e.g., ambient
temperature, display and output, and protective
accessories). Finally, ease-of-use, maintenance,
and calibration considerations may uncover hidden costs that will further influence the choice of
an infrared temperature sensor.
Determine temperature range
Infrared instruments are available for lowtemperature applications (from below freezing) to
high-temperature applications (over 5,000F). In
general, the narrower the temperature range, the
better the resolution of the output signal for monitoring and controlling process temperatures.
If monitoring start-up or cool-down temperatures is critical, it is necessary to choose a temperature sensor with a wider measurement range.

Infrared temperature sensor

Object

Optics Amplifier
Electronics

Detector
Atmosphere

This is critical in heat-treating applications, for

example, where temperature must be held within
a specific temperature range for a period of time
to affect a materials metallurgical properties.
Establish target size
In infrared temperature measurement, the area
to be measured (i.e., the target) should fill the
instruments field of view. Suppliers of infrared
temperature sensors typically recommend that the
measurement target exceed the field of view by
50%. If the target is smaller than the field of view,
background objects (e.g., furnace wall) will influence the temperature reading. Conversely, if the
target is larger than the instruments field of view,
the instrument will not capture a temperature
variation outside the measurement area. An illustration of field of view is shown in Figure 2.
To collect all the emitted radiation, single
wavelength infrared temperature sensors (i.e.,
point sensors) need a clear line of sight between
the instrument and the target. Sighting optics
allow the user to visually sight through the instrument on the target. Some instruments have a
built-in laser that pinpoints the target, which is
especially helpful in dark areas. Two-color or ratio

Best

Good

Figure 1. The infrared temperature

sensor collects energy emitted from the
object based on its optics and location.
Detectors measure the energy and convert it into an electrical signal.

Figure 2. For accurate temperature

measurement, the target should be
larger than the instruments field of view,
or spot size. If the spot size is larger
than the target, energy emitted from the
background or surrounding objects will
also be measured.

Incorrect

Sensor

Target greater Target equal Target smaller

than spot size to spot size than spot size

Background

TEMPERATURE
50

June 1998 In Tech

instruments, where temperature is determined

from the ratio of the radiated energies in two separate wavelength bands, are a good choice when
targets are very small or moving in and out of the
field of view. Energy received from two-color
instruments may be attenuated up to 95% and
still provide accurate temperature measurement.
Two-piece fiber-optic units, where the cable can
snake around the obstructions, may be a good
choice if a direct line of sight between the instrument and the target is otherwise impossible.

Figure 3. The smallest spot this instrument can measure is 0.25 inch at a distance of 8 inches. It would still be possible to accurately measure from a distance of 24 inches, but the minimum
spot size would increase to 2.0 inches.

Diameter of target
spot size

Spot diameter (mm)

Spot diameter (in)

Target spot size

at focal point

IR sensor

Determine optical resolution

Optical resolution is specified by the D:S
ratio, which is determined by comparing the distance from the object to the sensor (D) with the
size (i.e., diameter) of the spot being measured
(S). For example, a 1-inch spot on a target being
measured at a distance of 10 inches has a D:S
ratio of 10:1. Infrared sensors on the market
today have D:S ratios ranging from 2:1 (low
optical resolution) to more than 300:1 (high
optical resolution). The higher the optical resolution, the more expensive the instrument optics
tend to be. The choice of D:S ratio really
depends on the size of the object to be measured
and the distance the sensor is from the target.
For example, high resolution is needed for hightemperature applications (e.g., heat treating)
where the sensor must be mounted far away
from the target but must still measure a small
spot. Optical charts help determine the target
spot size at a specific distance for fixed-focus

Distance from
sensor to object

Distance: sensor to object (in)

0

12

18

24

0.25 in @ 8 in

0.9

23

0.3

0.6

15

1.3

32

6.4 mm @ 200 mm

300

150

450

Distance: sensor to object (mm)

D:S =

Distance to spot
Spot diameter

2.0

50

600

30

2.6

65

750

instruments. An optical chart for one sensor is

shown in Figure 3.
Infrared temperature sensors are available
with both fixed- and variable-focus lenses. The
instruments focal point is the smallest spot it can
measure. On a fixed-focus instrument, there is a
single focal point at a set distance. While it is
possible to accurately measure temperature at a
distance closer to or farther from the focal point,
the spot size will be larger than at the focal point.
Variable-focus instruments have a minimum
focal point that can be adjusted to correspond to
the distance from the target.
Target material impacts measurement
The target materials emissivity and surface
characteristics determine the spectral response or
wavelength needed in a sensor. Highly reflective
metals with different alloy compositions tend to
have low or changing emissivities. Thus, the
optimum wavelength for measuring hightemperature metal is the near infrared, around
0.8 to 1 micron. Because some materials are
transparent at certain wavelengths, choose a
wavelength at which the material is opaque. For
example, 5 microns is a good choice for surface
measurement of glass. Plastic films have transmission coefficients that vary according to the
wavelength and thickness of the materials.
Choosing 3.43 microns for polyethylene or polypropylene or 7.9 for polyester allows measurement of thin films (less than 10 mils). The typical
spectral response for low-temperature applications
is 8 to 14 microns. If there is any doubt, the manufacturer can test a sample of the material to
determine the optimum spectral band to use.
If processes are run with different target materials, select an instrument with adjustable emissivity. Fixed-emissivity instruments are sufficient
for some materials, especially in low-temperature
applications.
Fast response time
Infrared temperature sensors reach 95% of the
final temperature readinga common definition
of response timemuch faster than contact temperature sensors (e.g., thermocouples). This is
particularly important when measuring moving
or quickly heated objects. New infrared sensors
on the market have response times selectable
down to 1 millisecond. However, a fast response
time is not desirable for all applications, especially in those where a fast sensor may exceed the
capability of existing control instruments. In
addition, when there is significant thermal lag in
heating a process, speed in the instrument may be
unimportant.

TEMPERATURE

In Tech June 1998

Signal-processing needs vary

Discrete processes (e.g., parts manufacturing),
as opposed to continuous processing, require
instruments with signal processing (e.g., peak or
valley hold and averaging). Peak hold may be
used, for example, to measure the temperature of
glass bottles on a conveyor belt with temperature
output fed into a controller. Without peak hold,
the temperature sensor would read the lower
temperature between the bottles and respond by
increasing the process temperature. With peak
hold, the instrument response time is set slightly
longer than the time interval between bottles so
there will always be at least one bottle represented in the temperature measurement. A sensitive
control system can be fine-tuned by averaging the
temperature output.
Ease of use is important
Infrared temperature systems should be easy
and intuitive for plant operators to use. Today,
user interfaces may be located directly on the sensor, on a remote monitor panel, or through a software program. Sensors with a built-in display and
user interface are easy to install and set up. A separate, more accessible monitor is appropriate for
ongoing temperature monitoring when sensors
are installed in hard-to-reach locations. A typical
instrument with display is shown in Figure 4.
The simplest monitors provide a remote display of the current temperature. Additional features include adjustable set points that generate
an alarm or process correction. Digital displays,
which are replacing traditional analog displays,
provide averaging and trend plotting and help
minimize operator error. LED displays are easier
to read in low light, but may be difficult to see in
bright light. Graphical displays that plot temperature data over time are also available.
Infrared smart sensors house microprocessors and support bidirectional, serial communications between a sensor on the plant floor and
a PC. Software available with smart temperature
sensors, often running on the familiar Windows
platform, makes it easy to remotely monitor
temperature data and modify sensor parameters
from the safety of the control room, as shown in
Figure 5.
Environmental considerations
Sensors are specified for performance within
certain ambient temperature ranges. Dust, gases,
or vapor can cause inaccuracies in measurement
and/or damage sensor lenses. Noise, electromagnetic fields, or vibration are other conditions that
should also be considered before installation
begins. A protective housing, air purging, and/or

water cooling can protect the sensor and ensure

accurate measurements. These accessories are available from most manufacturers. In choosing accessories, consider the cost of bringing services (e.g.,
power, air, and water) to the unit. When possible,
choose accessories that require standard services to
minimize installation costs. The manufacturer will
specify cable lengths, and all cables must be rated
for the required ambient environment.
Two-color instruments are a good choice
when smoke, dust, or other particulates degrade
the measurement signal. Fiber-optic sensors,
where the optical head is separated from the sensor electronics with a fiber-optic cable, provide a
solution around electromagnetic fields or other
harsh environments.
In applications involving hazardous materials
(e.g., vacuum chambers), the sensor is mounted
to look through a window into the enclosure.
Window materials must be able to transmit the
wavelengths used by the sensor. When specifying
window materials, it is important to determine if
the operator also needs to be able to see through
the window. For example, in low-temperature
applications, the window may make the target
invisible to the eye, since it is often made of an
opaque material such as germanium or amorphous material transmitting infrared radiation.
If the operator needs to see through the window,
zinc selenide or barium fluoride windows are
recommended.

Figure 4. Typical instrument with

display.

51

TEMPERATURE
52

June 1998 In Tech

sors are part of the control instrumentation. Most

manufacturers offer calibration services for their
customers. Smart temperature sensors can be calibrated on-site using calibration software and a
blackbody calibration source.

Figure 5. PC software provides remote temperature monitoring, sensor configuration,

and data analysis for smart infrared sensors.

Behind the byline

Karen Ackland is marketing
manager for Raytek Corporation
in Santa Cruz, Calif. She has an
M.B.A. from UCLA, and has
more than 15 years of experience
marketing technology products,
including instrumentation, distributed systems, and robotics.

Maintainability important
The cost of an infrared sensor is usually
minor compared to the risk of process downtime. A sensor is a long-term investment that,
for the most part, can be expected to provide
reliable use for 10 years or more. With this
expectation, product reliability and vendor
responsiveness become important evaluation
criteria. If a unit needs repair, what kind of
turnaround can you expect from the vendor?
What is the average cost of repair compared to
the cost of a new unit? Are spare or loaner units
available? Does the vendor provide on-site operator training? While these issues are harder to
quantify, they potentially represent expenses
beyond the cost of the unit.
The new smart sensors offer functionality that
extends the life of the sensor. Because smart sensors contain processing capabilities at the sensing
node, if something goes wrong (e.g., a high ambient condition or failed component in the sensor),
fail-safe conditions are automatically used to protect the sensor. Updates to the sensor firmware
can be downloaded from a PC without removing
the sensor or returning it to the factory for an
upgrade.
Vendors recommend that infrared temperature sensors be recalibrated to a known temperature source at least once a year. This is required in
ISO 9001 plants where infrared temperature sen-

New uses for temperature data

Infrared temperature sensors are available with
voltage, current, and digital outputs. In many
cases, the choice of output will depend on the
existing control equipment. The most common
output is the 4-20 mA current loop, which can
easily be integrated into the control environment.
When an infrared temperature sensor is replacing
a thermocouple, choose an instrument with the
appropriate thermocouple output. Many smart
infrared systems support simultaneous analog
and digital output using RS-232 or RS-485 serial communications. The analog output is usually
integrated into an existing control environment,
while the digital output is used for ongoing
analysis and quality control.
Digital output supports sophisticated analysis where temperature can be combined with
other process variables. For example, on a paper
line a process engineer may be concerned with
the temperature, moisture, and weight of the
product. In this case, the temperature data is
used as a variable in a model to optimize
process efficiency. Digital output capabilities of
smart infrared units have recently caught the
attention of quality managers who can now
capture temperature data for each product or
run. This data can be archived, graphed, or
printed to document that the job was performed according to specifications. If documentation of process temperatures is required
for IS0 9001 or other quality programs, digital
output should be considered.
Choosing an instrument is straightforward
Infrared temperature measurement is based
on field-proven technology. With a basic understanding of infrared theory and the main selection criteria, choosing an infrared instrument is
a straightforward procedure. In addition to the
key specifications, ease-of-use, installation, and
maintenance requirements help determine if the
instrument is a good match for the process. In
addition, new process requirements (e.g., ISO
9001 documentation or statistical process control) can benefit from the latest smart sensors. A
wide variety of infrared temperature sensors on
the market today provide ongoing, accurate temperature measurement, regardless of whether the
instrument is selected to replace a thermocouple
or to integrate into a multivariable process. IT