TEMPERATURE

48 June 1998 • In Tech

Selecting the right infrared

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Infrared temperature sensors have been success-
fully used for years in process industries for
ongoing temperature monitoring and control.
Although the technology is proven, choosing
among units with different specifications is some-
times confusing, leaving the process engineer to
rely on more traditional temperature measurement
methods (e.g., those involving contact) or on ven-
dor recommendations. Recent innovations in
infrared temperature sensor design have provided
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 radia-
tion from a target in the field of view defined by
the instrument’s optics and location. The
infrared energy is isolated and measured using
photosensitive detectors. The detectors convert

the infrared energy to an electrical signal, which
is then converted into a temperature value based
on the instrument’s internal algorithms and the
target’s emissivity (a term referring to the emit-
ting qualities of the target’s surface). Infrared or
noncontact temperature sensors are very success-
ful in measuring hot, moving, or difficult-to-
reach objects, or where contact temperature
sensors would damage the target. A block dia-
gram 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 deter-
mine other sensor specifications (e.g., ambient
temperature, display and output, and protective
accessories). Finally, ease-of-use, maintenance,
and calibration considerations may uncover hid-
den costs that will further influence the choice of
an infrared temperature sensor.
Determine temperature range
Infrared instruments are available for low-
temperature applications (from below freezing) to
high-temperature applications (over 5,000°F). In
general, the narrower the temperature range, the
better the resolution of the output signal for mon-
itoring and controlling process temperatures.
If monitoring start-up or cool-down tempera-
tures is critical, it is necessary to choose a tem-
perature sensor with a wider measurement range.
Best
Sensor
Target greater Target equal Target smaller
than spot size to spot size than spot size
TEMPERATURE
In Tech • June 1998 49
Infrared temperature sensor
Object
Optics Amplifier
Electronics
Detector
Atmosphere
This is critical in heat-treating applications, for Figure 1. The infrared temperature
example, where temperature must be held within sensor collects energy emitted from the
a specific temperature range for a period of time object based on its optics and location.
to affect a material’s metallurgical properties. Detectors measure the energy and con-
vert it into an electrical signal.
Establish target size
In infrared temperature measurement, the area
to be measured (i.e., the target) should fill the
instrument’s 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 influ-
ence the temperature reading. Conversely, if the
target is larger than the instrument’s field of view,
the instrument will not capture a temperature
variation outside the measurement area. An illus-
tration of field of view is shown in Figure 2.
To collect all the emitted radiation, single
wavelength infrared temperature sensors (i.e., Figure 2. For accurate temperature
point sensors) need a clear line of sight between measurement, the target should be
the instrument and the target. Sighting optics larger than the instrument’s field of view,
allow the user to visually sight through the instru- or spot size. If the spot size is larger
ment on the target. Some instruments have a than the target, energy emitted from the
built-in laser that pinpoints the target, which is background or surrounding objects will
especially helpful in dark areas. Two-color or ratio also be measured.
Good Incorrect
Background
 TEMPERATURE

50 June 1998 • In Tech

Figure 3. The smallest spot this instru-
ment can measure is 0.25 inch at a dis-
tance of 8 inches. It would still be possi-
ble to accurately measure from a dis-
tance of 24 inches, but the minimum
spot size would increase to 2.0 inches.
Target spot size
at focal point
Spot diameter (in)
instruments, where temperature is determined
from the ratio of the radiated energies in two sep-
arate 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 instru-
ment and the target is otherwise impossible.
Determine optical resolution
Optical resolution is specified by the D:S
ratio, which is determined by comparing the dis-
tance 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 reso-
lution, 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 high-
temperature 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
Diameter of target Distance from
spot size sensor to object
Distance: sensor to object (in)
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
instrument’s 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 material’s 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 high-
temperature 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 trans-
mission coefficients that vary according to the
wavelength and thickness of the materials.
Choosing 3.43 microns for polyethylene or poly-
propylene or 7.9 for polyester allows measure-
ment 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 man-
ufacturer can test a sample of the material to
determine the optimum spectral band to use.
If processes are run with different target mate-
rials, select an instrument with adjustable emis-
sivity. Fixed-emissivity instruments are sufficient
for some materials, especially in low-temperature

0 6 12 18 24 30
applications.

Fast response time

0.25 in @ 8 in 2.6
2.0 Infrared temperature sensors reach 95% of the
0.9 1.3 final temperature reading—a common definition
IR sensor 0.3 0.6
of response time—much faster than contact tem-
perature sensors (e.g., thermocouples). This is
particularly important when measuring moving
Spot diameter (mm)

8 15
23 32
50
or quickly heated objects. New infrared sensors
6.4 mm @ 200 mm 65 on the market have response times selectable
down to 1 millisecond. However, a fast response
0 150 300 450 600 750
time is not desirable for all applications, especial-
ly in those where a fast sensor may exceed the
Distance: sensor to object (mm) capability of existing control instruments. In
addition, when there is significant thermal lag in
Distance to spot heating a process, speed in the instrument may be
D:S =
Spot diameter unimportant.
 TEMPERATURE

In Tech • June 1998 51

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 represent-
ed 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 sen-
sor, on a remote monitor panel, or through a soft-
ware program. Sensors with a built-in display and
user interface are easy to install and set up. A sep-
arate, 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 dis-
play of the current temperature. Additional fea-
tures 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 temper-
ature data over time are also available.
Infrared smart sensors house microproces-
sors and support bidirectional, serial communi-
cations 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, electromag-
netic 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 Figure 4. Typical instrument with
accurate measurements. These accessories are avail- display.
able from most manufacturers. In choosing acces-
sories, 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 sen-
sor 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 amor-
phous material transmitting infrared radiation.
If the operator needs to see through the window,
zinc selenide or barium fluoride windows are
recommended.
 TEMPERATURE
52 June 1998 • In Tech
Figure 5. PC software provides remote tem-
perature 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, dis-
tributed systems, and robotics.
Maintainability important
The cost of an infrared sensor is usually
minor compared to the risk of process down-
time. 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 oper-
ator 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 sen-
sors contain processing capabilities at the sensing
node, if something goes wrong (e.g., a high ambi-
ent condition or failed component in the sensor),
fail-safe conditions are automatically used to pro-
tect 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 tempera-
ture sensors be recalibrated to a known tempera-
ture source at least once a year. This is required in
ISO 9001 plants where infrared temperature sen-
sors are part of the control instrumentation. Most
manufacturers offer calibration services for their
customers. Smart temperature sensors can be cal-
ibrated on-site using calibration software and a
blackbody calibration source.
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 seri-
al 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 analy-
sis 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 per-
formed according to specifications. If docu-
mentation 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 under-
standing of infrared theory and the main selec-
tion 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 con-
trol) can benefit from the latest smart sensors. A
wide variety of infrared temperature sensors on
the market today provide ongoing, accurate tem-
perature measurement, regardless of whether the
instrument is selected to replace a thermocouple
or to integrate into a multivariable process. IT