Thermocouple Wire Insulators

The dissimilar wires of a thermocouple must be insulated. Traditionally, ceramics have

been used (Fig. 8).

FIGURE 8 Thermocouple wire insulators.

Special Thermocouples

In addition to the traditional industrial thermocouples just described, there also are
surface probes and cement-on styles. Thermocouples can be drawn in metal-sheathed
form to as small as 0.25-mm (0.01-inch) OD. In wire form, 0.013-mm (0.0005-inch)
thermocouples can be made. Types K and E surface probes are commercially available.
Type E usually is preferred because of its high accuracy in most low-temperature
applications. Type K is used where high temperatures must be measured. Types J and T
are not commonly used as probes. Cement-on style thermocouples have grown in
popularity in recent years. Special fast-responding techniques include thin-foil couples
with plastic laminates for cementing directly on equipment. The full sensor is embedded
between two thin glass-reinforced, high-temperature polymer laminates that both support
and electrically insulate the foil section as well as provide a flat surface for cementing.

The polymer-glass laminate, in general, determines the maximum temperature of the

construction, which is 260C (500F) in continuous service (Fig. 9).

Thermocouple Circuit Flexibility

Normally one envisions the use of thermocouples one at a time for single temperature
measurements. As shown in Fig. 10, thermocouples may be used in parallel, in series, and
in switching and differential circuits.

FIGURE 10 Use of thermocouples in multiples. (a) Thermocouples in parallel. (b)

Thermocouples in switch circuit. Switch must be isothermal or made of the same
thermocouple alloy material. (c) Thermocouples in series (thermopile). Note: VB, VD,
and VF are negative thermoelectric voltages compared with VA, VC, VE, and VG.
However, the alloys are also reversed, thus creating a net voltage. (d ) Differential circuit.
Note: Output voltage cannot be accurately cold-junction compensated because of the
nonlinearity of thermocouple EMF versus temperature. Approximations can be made if
he absolute temperature is known.