MaintenanceCircleTeam Page 1 May 7th 2007

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NEWSLETTER FOR MAINTENANCE COMMUNITY
c ircle
Word for the day: THERMOCOUPLES

The word THERMOCOUPLE can be split into two separate words – THERMO & COUPLE – to understand its
purpose which has a history of more than 200 years. THERMO means heat and COUPLE means a pair. Hence, when
pair of different metal wires is joined together at the end, it generates a voltage proportional to the heat or temperature.
In 1821, T J Seebeck discovered that an electromotive force – emf for short which also means mild voltage, something
similar to back emf in a motor – exists across a junction formed of two unlike metals. For example, if a circuit is
formed using two dissimilar metals A & B – thermocouple – as shown in Figure 1, two junctions, p & q will be
formed, which are at two different temperatures, T1 & T2. If the temperatures are same, the two voltages will be same
but opposed and hence net difference is zero. However, if the temperatures are different, the voltages will not balance
and a current will flow. Therefore, the net voltage generated will be a function of two materials used to form the
circuit and the temperatures of the two junctions.

Note that a thermocouple always requires two junctions, one of which

T1 A T2 measures the required temperatures and other one is maintained at
known fixed temperature, known as cold or reference junction.
p q
Historically, the cold junction was maintained at 0°C in an ice bath. In
practical wiring today, we actually only connect two wires to a
B controller. The cold junction will be pre-wired inside the controller
Figure 1 and solid state device adjusts the cold junction temperature
accordingly to match ambient conditions. Theoretically, any two unlike materials can be used to form a thermocouple.
Actually, of course, certain materials and combinations are better than others, and some have practically become
standard for given temperature ranges. Materials commonly used in thermocouples may be listed as follows:

Copper, Iron, Platinum, Rhodium, Iridium, Constantan (60% Copper, 40% Nickel), Chromel (10% Chromium, 90%
Nickel), Alumel (2% Aluminum, 90% Nickel, remaining 8% being silicon and manganese).Refer to Table 1 for
features of few commonly used commercial thermocouples. Generally, these thermocouples have an average of 50µV
per °C and hence need large amount of amplification.

Style (Commercial Minimum Maximum

Metal Combination Sensitivity at 25°C
Term) Temperature °F (°C) Temperature °F (°C)
J Iron-Constantan -346(-210) 2193 (1200) 51.7µV / °C
K Chromel-Alumel -454(-270) 2501(1372) 40.6µV / °C
T Copper-Constantan -454(-270) 752(400) 40.6µV / °C
E Chromel-Constantan -454(-270) 1832(1000) 60.9µV / °C
R Platinum 13%- -58(-50) 3214(1768) 6µV / °C
Rhodium
S Platinum 10% - -58(-50) 3214(1768) 6µV / °C
Rhodium
Table 1

Based on the application requirement, any of the above thermocouples can be selected. As you can see from the table
for example, R & S thermocouples have more sensitivity than J & K type and hence can give accurate readings. But as
sensitivity increases, the distance between sensing and input point reduces. Hence a balance must be made between
the importance of application and where the controller can be located before taking a decision. One major
disadvantage of these thermocouples is oxidation. As it becomes older, the tip gets oxidized and sensitivity starts
reducing. Based on the working conditions, it is suggested to replace them on a regular interval – one year for example
– or create a calibration plan. This will prevent costly product or process rejections and avoid errors in the process
control.
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Apart from these regular thermocouples, Pt100 and RTD are two most popularly used temperature measuring sensors
used in the industry. Pt100 is the abbreviation for most common type of resistance temperature sensor used in the
industry. It is made from pure platinum and generally has a specific resistance of 100 ohms at 0°C. It accurately
follows a temperature versus resistance characteristic. Its temperature sensing range is from -200° to 850°C and hence
is very commonly used in cold temperature applications.

Resistance Temperature Detectors are sensors that measure temperature by correlating the resistance of the RTD
element with temperature. Most RTD elements consist of a length of fine coiled wire wrapped around a ceramic or
glass core. The element is typically relatively fragile, so it is generally installed inside a sheath to protect it. The RTD
element is constructed from a pure material, the resistance of which, at various temperatures, has been documented by
various international standards institutes. The material has a predictable change in resistance as the temperature varies;
it is this change that is used to determine temperature. RTDs are generally considered to be among the most accurate
temperature sensors available. In addition to offering very good accuracy, they provide excellent stability and
repeatability. RTDs also feature high immunity to electrical noise and are, therefore, well suited for applications in
process and industrial automation environments, especially around motors, generators and other high voltage
equipment.

Table 2 gives a brief overview of various temperature sensors used in the control system. Apart from these
conventional methods, Infrared, Ultraviolet, Radio frequency sensing methods are becoming very popular and are
widely used in difficult to access – steel melting furnace for example – applications.

Thermocouples Pt100 RTD Solid State Devices

Very wide: Type T
Very narrow:
can go down below - Wide: -200°C to Narrow. Typically -
Operating Range Typically -40°C to
200°C. Type W5 can 600°C 40°C to 300°C
125°C
approach 1800°C
Generally Low accuracy types
inexpensive although very inexpensive -
Price type R & S use Fairly inexpensive high accuracy types Inexpensive
expensive platinum more expensive than
wire. Pt100
Accuracy Moderate Excellent Poor to excellent Moderate
Linearity Poor Good Poor Very good
Poor to very good - Poor to very good - Good to very good -
Physical Strength Excellent Depends on probe Depends on probe Depends on probe
construction construction construction
Change in
characteristics with Small Reasonable Very large Large
temperature
Long term stability Reasonable Excellent Poor to excellent Reasonable
Industrial processes All industrial
Preset temperature Simple control
where temperature processes within
applications. applications and
Preferred range or physical operating range
Control where ambient
Applications requirements where accuracy and
narrow hysteresis is compensating
preclude other repeatability are
required. circuits.
devices. required.
Table 2

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In order to obtain better accuracy and consistency in temperature control, some of the precautions to be
taken are listed below:
z Place thermocouples as close to the process as possible. For instance, if a heater is melting plastic
material, the thermocouple should be as close to heater as possible
z Thermocouple cables should not have any sharp bends or too many joints
z Clean the thermocouple tip on a regular basis
z Avoid running thermocouple cable too long. If it necessary, install necessary amplifiers
z Do not use regular electrical cables to extend the length as they will reduce the voltage levels seriously
z Standard thermocouples should not run too close to other electrical cables
z It is not normal to connect same thermocouple in parallel to more than two controller units – PLEASE
AVOID
z Replace same type of thermocouples
z Proper selection, maintenance, calibration of thermocouples avoid process rejections, reduces energy
consumption, avoids unnecessary temperature under and over shooting
z As much as possible, standardize thermocouples in a company. This will avoid mixing up during
replacements and multiple inventories

Even though thermocouple is a small sensor in entire control system, if they are faulty major breakdowns can occur.
Few of them are listed below to understand the seriousness which can be avoided by little preventive maintenance and
Simple control applications and ambient compensating circuits.regular observation.

z Overheating and eventual burning of motor winding since RTD did not sense the temperature
z Overheating of steam resulting in explosion due to faulty thermostat
z Control cabinet of a machine tripping due to failure of temperature sensor
z Over freezing of room by air conditioner due to faulty thermostat
z Material decomposing due to overheating, since thermocouple failed to measure required temperature
And list can be endless.

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This document contains information for reference only. We assume no responsibility for its implication.