What is a Thermocouple?

A Thermocouple is a sensor used to measure temperature. Thermocouples consist of two wire legs made from
different metals. The wires legs are welded together at one end, creating a junction. This junction is where the
temperature is measured. When the junction experiences a change in temperature, a voltage is created. The voltage
can then be interpreted using thermocouple reference tables to calculate the temperature.

There are many types of thermocouples, each with its own unique characteristics in terms of temperature range,
durability, vibration resistance, chemical resistance, and application compatibility. Type J, K, T, & E are Base Metal
thermocouples, the most common types of thermocouples.Type R, S, and B thermocouples are Noble Metal
thermocouples, which are used in high temperature applications (see thermocouple temperature ranges for details).

Thermocouples are used in many industrial, scientific, and OEM

applications. They can be found in nearly all industrial markets: Power Generation, Oil/Gas, Pharmaceutical, BioTech,
Cement, Paper & Pulp, etc. Thermocouples are also used in everyday appliances like stoves, furnaces, and toasters.

Thermocouples are typically selected because of their low cost, high temperature limits, wide temperature ranges,
and durable nature.

Types of Thermocouples:
Before discussing the various types of thermocouples, it should be noted that a thermocouple is often enclosed in a
protective sheath to isolate it from the local atmosphere. This protective sheath drastically reduces the effects of
corrosion.

1
Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the most common type of thermocouple.
Its inexpensive, accurate, reliable, and has a wide temperature range.

Temperature Range:

Thermocouple grade wire, 454 to

2,300F (270 to 1260C)
Extension wire, 32 to 392F (0 to 200C)

Accuracy (whichever is greater):

Standard: +/- 2.2C or +/- .75%

Special Limits of Error: +/- 1.1C or 0.4%

2
Type J Thermocouple (Iron/Constantan): The type J is also very common. It has a smaller temperature range and
a shorter lifespan at higher temperatures than the Type K. It is equivalent to the Type K in terms of expense and
reliability.

Temperature Range:

Thermocouple grade wire, -346 to

1,400F (-210 to 760C)
Extension wire, 32 to 392F (0 to 200C)

Accuracy (whichever is greater):

Standard: +/- 2.2C or +/- .75%

Special Limits of Error: +/- 1.1C or 0.4%

3
Type T Thermocouple (Copper/Constantan): The Type T is a very stable thermocouple and is often used in
extremely low temperature applications such as cryogenics or ultra low freezers.

Temperature Range:

Thermocouple grade wire, -454 to 700F

(-270 to 370C)
Extension wire, 32 to 392F (0 to 200C)

Accuracy (whichever is greater):

Standard: +/- 1.0C or +/- .75%

Special Limits of Error: +/- 0.5C or 0.4%

4
Type E Thermocouple (Nickel-Chromium/Constantan): The Type E has a stronger signal & higher accuracy than
the Type K or Type J at moderate temperature ranges of 1,000F and lower. See temperature chart (linked) for
details.

Temperature Range:
 Thermocouple grade wire, -454 to 1600F
(-270 to 870C)
Extension wire, 32 to 392F (0 to 200C)

Accuracy (whichever is greater):

Standard: +/- 1.7C or +/- 0.5%

Special Limits of Error: +/- 1.0C or 0.4%

5
Type N Thermocouple (Nicrosil / Nisil): The Type N shares the same accuracy and temperature limits as the Type
K. The type N is slightly more expensive.

Temperature Range:

Thermocouple grade wire, -454 to

2300F (-270 to 392C)
Extension wire, 32 to 392F (0 to 200C)

Accuracy (whichever is greater):

Standard: +/- 2.2C or +/- .75%

Special Limits of Error: +/- 1.1C or 0.4%

NOBLE METAL THERMOCOUPLES (Type S,R, & B):

Noble Metal Thermocouples are selected for their ability to withstand extremely high temperatures while maintaining
their accuracy and lifespan. They are considerably more expensive than Base Metal Thermocouples.

6
Type S Thermocouple (Platinum Rhodium - 10% / Platinum): The Type S is used in very high temperature
applications. It is commonly found in the BioTech and Pharmaceutical industries. It is sometimes used in lower
temperature applications because of its high accuracy and stability.

Temperature Range:
 Thermocouple grade wire, -58 to 2700F
(-50 to 1480C)
Extension wire, 32 to 392F (0 to 200C)

Accuracy (whichever is greater):

Standard: +/- 1.5C or +/- .25%

Special Limits of Error: +/- 0.6C or 0.1%

7
Type R Thermocouple (Platinum Rhodium -13% / Platinum): The Type R is used in very high temperature
applications. It has a higher percentage of Rhodium than the Type S, which makes it more expensive. The Type R is
very similar to the Type S in terms of performance. It is sometimes used in lower temperature applications because of
its high accuracy and stability.

Temperature Range:

Thermocouple grade wire, -58 to 2700F

(-50 to 1480C)
Extension wire, 32 to 392F (0 to 200C)

Accuracy (whichever is greater):

Standard: +/- 1.5C or +/- .25%

Special Limits of Error: +/- 0.6C or 0.1%

8
Type B Thermocouple (Platinum Rhodium 30% / Platinum Rhodium 6%): The Type B thermocouple is used
in extremely high temperature applications. It has the highest temperature limit of all of the thermocouples listed
above. It maintains a high level of accuracy and stability at very high temperatures.

Temperature Range:

Thermocouple grade wire, 32 to 3100F

(0 to 1700C)
 Extension wire, 32 to 212F (0 to 100C)

Accuracy (whichever is greater):

Standard: +/- 0.5%

Special Limits of Error: +/- 0.25%

Thermocouple Junctions:
Grounded Thermocouples: This is the most common junction style. A thermocouple is grounded when both
thermocouple wires and the sheath are all welded together to form one junction at the probe tip. Grounded
thermocouples have a very good response time because the thermocouple is making direct contact with the sheath,
allowing heat to transfer easily. A drawback of the grounded thermocouple is that the thermocouple is more
susceptible to electrical interference. This is because the sheath often comes into contact with the surrounding area,
providing a path for interference.
Ungrounded Thermocouples (Or Ungrounded Common Thermocouples): A thermocouple is ungrounded when
the thermocouple wires are welded together but they are insulated from the sheath. The wires are often separated by
mineral insulation.
Exposed Thermocouples (or bare wire thermocouples): A thermocouple is exposed when the thermocouple
wires are welded together and directly inserted into the process. The response time is very quick, but exposed
thermocouple wires are more prone to corrosion and degradation. Unless your application requires exposed
junctions, this style is not recommended.
Ungrounded Uncommon: An ungrounded uncommon thermocouple consists of a dual thermocouple that is
insulated from the sheath and each of the elements are insulated from one other.

Thermocouple Sheath Comparison:

316SS (stainless steel): This is the most common sheath material. It is relatively corrosion resistant and is cost
effective.
304SS: This sheath is not as corrosion resistant as 316SS. The cost difference between 316SS and 304SS is
nominal.
Inconel (registered trademark) 600: This material is recommended for highly corrosive environments.

What are Special Limits of Errors (SLE)?

Special Limits of Error: These thermocouples are made with a higher grade of thermocouple wire, which increases
their accuracy. They are more expensive than standard thermocouples.

Standard Limits of Error: These thermocouples use standard thermocouple grade wire. They are less expensive
and more common.

What is M.I. Cable?

M.I. (Mineral Insulated) cable is used to insulate thermocouple wires from one another and from the metal sheath that
surrounds them. MI Cable has two (or four when duplex) thermocouple wires running down the middle of the tube.
The tube is then filled with magnesium oxide powder and compacted to ensure the wires are properly insulated and
separated. MI cable helps to protect the thermocouple wire from corrosion and electrical interference.

What is System Error?

System error is calculated by adding the accuracy of the temperature sensor (thermocouple) and the accuracy of the
meter used to read the voltage signal together. For example, a Type K thermocouple has an accuracy of +/- 2.2C
above 0C. Lets say the meter has an accuracy of +/- 1C. That means the total system error is +/- 3.3C above 0C.

Thermocouple vs. RTD

Temperature range:
First, consider the difference in temperature ranges. Noble Metal Thermocouples can reach 3,100 F, while standard
RTDs have a limit of 600 F and extended range RTDs have a limit of 1,100 F.

Cost:
A plain stem thermocouple is 2 to 3 times less expensive than a plain stem RTD. A thermocouple head assembly is
roughly 50% less expensive than an equivalent RTD head assembly.

Accuracy, Linearity, & Stability:

As a general rule, RTDs are more accurate than thermocouples. This is especially true at lower temperature ranges.
RTDs are also more stable and have better linearity than thermocouples. If accuracy, linearity, and stability are your
primary concerns and your application is within an RTDs temperature limits, go with the RTD.

Durability:
In the sensors industry, RTDs are widely regarded as a less durable sensor when compared to thermocouples.
However, REOTEMP has developed manufacturing techniques that have greatly improved the durability of our RTD
sensors. These techniques make REOTEMPs RTDs nearly equivalent to thermocouples in terms of durability.

Response Time:
RTDs cannot be grounded. For this reason, they have a slower response time than grounded thermocouples. Also,
thermocouples can be placed inside a smaller diameter sheath than RTDs. A smaller sheath diameter will increase
response time. For example, a grounded thermocouple inside a 1/16 dia. sheath will have a faster response time
than a RTD inside a dia. sheath.
What is m.i. cable?
Mineral insulated cable is manufactured from completely inorganic material. The
copper sheath and conductors, insulated with magnesium oxide ensure that the cable
is able to withstand the effects of fire and is fully usable afterwards. The m.i. cable
system provides a simple solution to many difficult wiring problems and makes for a
dependable and permanent installation for virtually all types of electrical circuits. The
copper cable sheath meets NEC grounding requirements. Suitable for 300 and 600
volt applications. Pressure tested to 2000 psi. Mineral insulated cable complies with
Articles 330, 500 and 501 and all other applicable provisions of the National Electric
Code.

To produce assemblies, the cable is cut to the desired

length, pigtails brazed on and terminated with union
type glands with male NPT threads.

How is mineral insulated cable made

Solid copper conductor rods are first inserted into a vertical 2.5" diameter copper tube
30 foot long, kept at the correct spacing with mineral insulated block inserts. The tube
is packed with magnesium oxide, which acts as a seal and fireproof insulator. The end
of the copper tube is sealed off and a steel draw wire attached. Using special
machinery, the filled tube is put through a swaging process which reduces the sheath
and conductor diameter proportionately while lengthening the cable. For example, a
two conductor cable #16 AWG. has a nominal length of 1221 feet.

Swaging or drawing down locks the conductors into place so the position of the
conductors inside the sheath never varies, even when formed or bent. During the
swaging process, the cable is put through an annealing or heating process to align the
copper molecules and keep the cable flexible.

Material specifications
Mineral insulated cable is manufactured from high conductivity copper ASTM B4 or B5;
insulated with compressed magnesium oxide powder; a seamless phosphorous
deoxidized copper sheath; maximum continuous operating temperature of 250C; a
working voltage of 0-300 volts AC/DC and 0-600 volts AC/DC; factory test voltage 1500
volts RMS (300 volt cable) and 2500 volts RMS (600 volt cable); a power factor of
0.1%;dielectric constant (SIC) at 3.7 and dielectric strength 70 volts/ml at 475C.

NOTE:
For electrical data of Alloy 825 outer sheath with solid nickel conductors, please
contact our sales department.

Mineral insulated cable vs. conduit

By using mineral insulated cable, you not only eliminate the uncertainty of conduit and
wire, but also the cost of additional materials, including pull boxes, unions, grounding
wires, conduit seals and other fittings. Pressure tested to 2000 psi, mineral insulated
cable delivers superior performance by blocking the passage of vapors, gases, liquids
and flames; eliminates pressure piling and confines any exploding gases to their
immediate area.

With conduit, seals must be placed

within 18" of the arcing device or
instrument to be connected to the
conduit system. If a conduit seal fails,
gas or liquids can migrate freely and
it is for this reason that some
companies require single or double
conduit seals in hazardous areas to
be annually x-rayed and inspected.

MICC cable assemblies are exempt

from these requirements and are UL
approved for use in Class I, groups
B, C and D, Division I hazardous
areas and meet the requirements of
NEC Article 501-5 (f)(3) for canned
pumps etc.

Uses of m.i. cable

MICC cable assemblies are ideal for power, control, instrumentation and thermocouple
applications in classified areas. The copper outer sheath is approved as a ground
conductor and the high current rating can satisfy virtually all power applications. In
addition m.i. cable features a low physical profile that allows unlimited bends without
pull boxes.

MICC offers four types of cable assemblies:

o copper sheathed cable, copper conductors; UL fire rated for two hours at
1850F.

o twisted pair and shielded twisted pair with copper conductors, inner shield and
outer sheath, UL fire rated for two hours at 1850F.

o alloy 825 sheath, solid nickel conductors, fire rated for 30 minutes at 2200F or
nickel clad copper conductors, fire rated for 30 minutes at 2000F.

o stainless steel 316 thermocouple extension cable, all types

All cable assemblies are appropriate for the following conditions:

Fire and heat resistant

The inorganic construction of mineral insulated cable makes it extremely fire and heat
resistant. With an operating limit equal to the melting point of copper, 1982F, 1083C -
it can easily withstand high temperatures and heavy current overloads. It emits no
smoke or toxic substances and allows no flame propagation. In contrast, a third party
test proved standard conduit and wire failed at 425F. These fireproof properties make
it the best choice for connecting motor operated valves, control stations, plant
shutdown systems, instruments and power devices that must remain operational under
actual fire conditions.

Mineral insulated cable and cable assemblies are

extremely reliable as power and control cables in
hospitals, hotels, high rise buildings for emergency
generators, fire pumps, smoke and vent exhaust
fans, communication circuits, multiplex alarm
systems and instrumentation.

Other applications include wiring connections to electric heaters on boilers, tanks and
furnace wiring, metal smelters and lumber kilns, where regular pvc insulation hardens
and cracks and has to be replaced regularly.

Waterproof
The cable is solid and constructed with an extruded copper sheath that makes it
impervious to liquids. Neither water, process liquids or corrosive solutions can migrate
into the system. In copper and brass corrosive environments, or for direct burial an
extruded outer HDPE jacket may be specified to provide additional protection. PVC
boots cover the brass connectors. Epoxy end terminations provide lifetime sealing to
moisture ingress.

Industrial applications include light fitting connections in oil

tanks that are periodically washed out with kerosene.

M.I cable assemblies are US Coast Guard approved and are

currently used to connect warning beacons, fog horns and lanterns on offshore
platforms. They also solve many electrical wiring problems on oil tankers and marine
vessels that operate under the worst of climatic conditions.

Temperature stable
Mineral insulated cable does not deteriorate at low temperatures and assemblies are
unaffected by continuous, even extreme changes in
temperature.

Daily temperature changes cause condensation and moisture to

accumulate in exposed conduit above the seal packing, causing rust
and corrosion to build up and block the conduit drain. In cold
temperatures this moisture can freeze, splitting the conduit or seal and possibly
damaging the instrument or electrical device, especially if the wiring is top entry.

Because m.i. cable assemblies are solid and completely moisture resistant, this risk is
eliminated. Industrial applications include power wiring to motors in LNG tanks, freezer
rooms and instrument connections in harsh climates such as Alaska and Canada.

Radiation resistant
Magnesium oxide, the insulation in mineral insulated cable, provides superior radiation
resistance over any other material and for this reason, MICC cable assemblies are an
excellent choice for nuclear power plant applications.

What is a Thermocouple & How Does it Work?

written by: Haresh Khemani edited by: Lamar Stonecypher updated: 10/23/2013

A thermocouple is a device used extensively for measuring temperature. Learn how the device works
here.
 A thermocouple is comprised of at least two metals joined together to form two
junctions. One is connected to the body whose temperature is to be measured; this is the hot or
measuring junction. The other junction is connected to a body of known temperature; this is the cold or
reference junction. Therefore the thermocouple measures unknown temperature of the body with
reference to the known temperature of the other body.

Working Principle

The working principle of thermocouple is based on three effects, discovered by Seebeck, Peltier and
Thomson. They are as follows:

1) Seebeck effect: The Seebeck effect states that when two different or unlike metals are joined
together at two junctions, an electromotive force (emf) is generated at the two junctions. The amount
of emf generated is different for different combinations of the metals.

2) Peltier effect: As per the Peltier effect, when two dissimilar metals are joined together to form two
junctions, emf is generated within the circuit due to the different temperatures of the two junctions of
the circuit.

3) Thomson effect: As per the Thomson effect, when two unlike metals are joined together forming
two junctions, the potential exists within the circuit due to temperature gradient along the entire
length of the conductors within the circuit.

In most of the cases the emf suggested by the Thomson effect is very small and it can be neglected by
making proper selection of the metals. The Peltier effect plays a prominent role in the working principle
of the thermocouple.

Diagrams

How it Works

The general circuit for the working of thermocouple is shown in the figure 1 above. It comprises of two
dissimilar metals, A and B. These are joined together to form two junctions, p and q, which are
maintained at the temperatures T1 and T2 respectively. Remember that the thermocouple cannot be
formed if there are not two junctions. Since the two junctions are maintained at different temperatures
 the Peltier emf is generated within the circuit and it is the function of the temperatures of two
junctions.

If the temperature of both the junctions is same, equal and opposite emf will be generated at both
junctions and the net current flowing through the junction is zero. If the junctions are maintained at
different temperatures, the emfs will not become zero and there will be a net current flowing through
the circuit. The total emf flowing through this circuit depends on the metals used within the circuit as
well as the temperature of the two junctions. The total emf or the current flowing through the circuit
can be measured easily by the suitable device.

The device for measuring the current or emf is connected within the circuit of the thermocouple. It
measures the amount of emf flowing through the circuit due to the two junctions of the two dissimilar
metals maintained at different temperatures. In figure 2 the two junctions of the thermocouple and the
device used for measurement of emf (potentiometer) are shown.

Now, the temperature of the reference junctions is already known, while the temperature of measuring
junction is unknown. The output obtained from the thermocouple circuit is calibrated directly against
the unknown temperature. Thus the voltage or current output obtained from thermocouple circuit
gives the value of unknown temperature directly.

Devices Used for Measuring EMF

The amount of emf developed within the thermocouple circuit is very small, usually in millivolts,
therefore highly sensitive instruments should be used for measuring the emf generated in the
thermocouple circuit. Two devices used commonly are the ordinary galvanometer and voltage
balancing potentiometer. Of those two, a manually or automatically balancing potentiometer is used
most often.

Figure 2 shows the potentiometer connected in the thermocouple circuit. The junction p is connected
to the body whose temperature is to be measured. The junction q is the reference junction, whose
temperature can be measured by the thermometer. In some cases the reference junctions can also be
maintained at the ice temperature by connecting it to the ice bath (see figure 3). This device can be
calibrated in terms of the input temperature so that its scale can give the value directly in terms of
temperature.