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Low Resistance Measurement Handbook

Valhalla Scientific is a technology leading manufacturer of precision electronic measurement and calibration instrumentation. This part of our website discussion is focused on resistance measurement.
Low Resistance Figure 1
Kelvin 4-Wire Error Compensation

The diagram above illustrates how the 4-wire principle is used to eliminate lead and contact resistances as potential error sources. Errors normally caused by test lead and contact resistance are eliminated by use of 4-terminal configuration on all Valhalla Digital Ohmmeters. In many applications the contact resistance can exceed the value of the load by several orders of magnitude. Valhalla ohmmeters by-pass this potential error source by providing two terminals for a high input impedance voltage measurement. The result is a fast, accurate resistance measurement of the load, independent of the resistance in the current carrying leads. The internal current source inherently overcomes all series resistance (within compliance voltage limits) and delivers stable constant current. The high impedance DVM senses the voltage dropped across the load. There is no contact and lead resistance error created by the voltage measurement because there is essentially no current flow in the voltage sense leads. All ohmmeter probes, clips and cable accessories offered by Valhalla are 4-wire Kelvin configured.

Digital Ohmmeters

Valhalla's line of Digital Ohmmeters have been designed to tackle a wide variety of tough resistance measurement applications. At the heart of each unit lies Valhalla's patented constant current technology. Combining this ultra-stable constant current source with a 4½ digit integrating A/D converter provides for a low noise, fast responding, 4 terminal resistance measurement. LSI construction minimizes parts count while 100% burn-in insures maximum reliability.

Long term accuracy is achieved by use of highly stable semiconductor reference elements and precision, aged, stabilized resistors in the accuracy determining portions of the instrument. You can count on accurate measurements for longer time periods and big savings in calibration costs.

ATC-Automatic Temperature Compensation

Available on Models 4100ATC and 4150ATC and 4300B, this feature simulates a constant ambient temperature chamber for materials which are normally subject to varying ambient temperatures. When in the ATC mode, the temperature sensor automatically senses the ambient temperature and compensates the reading to indicate what the actual resistance value should be in a controlled 20°C environment. Materials such as copper and aluminum will exhibit approximately a 4% change in resistance for a 10°C change in temperature.

Prior to Valhalla's introduction of the Automatic Temperature Compensation in 1972 users were required to note ambient temperatures and manually correct readings back to a predetermined referenced temperature (usually 20°C). This tedious, time consuming and error prone process is totally eliminated through the implementation of Valhalla's ATC feature. Without temperature compensation, materials can easily be erroneously classified during the process of acceptance testing. Valhalla uses 3931 ppm/°C and 4030 ppm/°C for copper and aluminum respectively, referenced to 20°C. Other material coefficient and reference temperatures are available on special order.

GPIB, RS232C, & Centronics I/O Capabilities

Valhalla now optionally offers a series of microprocessor based "smart interfaces" for a variety of sample tracking applications. For ISO 9000 customers all Valhalla "smart interfaces" use an onboard real time clock feature (user selectable) to time date stamp the resistance printout, increment the test sample number along with a statistical sample summary report including standard deviation, and mean value. Custom resistance printouts (i.e. Test Name ) are available at no extra charge, contact the Valhalla sales Department for specifics. The GPIB talker interface offers a high speed rate of 12 readings per second. GPIB, RS232C, or Centronics parallel printer interfaces are now available on the 4100ATC, 4150ATC, 4165 and 4014 Ohmmeters. Each of these instruments and also the 4314, 4020, 4300B (GPIB and BCD only) have an optional BCD (binary coded decimal) interface, for HI-LOW limit comparator sorting applications.

The BCD data output option permits the digital ohmmeter to be used in conjunction with a printer, data logger or data acquisition system. When used with our model 1248 Dual Limit Digital Comparator, a high speed "GO/NO-GO" test system can be set up for a surprisingly low cost.

Low Resistance Figure 2


Wire Gauge Resistance Index - Resistivity of Conductors

Low Resistance Figure 5



The resistance of wire is measured in ohms per thousand feet, or milliohms per foot. The resistance of wire increases linearly with its length and decreases in proportion to its cross sectional area.

It may also be useful to note the diameter of 10 AWG is 0.1019 inches, 20 AWG is 0.032 inches, and 30 AWG is 0.010 inches for solid core wire. For wire as thin as 40 AWG ( ~ 0.001 inch diameter) the resistance rises significantly. Due to the fragile nature of 40 AWG, the winding of micro-coils and minature transformers is an extremely delicate task.

Copper values are for bare wire (no coating), and increase slightly for tin coated copper. Typical resistance values for tin coated copper are 10.5 ohms/ 1000 feet for 20 AWG and 113 ohms/ 1000 feet for 30 AWG. For large gauges such as 2 AWG (tin coated) the resistance is as low as 0.18 ohms/ 1000 feet.

Low Resistance Figure 6
The "Resistivity Index Table" above is taken from a one centimeter cube of the material under test. The face to face resistance or "resistivity" for a unit cube is denoted by the Greek Letter rho (Ρ). The lowest resistivity electrical conductor is silver (1.6 µohm per cm3) with copper being the next best conductor (1.7 µohm per cm3).
Low Resistance Figure 7

As a reference tool, the following charts are included for resistance in copper wire of varying gauges.

Copper Wire Resistance Chart

Standard Copper Wire Specs Chart



Introduction-Resistance Measurement Applications
High Inductance Resistance Measurement

For low resistance inductors (i.e., utility transformers) the ability of a micro-ohmmeter to perform a valid measurement requires considerable application insight and is dependent upon several parameters. The larger the test current (10 Amps is better than 1 Amp) the easier it is to resolve a low ohm value, however there is normally an increase in settling time with large inductors. Settling times can be decreased substantially if a large compliance voltage is used with the current source circuitry of the ohmmeter.

The actual equation is as follows: Low Resistance Figure 8
Where:
  • T=Settling time in seconds
  • L=Inductance in Henries
  • I=Current in Amps
  • V=Compliance voltage of the ohmmeter current source

Charging Inductor-Boosted Compliance Mode

The Valhalla 4300B uses up to 10 amperes of test current while typical ohmmeters use only 100mA. Accuracy and measurement resolution improve with higher test currents when measuring low resistance. For rapid settling time, the 4300B charging inductor mode kicks in a high level boosted compliance >20 volts (low current models are typically 1-3 volts compliance.) The higher the ohmmeter compliance voltage the shorter the settling time when measuring inductors. Don't be mislead by a competitors 5-7 volts open circuit specification, it is not the 'compliance voltage under load'. Once the inductor is charged, the 4300B drops out of 'charging mode' and delivers a full 10 ampere output rated to 7 volts compliance under load.

Low Resistance Figure 6
4 Wire Kelvin Leads, Miniprobes and Accessories

Valhalla offers a variety of four-wire Kelvin based lead sets. The most common lead set is the "option K" , which is a Gold Copper-Tellurium Kelvin Clip with 48 " cabling terminated with dual banana posts. There is also a wide selection of four-wire spring tipped microprobes, miniprobes, and surface probes to choose from. For hook-up to larger devices the "JAWS" terminated leads (opens to 2") are also available. Please refer to the back section of this catalog for a detailed listing.

Low Level Resistance Measurement Applications

Winding resistance and shorted turns of: motors, generators, alternators, transformers, coils, solenoids, relays, and ballasts.

Bonding resistance measurement: any metal to metal connection, weld joints, crimp lug connections for cables, PCB to switch or connector integrity testing, switch gear to power lines connections, and bolted joint resistance on bus bars.

Contact resistance measurement on: switches, resistive trimmers, mating connectors, relay contacts, utility switch gear, circuit breakers.

Component testing, matching and sorting: Resistors, pots, shunts, strain gauges, I.C. substrates, thick film circuits, small motors and transformers, chokes, thermistors fuses, extruded copper wire, squibs, heating elements, printed circuit board clad resistance, plated through holes, plating thickness, plating hook resistance.

Low Resistance Figure 10
Competitive Claims of Low Ohm Resolution

When measuring 1 milliohm with 10 amps of test current the Valhalla 4300B senses a 10.000mV drop across the device. Competitive ohmmeters typically claiming equivalent low resistance ranges or resolution don't tell the whole story. For example an ohmmeter with only 100 milliamps of test current having a 1 millohm range would only sense 100.00µV drop across the same 1 milliohm device mentioned above. How does a 10.000 mV drop versus 100.00 µV drop impact the measurement? The lower level is one hundred times more susceptible to noise, and measurement errors. A 1-2µV thermal EMF offset, and 3µVolts of 60 Hz noise (i.e. fluorescent lights) are common. The result is a low current ohmmeter with several hundred counts of randomly changing readings and 5-10% error at best.



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