Thermocouple Thermocouples

Nimish Shah Most frequently used method to

measure temperatures with an
electrical output signal.

Outline What Is A Thermocouple Sensor??

What Is A Thermocouple Sensor?? Thermocouple comprises of at least two
Basic Working Principle metals joint together to form two junctions:
Practical Thermocouple Construction Hot junction & Cold junction
Thermocouple Materials
hot or measuring junction : connected to the
Standard Thermocouple Types
body
Thermocouple Color Codes
Characteristics
Major Specifications
Capabilities and Limitations
Selecting A Temperature Sensor
Comparisons

What Is A Thermocouple Sensor?? Working principle: thermocouple

cold or reference junction: connected to the
body of known temperature.
Thus the thermocouple enables measuring
the unknown temperature of the body with
reference to the known temperature of the
other body.
Principle: A circuit made by connecting two
dissimilar metals produces a measurable
voltage (emf-electromotive force) when a
temperature gradient is imposed between one
end and the other.
 Thermocouples Thermocouples
Two alloys joined at Junction
one end and free at composition does
the other. not affect
At the open end, the thermocouple action
emf is a function of T1 must be kept
temperature T1 at constant throughout
closed end the junction
As T rises, emf Junction material
increases must be electrically
T2 must be kept at a conductive
standard temp (0°C)

Basic Working Principle

Thermocouples
Seeback effect Background
Thomson effect Seebeck – 1822 – Current flow is proportional
to temperature difference
Peltier effect
Peltier – 1834 – If battery inserted in the
circuit, flowing current will cause heat to be
absorbed & liberated
Thomson – analyzed effect thermodynamically

Seeback Effect Thermocouples Principle of Operation

In, 1821 T. J. Seebeck observed the existence
of an electromotive force (EMF) at the junction
formed between two dissimilar metals (Seebeck
effect).
Seebeck effect is actually the combined
result of two other phenomena, Thomson
and Peltier effects.
Thomson observed the existence of
an EMF due to the contact of two
dissimilar metals at the junction
temperature.
Peltier discovered that temperature
gradients along conductors in a circuit
generate an EMF.
The Thomson effect is normally much
smaller than the Peltier effect.
 Practical Thermocouple Construction
A thermocouple construction consist of two
Practical Thermocouple conductors, welded together at the
measuring point and insulated from each
Construction
other long the length.
It will usually have an outer protection sheath.

Practical Thermocouple Construction Practical Thermocouple Construction

Thermocouple Materials
 Which materials should be used? Thermocouple Material Vs EMF

Depends on requirements:
Temperature range
Required accuracy
Chemical resistance issues
Abrasion or vibration resistance
Installation requirements (size of wire)
Thermal conduction requirements

Thermocouple Materials
Most commonly used three materials:
Iron-Constantan (Type J),
Copper-Constantan (Type T), and
Chromel-Alumel (Type K).
1-) The first named element of the pair is
the positive element.
2-) The negative wire is color coded red.

Standard Thermocouple Types

Standard Thermocouple Types
Iron-Constantan: (Type J)
 color code: white and red
 generates about 50 µV/°C (28 µV/°F).
 The Iron wire is magnetic.
 Junctions made by welding or soldering
with commonly available solders and fluxes.
 can generate a galvanic EMF between the
two wires and should not be used in
applications where they might get wet.
 Major Specifications
Type J: Iron / Constantan:
Useful range of temperature is -300F to
1200F.
Maximum temperature 1600F.
Possible problems: Oxidizes rapidly due to the
iron wire.
preferred over the beaded bare wire style of
thermocouple.
Major Specifications
Type K: Chromel / Alumel
Useful range of temperature is -300F to
1800F.
Maximum temperature 2300F.
Type E: Chromel / Constantan
Useful range of temperature is -300F to
1800F.
Maximum temperature 1000F.
Major Specifications
Type T: Copper / Constantan
Useful range of temperature is -300F to 700F.
Maximum temperature 700F.
Standard Thermocouple Types
Chromel Alumel: (Type K)
 color code: yellow and red
 generates about 40 µV/°C (22 µV/°F).
 The Alumel wire is magnetic.
 Junctions made by welding or soldering,
but high temperature silver-solders and
special fluxes must be used.
 generate electrical signals, while the
wires are being bent, and
 should not be used on vibrating systems,
unless strain relief loops provided.
Standard Thermocouple Types
Copper-Constantan: (Type T)
 color coded blue and red
 generates about 40 µV/°C (22 µV/°F).
Neither wire is magnetic.
 Junctions made by welding or soldering
with commonly available solders and fluxes.
 Are very susceptible to conduction error
 due to the high thermal conductivity of
the copper, and should not be used unless
long runs of wire (100 to 200 wire diameters)
can be laid along an isotherm.
Thermocouple Color Codes
 Thermocouple Color Codes
Thermocouple wiring is color coded by
thermocouple types.
Different countries utilize different color
coding.
Jacket coloring is sometimes a colored stripe
instead of a solid color as shown.

Characteristics Capabilities and Limitations

Thermocouples have non-linear
Capabilities:
characteristics given by an approximating
polynomial. - Wide Range
For example for type J (range 1, -210 to - Fast Response
760°C) the characteristic is given by
- Passive
- Inexpensive
where V is in and T in °C
Limitations:
The output signal from a thermocouple is
- Non-Linear
up to 50mV.

Selecting A Temperature Sensor

Advantages & Disadvantages
Thermocouple can be used over great
distances since emf is a function of
T1only
These long leads can cause problems
There could be a break in the circuit or
a reversal of leads
Induced voltage from nearby A/C
magnetic field
 Comparisons

Resistance
Thermocouple Thermometer (RTD) Thermistor Infrared

Reasonable for
Stability (Drift) limited lifetime Good Good Good
Repeatability Reasonable Good Good Good
Hysteresis Excellent Good Good Good

Vibration Very Resistant Less Resistant Good

Whole Tolerant
bead
Measurement Area Single Point Whole RT Element (Small)
Small Varies
Small Sizes (to (0.5mm
Diameter 0.25mm) Larger (3.0mm min) min) Varies
Reasonably
Linearity Not Linear Reasonably Linear Not Linear Linear
Not
Reference Junction Required Not Required Required Not Required

Lead Wire Resistance No Problem Must be Considered No Problem Not Required

Contact Required Y es Y es Yes No
Response Fast Slower Medium Fast