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What is a thermocouple

A thermocouples is a temperature sensors that measure temperature by generating a small voltage signal proportional to the temperature difference between the junctions of two dissimilar metals. One junction (the hot junction) is typically encased in a sensor probe at the point of measurement; the other junction (the cold junction) is connected to the measuring instrument. The measurement instrument measures the voltage signal and the cold junction temperature then computes the temperature.

Precautions and considerations for using thermocouples
Most measurement problems and errors with thermocouples are due to a lack of understanding of how thermocouples work. Listed below are some of the common problems.

Connection problems: Many measurement errors are caused by unintentional thermocouple junctions. Remember that any junction of two different metals will cause a junction. If you need to increase the length of wires from your thermocouple, you must use the correct type of thermocouple extension wire. Using the wrong wire will introduce a thermocouple junction. Any connectors used must be made from the correct thermocouple material and correct polarity must be observed.

Lead Resistance: To minimize thermal shunting and improve response time, thermocouples are made from thinner wire. Remember that thinner wire will cause high resistance which can make it sensitive to noise and can cause errors due to the input impedance of the measuring intrument. Using twisted or shielded thermocouple wires will help to reduced the noises.

Thermocouple Type: Select the correct type of calibration will help to extend the life of any temperature sensors.

Insulations Type: Choice the correct insulations for the correct working temperature and to suit that environment will extend the life of the sensors.

Elements Protecting Sheath
Remember when ordering thermocouple probes, that the thicker the sheath or insulated material the slower the respond time.
If possible used grounded thermocouple for larger diameter protection tubing.

Temperature Probe Sensors Head Mounted Type
Rtds Pt100 Pt1000 Platinum Thin Film Elements
 
Rtd Probe with Compression Fitting
 

Thermocouple Junctions

Basically, they are 3 junction types, grounded, ungrounded and exposed. For grounded thermocouples it has a metal sheath and the thermocouple wires are welded to the casing. Usually, it is done with a tig welding machine, but it can be done by soldering the wires. However, it may cause contamination to the thermocouple wires.

Usually, grounded thermocouples are not filled with MgO power unless it is intended for higher temperature applications. Alternatively, to mineral insulated thermocouples, the wires can be insulated with ceramic insulators for high temperature applications.

Why grounded thermocouples? Grounded thermocouple temperature sensors are widely used, because it offer faster respond time, more accurate reading at short distant. It is a preferred junction type for high temperature applications. Precaution for ground loop at long distances and at low temperature usage.

Why ungrounded Thermocouples? Ungrounded thermocouples are used primarily for isolating the control system from the sensor and to prevent ground loop. It is more inaccurate and slow respond time.

Exposed Junction, offer the fastest respond time. It is not intended for pressurized or corrosive environments.

Thermocouple Types

Type K --- Chromel ( Nickel-Chromium Alloy ) / Alumel ( Nickel-Aluminium Alloy )
This is the most commomly used "general purpose" thermocouples. They are available in the ~ -200 °C to +1200 °C range. The characteristic of the thermocouple undergoes a step change when a magnetic material reaches its Curie point. This occurs for this thermocouple at ~ 352°C. Sensitivity is ~ 41 µV/°C. Type K and N are the most oxidation resistant base metal thermocouples. Not recommended for temperature of 1200C for long period.


Type J --- Iron / Constantan

Limited range (~ -40 to +750 °C) makes type J less popular than type K. The main application is with old equipment that cannot accept modern thermocouples. J types cannot be used above 760 °C as an abrupt magnetic transformation causes permanent decalibration. The magnetic properties also prevent use in some applications. Type J's have a sensitivity of ~ 53µV/°C. Not recommended for temperature higher than 480C because of the higher oxidation rate of the iron element.

Type T --- Copper / Constantan
Good for temperature in the ~ -200 to 350 °C range. Non-magnetic, type T thermocouples are a popular choice for strong magnetic fields and subzero environments. Type T thermocouples have a sensitivity of ~ 43 µV/°C. Most accurate base-metal thermocouple. Can be used in vacuum and in oxidizing, reducing, or inert atmospheres.

Type E --- Chromel / Constantan ( Copper-Nickel Alloy )
Type E has a high output ~ 68µV/°C which makes it well suited to cryogenic use. It is also non-magnetic. Recommended for use up to 870C in oxidizing or inert atmospheres.

Type N --- Nicrosil (Nickel-Chromium - Silicon Alloy) / Nisil (Nicke l- Silicon Alloy)
High stability and resistance to high temperature oxidation makes type N suitable for high temperature measurements without the cost of platinum (B, R, S) types. They can withstand temperatures above ~1200 °C. Sensitivity ~ 38 µV/°C at 900°C.

Thermocouple types R, S and B are all noble metal thermocouples and exhibit similar characteristics. They are the most stable of all thermocouples, but due to their low sensitivity ~ 10 µV/°C they are usually used for high temperature measurement (>300 °C).

Type B --- Platinum 30% Rhodium / Platinum 6% Rhodium
Good for high temperature measurements up to ~ 1800 °C. Type B thermocouples (due to the shape of their temperature to voltage curve) give the same output at 0 °C and 42 °C. This makes them useless below 50°C.

Type C --- Tungsten 5% Rhenium / Tungsten 26% Rhenium
Good for temperature ~ 35 to 4200°F. This thermocouple is well suited for vacuum furnaces at extremely high temperatures and must never be used in the presence of oxygen at temperatures above 500°F.

Type R --- Platinum 13% Rhodium / Platinum
Good for high temperature up to ~1600 °C. Low sensitivity ~10 µV/°C and high cost makes them unsuitable for general purpose use.

Type S --- Platinum 10% Rhodium / Platinum
Good for high temperature measurements up to 1600 °C. Low sensitivity ~10 µV/°C and high cost makes them unsuitable for general purpose use. Due to its high stability, type S is used as the standard of calibration for the melting point of gold (1064.43 °C).

Type M --- Nickel Alloy 19 / Nickel-Molybdenum Alloy 20
This type is used in the vacuum furnaces as well for the same reasons as with type C above. Upper temperature is limited to 2490°F.

Thermocouple Cable
E 601-81(1997)..Test Method for Comparing EMF Stability of Single-Element Base-Metal Thermocouples Materials in Air
E 608/E 608M-00. Standard Specification for Mineral-Insulated, Metal-Sheathed Base-Metal Thermocouples
E 696-00 Standard Specification for Tungsten-Rhenium Alloy Thermocouple Wire
E 710-86(1997) Standard Test Method for Comparing EMF Stabilities of Base-Metal Thermo elements in Air Using Dual, Simultaneous, Thermal-EMF Indicators
E 780-92(1998) Standard Test Method for Measuring the Insulation Resistance of Sheathed Thermocouple Material at Room Temperature
E 839-96 Standard Test Method for Sheathed Thermocouples and Sheathed Thermocouple Material
E 988-96(2002) Standard Temperature-Electromotive Force (EMF) Tables for Tungsten-Rheniu

Applications
E 452-02..Test Method for Calibration of Refractory Metal Thermocouples Using a Radiation Thermometer
E 574-00..Specification for Duplex, Base-Metal Thermocouple Wire with Glass Fiber or Silica Fiber Insulation
E 585/E 585M-01a ..Standard Specification for Compacted Mineral-Insulated, Metal-Sheathed, Base Metal

Thermocouples
E1129/E1129M-98 Standard Specification for Thermocouple Connectors
E 1159-98 Standard Specification for Thermocouple Materials, Platinum-Rhodium Alloys and Platinum
E 1350-97(2001) Standard Test Methods for Testing Sheathed Thermocouples Prior to, During and After Installation
E 1652-00 Standard Specification for Magnesium Oxide and Aluminum Oxide Powder and Crushable Insulators Used in the Manufacture of Metal-Sheathed Platinum Resistance Thermometers, Base Metal Thermocouples, and Noble Metal Thermocouples
E 1684-00 Standard Specification for Miniature Thermocouple Connectors
E 1751-00 Standard Guide for Temperature Electromotive Force (emf) Tables for Non-Letter Designated Thermocouple Combinations
E 2181/E 2181M-01 Standard Specification for Compacted Mineral-Insulated, Metal-Sheathed, Noble Metal Thermocouples and Thermocouple Cable.

ASTM Standards Related to Thermocouples
E 207-00...Method of Thermal EMF Test of Single Thermo element Materials by Comparison with a Secondary Standard of Similar EMF-Temperature Properties
E 220-02 Standard Test Method for Calibration of Thermocouples By Comparison Techniques
E 230-98e1..Temperature Electromotive Force (EMF) Tables for Standardized Thermocouples
E 235-88(1996)e1..Specification for Thermocouples, Sheathed, Type K, for Nuclear or Other High-Reliability

Note: Important information should always be double checked with alternative sources.

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