Proof read by Hazel in the elephant and Castle
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\begin{abstract}
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The PT100, or platinum wire \ohms{100} sensor is
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a wisely used industrial temperature sensor that is
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are slowly replacing the use of thermocouples in many
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a widely used industrial temperature sensor that is
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slowly replacing the use of thermocouples in many
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industrial applications below 600\oc, due to high accuracy\cite{aoe}.
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This chapter looks at the most common configuration, the
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four wire circuit, and analyses it from an FMEA perspective twice.
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Once considering single faults (cardinality constrained powerset of 1) and then again, considering the
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possibility of double simultaneous faults (cardinality constrained powerset of 2).
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possibility of double faults (cardinality constrained powerset of 2).
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The analysis is performed using Propositional Logic
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diagrasms to assist the reasoning process.
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diagrams to assist the reasoning process.
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This chapter describes taking
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the failure modes of the components, analysing the circuit using FMEA
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and producing a failure mode model for the circuit as a whole.
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Thus after the analysis the PT100 temperature sensing circuit, may be veiwed
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from an FMEA persepective as a component itsself, with a set of know failure modes.
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from an FMEA persepective as a component itself, with a set of known failure modes.
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\end{abstract}
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@ -34,10 +34,11 @@ from an FMEA persepective as a component itsself, with a set of know failure mod
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\section{Overview of PT100 four wire circuit}
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The PT100 four wire circuit consists of two resistors supplying
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a current to a third, the thermistor or PT100. By measuring volatges
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The PT100 four wire circuit consists supplies a test current vis two wires
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and returns two sense volages by the other two.
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By measuring volatges
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from sections of this circuit forming potential dividers, we can determine the
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current resistance of the platinum wire sensor. The resistance
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resistance of the platinum wire sensor. The resistance
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of this is directly related to temperature, and may be determined by
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look-up tables or a suitable polynomial expression.
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@ -53,9 +54,9 @@ look-up tables or a suitable polynomial expression.
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The voltage ranges we expect from from this three stage potential divider
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The voltage ranges we expect from this three stage potential divider
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are shown in figure \ref{fig:pt100vrange}. Note that there is
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an expected range for each reading for a given temperature span.
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an expected range for each reading, for a given temperature span.
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Note that the low reading goes down as temperature increases, and the higher reading goes up.
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For this reason the low reading will be reffered to as {\em sense-}
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and the higher as {\em sense+}.
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@ -63,7 +64,7 @@ and the higher as {\em sense+}.
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\subsection{Accuracy despite variable resistance in cables}
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For electronic and accuracy reasons a four wire circuit is preffered
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because of resistance in the cables. Resitance from the supply
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because of resistance in the cables. Resistance from the supply
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causes a slight voltage
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drop in the supply to the PT100. As no significant current
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is carried by the two `sense' lines the resistance back to the ADC
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@ -77,7 +78,7 @@ whole circuit can be measured on the PCB by reading a third
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sense voltage from one of the load resistors. Knowing the current flowing
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through the circuit
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and knowing the voltage drop over the PT100, we can calculate its
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resistance by ohms law $V=I.R$, $R=\frac{I}{V}$.
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resistance by ohms law $V=I.R$, $R=\frac{V}{I}$.
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Thus a little loss of supply current due to resistance in the cables
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does not impinge on accuracy.
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The resistance to temperature conversion is achieved
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@ -88,7 +89,7 @@ through the published PT100 tables\cite{eurothermtables}.
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This sub-section looks at the behaviour of the PT100 four wire circuit
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for the effects of component failures.
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All components have a set of known `failure modes'.
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In other words we know that a given component can fail in several distict ways.
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In other words we know that a given component can fail in several distinct ways.
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Studies have been published which list common component types
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and their sets of failure modes, often with MTTF statistics \cite{mil1991}.
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Thus for each component, an analysis is made for each of it failure modes,
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@ -109,7 +110,7 @@ Resistors according to the DOD Electronic component fault handbook
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1991, fail by either going OPEN or SHORT circuit \cite{mil1991}.
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%Should wires become disconnected these will have the same effect as
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%given resistors going open.
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For the purpose of his analyis;
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For the purpose of this analyis;
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$R_{1}$ is the \ohms{2k2} from 5V to the thermistor,
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$R_3$ is the PT100 thermistor and $R_{2}$ connects the thermistor to ground.
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@ -119,9 +120,9 @@ in the diagram we can consider this a fault.
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Should the reading be above its expected range this is a `High Fault'
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and if below a `Low Fault'.
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The Table \ref{ptfmea} plays through the scenarios of each of the resistors failing
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Table \ref{ptfmea} plays through the scenarios of each of the resistors failing
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in both SHORT and OPEN failure modes, and hypothesises an error condition in the readings.
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The range 0\oc to 300\oc will be analysed using potential divider equations to
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The range {0\oc} to {300\oc} will be analysed using potential divider equations to
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determine out of range voltage limits in section \ref{ptbounds}.
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\begin{table}[ht]
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@ -195,7 +196,7 @@ and \ref{pt100temp}.
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\subsection{Range and PT100 Calculations}
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\label{pt100temp}
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PT100 resistors are designed to
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have a resistance of ohms{100} at 0 \oc \cite{eurothermtables}.
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have a resistance of \ohms{100} at 0 \oc \cite{eurothermtables}.
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A suitable `wider than to be expected range' was considered to be {0\oc} to {300\oc}
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for a given application.
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According to the Eurotherm PT100
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@ -293,8 +294,10 @@ will detect it.
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\subsection{Single Fault Modes as PLD}
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The component~failure~modes in table \ref{ptfmea} can be represented as contours
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on a PLD diagram. Each test case, or analysis into the effects of the component failure
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caused by the component~failure is represented by an labelled asterisk.
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on a PLD diagram.
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Each test case, is defined by the contours that enclose
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it. The test cases here deal with single faults only
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and are thus enclosed by one contour each.
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\begin{figure}[h]
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@ -307,7 +310,7 @@ caused by the component~failure is represented by an labelled asterisk.
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This circuit supplies two results, sense+ and sense- voltage readings.
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To establish the valid voltage ranges for these, and knowing our
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valid tempperature range for this example ({0\oc} .. {300\oc}) we can calculate
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valid temperature range for this example ({0\oc} .. {300\oc}) we can calculate
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valid voltage reading ranges by using the standard voltage divider equation \ref{eqn:vd}
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for the circuit shown in .
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@ -324,7 +327,7 @@ With pt100 at 0\oc
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$$ highreading = 5V $$
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Since the highreading or sense+ is directly connected to the 5V rail,
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both temperature readings will be 5V..
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$$ lowreading = 5V.\frac{2k2}{2k2+68\Omega} = 4.85V$$
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$$ lowreading = 5V.\frac{2k2}{2k2+100\Omega} = 4.78V$$
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With pt100 at the high end of the temperature range 300\oc.
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$$ highreading = 5V $$
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$$ lowreading = 5V.\frac{2k2}{2k2+212.02\Omega} = 4.56V$$
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@ -339,13 +342,13 @@ therefore both readings are outside the
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proscribed range in table \ref{ptbounds}.
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\subsubsection{ TC 4 : Voltages $R_2$ SHORT }
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\subsubsection{ TC 3 : Voltages $R_2$ SHORT }
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With pt100 at -100\oc
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With pt100 at 0\oc
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$$ lowreading = 0V $$
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Since the lowreading or sense- is directly connected to the 0V rail,
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both temperature readings will be 0V.
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$$ lowreading = 5V.\frac{68\Omega}{2k2+68\Omega} = 0.15V$$
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$$ lowreading = 5V.\frac{100\Omega}{2k2+100\Omega} = 0.218V$$
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With pt100 at the high end of the temperature range 300\oc.
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$$ highreading = 5V $$
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$$ lowreading = 5V.\frac{212.02\Omega}{2k2+212.02\Omega} = 0.44V$$
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@ -353,9 +356,9 @@ $$ lowreading = 5V.\frac{212.02\Omega}{2k2+212.02\Omega} = 0.44V$$
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Thus with $R_2$ shorted both readingare outside the
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proscribed range in table \ref{ptbounds}.
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\subsubsection{ TC : 5 Voltages $R_2$ OPEN }
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\subsubsection{ TC : 4 Voltages $R_2$ OPEN }
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Here there is no potential divider operating and both sense lines
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will read 5V, outside of the proscibed range.
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will read 5V, outside of the proscribed range.
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\subsubsection{ TC 5 : Voltages $R_3$ SHORT }
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