THERMOCOUPLES

Types of thermocouples
Thermocouples are classified by calibration type because they have varying electromotive force (EMF) versus temperature curves. Some generate considerably more voltage at lower temperatures, while others do not begin to develop a significant voltage until subjected to high temperatures. Also, calibration types are designed to deliver as close to a straight line voltage curve inside their temperature application range as possible. This makes it easier for an instrument or temperature controller to correctly correlate the received voltage to a particular temperature.

Mill volts Vs Temperature graph

Calibration Types
The eight main thermocouple types - B, E, J, K, N, R, S and T
Type B Maximum recommended operating temperature for Type B is 3100F (1700C). Suitable for use in an oxidizing or inert atmosphere. Do not insert in metal tubes. Beware of contamination at high temperatures. Not suitable for use below 122F (50C) Type E The Type E thermocouple is suitable for use at temperatures up to 1650F (900C) in a vacuum, inert, mildly oxidizing or reducing atmosphere. At cryogenic temperatures, the thermocouple is not subject to corrosion. This thermocouple has the highest EMF output per degree of all the commonly used thermocouples Type J Type J is the second most common calibration type and is a good choice for general purpose applications where moisture is not present. The Type J thermocouple may be used, exposed or unexposed, where there is a deficiency of free oxygen. For cleanliness and longer life, a protection tube is recommended. Since iron (JP) wire will oxidize rapidly at temperatures over 1000F (540C), it is recommended that larger gauge wires be used to compensate. Maximum recommended operating temperature is 1400F (760C).

Type K Type K thermocouples usually work in most applications as they are nickel based and exhibit good corrosion resistance. It is the most common sensor calibration type providing the widest operating temperature range. Due to its reliability and accuracy the Type K thermocouple is used extensively at temperatures up to2300F (1260C). This type of thermocouple should be protected with a suitable metal or ceramic protection tube, especially in reducing atmospheres. In oxidizing atmospheres, such as electric furnaces, tube protection is not always necessary when other conditions are suitable; however, it is recommended for cleanliness and general mechanical protection Type N This nickel-based thermocouple alloy is used primarily at high temperatures up to 2300F (1260C). While not direct replacement for Type K, Type N provides better resistance to oxidation at high temperatures and longer life in applications where sulfur is present. It also outperforms Type K in Ks aging range.

Types S and R Maximum recommended operating temperature for Type S or R is 2700F (1480C). These thermocouples are easily contaminated. Reducing atmospheres are particularly damaging to the calibration. Noble metal thermocouples should always be protected with a gas-tight ceramic tube, a secondary tube of porcelain,and a silicon carbide or metal outer tube as conditions require.

Type T This thermocouple can be used in either oxidizing or reducing atmospheres, though for longer life, a protecting tube is recommended. Because of its stability at lower temperatures, this is a superior thermocouple for a wide variety of applications in low and cryogenic temperatures. Its recommended operating range is-330 to 660F (-200 to 350C), but it can be used up to -452F (-269C) (boiling helium)

Thermocouple Wire
Thermocouple Grade Wire is generally used to make the actual thermocouple element. (Although it can be used as extension wire as well, the outer jacket insulation may have a different color and it may not be as cost effective.) Each of the calibration types has their own insulation standard color code for easy identification Available in AWG sizes from 6 AWG (0.1620) to 40 AWG (0.0031)

AWG American wire gauge (AWG), also known as the Brown & Sharpe wire gauge, is a standardized wire gauge system

Thermocouple wire gauge

At high temperatures, thermocouple wire can under go irreversible changes in the form of modified crystal structure, selective migration of alloy components and chemical changes originating from the surface metal reacting to the surrounding environment. With some types, mechanical stress and cycling can also induce changes. Increasing the diameter of the wire where it is exposed to the high temperatures can reduce the impact of these effects. The diameter of the sensor wires determines the uppermost operating temperature. The larger the diameter, the higher the temperature rating

The following table can be used as a very approximate guide to wire gauge:

Extension Wire
Extension Grade Wire is used to complete the thermocouple circuit from the thermocouple element to the instrumentation. Extension grade wire should not be used to make the actual elements. The extension wire and thermocouple wire must both be of the same calibration type to maintain the accuracy of the thermocouple. Also, the polarity of each set of wires must be maintained during installation in order for the thermocouple circuit to function properly. Each of the calibration types has their own insulation standard color code for easy identification

Sheathed Thermocouples
Thermocouple wire is inserted in a metal protective tube (sheath) and is filled by inorganic insulator (high purity magnesium oxide). The sheathed thermocouples have excellent performance on insulation, airtight and response, and withstand long term continuous operation in various unfavorable atmospheric conditions.

Sheath Material and their maximum operating temperatures

Types of junctions
Basically, they are 3 junction types
1. Exposed Junction 2. Grounded Junction 3. Ungrounded Junction

Exposed Junction (E)

Thermocouple wires are butt-welded. Insulation is sealed against liquid or gas penetration prior to use. This junction style provides the fastest possible response time but leaves the thermocouple wires unprotected against corrosive or mechanical damage.

Grounded Junction (G)

The sheath and thermocouple wires are welded together, forming a completely sealed integral junction. Recommended in presence of liquids, moisture, gas or high pressure. The wire is protected from corrosive or erosive conditions. In the Grounded Junction, response time approaches that of the Exposed Junction

Ungrounded Junction (U)

Thermocouple junction is fully insulated from welded sheath end. Excellent for applications where stray emfs would affect the reading and for frequent or rapid temperature cycling. With the Ungrounded Junction, response time is slightly longer than for the Grounded Junction.

Stray voltage is the occurrence of electrical potential between two objects that ideally should not have any voltage difference between them