THERMOCOUPLE

DESIGN
A COMPREHENSIVE GUIDE

+44 (0) 1246 261999

Made By Peak Sensors Limited
pslsales@peaksensors.com
UK Temperature Sensor Manufacturer & Supplier
peaksensors.com
Notes From
The Author
This guide is for engineers who are unfamiliar
with temperature sensing technology
to give a good starting place to help you solve
your temperature related problems.
It covers:
Different temperature sensing technologies
Decision making criteria
Common sensing techniques
How to use temperature sensors
Choosing the right sensor for your problem

Author
Peter Smith
 Data

Contents
1 Requirements

Economic
2 Considerations

Application
3 Considerations

Moderate and Light

4 Use Sensor Design

Harsh Use Sensor

5 Design

6 Summary
 1
Data
Requirements
 Data
Requirements

What is your required temperature

range?

The temperature sensor you choose will depend on the

usual temperature it will experience and also the
maximum over-temperature that may be experienced.

Pushing a temperature sensor to its limits for long

periods of time could make it develop an error (called
drift) and the temperature sensor will record a lower
temperature than it is actually experiencing.

If you are using the temperature sensor in extreme

temperatures its best to use the sensor only once so you
don’t get drift. If the sensor experiences temperatures
within its operating range drift will not happen and the
temperature sensor can be reused many times
accurately.

The chart below should help you choose which sensor is

suitable for your application:
 Data
Requirements

What is your desired accuracy?

Different types of sensors have different accuracy tolerances. All

sensors we manufacture are within defined tolerance bands to
European and International standards (BS EN 60584-1, IEC 60751
etc).
 Data
Requirements
If small inaccuracies are tolerable in your process then standard
sensors are fine. Our sensors are sold to operate within their
defined tolerance, although they have not been proven in finished
form. All our sensors are made with calibrated materials and we
can supply certificates to prove their tolerance. If required we can
calibrate a representative sensor from the same batch. A
calibration certificate will be supplied in this case.

If tighter tolerances are required then all sensors can be supplied

with calibration certificates. If you require tight tolerances with high
reliability, our sensors can be tested to UKAS laboratory standards
and supplied with a UKAS calibration certificate provided. These
calibrations are carried out in a fully controlled environment and are
the tightest accuracies available.

This chart shows the tolerances that Peak Sensors will normally
supply to:
 2
Economic
Considerations
 Economic
Considerations

Many variables will affect the price of the temperature sensors

you require. If you require lower temperatures, with low accuracy,
sensors will generally be cheaper, but if you require robust,
higher accuracy sensors, it might be more costly.

Here are a number of factors to consider that can affect the price
of a temperature sensor you require:

Number of sensors required

If you require a single sensor it might not increase its cost if it is a

standard design, but the more customised your design the more
development cost will be included in your sensor.

Development costs will easily be absorbed by manufacturing

volumes of temperature sensors. If you do require 1000’s of
temperature sensors, or sensors on a regular basis, we can work
with you to produce massive cost reductions by design for
manufacturing principles with varying levels of automation and
simplification.

We often work with OEMs where this is the case and help them
to keep their unit costs for temperature sensors down while
providing the perfect temperature sensor for their application.
 Economic
Considerations

Material sizes that are available

Cables, ceramics and other sensor components all have standard
sizes. Being flexible in your temperature sensor design will
enable you to reduce costs by choosing components in standard
sizes. Special sizes will be available but will require custom
manufacture and may have minimum order quantities.

There is a general rule that small diameter sensors are usually

cheaper up to a certain point. Very small diameter sensors are
often more costly as they are more intricate to manufacture and
are very fragile.

Operating and maximum temperature

of your process
As mentioned in temperature requirements, your measuring
temperature will affect sensor selection but also the higher the
measuring temperature the more expensive the sensor
component materials.

When you are at the operating limits of a type k thermocouple,

there is quite an increase in moving to type r thermocouples to
measure the higher temperatures.

Overestimating the temperature of your process can increase

temperature sensor cost, when cheaper alternatives may be
adequate.
 Economic
Considerations

Expected life-cycle of the sensor

A sensor design can be cost-effective to replace if it fails, or you
can design a sensor to be very robust to increase maximum
lifetime.

You will need to conduct a cost-benefit analysis in order to decide

which option suits your process. We have helped customers
move from both options to the alternative.

Customers have been using cheap sensors that fail often and
have found that by increasing the robustness of the sensor
although it increased cost per unit, in the long run, it was
cheaper. Looking at the opposite, we have helped customers
which were using costly, over-engineered sensors.

By switching the customers to cheaper, easy-to-replace sensors,

although they witnessed more failures in the long run their costs
were also reduced. Economic
Considerations
How long you require a sensor to last is very specific to your
application. We also manufacture ‘fault-free’ temperature sensors
that are designed to not fail through normal use.

Potential reuse of components in

sensor repair
Being able to reuse components when sensors fail may help to
reduce their replacement cost.
 Economic
Considerations

Components such as heads and temperature transmitters can be

reused in new sensors to help reduce costs. It is our
environmental policy to work with customers to help minimise the
impact of our products on the environment through the reuse of
as many components as possible.

We also comply with the Restriction of Hazardous Substances in

Electrical and Electronic Equipment (ROHS) Directive.

Scrap value of the sensor

Rare metal thermocouples such as type r, type s and type b
contain precious metal wire which is a significant cost of the
temperature sensor. We are able to recycle this material which
will help reduce the cost of repairing and replacing your existing
sensors.

Calibration requirements
As mentioned when looking at accuracy, temperature sensors
can be calibrated with both UKAS and laboratory traceable
calibration.

Both types of calibration will have costs associated but also the
number of temperature points you have calibrated will affect the
cost as each point is added cost. You can also decide to calibrate
every individual sensor or batch calibrate a sample of produced
temperature sensors.
 Economic
Considerations

Lead-time for delivery

All of our temperature sensors have a standard lead-time for
manufacturing. We carry stock of most sensor components but
specialist materials will need to be ordered.

As with most manufactured products requiring something quick

can often carry a premium because production schedules will
need to be rearranged or quick delivery of sourced components
arranged.

The more information you can gather about what you require
makes it easier is to help us design a temperature sensor that will
meet your requirements and budget.

The graph below can help in deciding what type of sensors you
should use:
 3
Application
Considerations
 Application
Considerations

Temperature sensors consist of not only the sensor but means to

protect it. More time is spent choosing the best method of
protection than choosing the type of sensor.

The way a sensor is protected is called the protection sheath and

its selection can be independent of the type of sensor.

Protection Sheath Functions

The protection sheaths' main aim is to defend the temperature

sensor from the environment and your process. Without
protection, the temperature sensor lifespan and accuracy could
be impacted.

Protection sheath functions include:

Prevent dust or particles from contaminating the temperature

sensor
Protect the sensor from pressure, abrasion or chemical
conditions of the process
Provide a means for the sensor to attach to a process
Ensure that the sensor reading is dominated by the process
temperature
Provide a means to easily change sensors
Protect the temperature sensor in transport, storage and use
 Application
Considerations

Light Use vs Harsh Use

Temperature sensors can be divided into two groups with
different protection needs:

Light Use
Temperature sensors can be divided into two groups with
different protection needs:

The most important design consideration when looking at this

type of sensor is how the sensor will be connected and mounted
to your process.

These sensors are often categorised by:

Mainly used with equipment
Often included within customers' products
Lower temperatures
Integral housing and sensor assembly
Inexpensive
Single-use or long life
High design effort to reduce unit cost
Can be a high volume

Harsh Use

The most important design consideration when looking at this

type of sensor is the selection of protection sheath to protect the
sensor from high temperature or chemical attack.
 Application
Considerations

These sensors are often categorised by:

Mainly used in plants/factories

Helps control a process
Smaller volumes
High temperatures
Harsh environment – chemical attack, pressure, abrasion,
carburisation
Can be dismantled for repair or precious metal recycling
Higher unit cost
 4
Moderate and Light
Use Temperature
Sensors
 Moderate and Light Use
Temperature Sensors

Moderate and light use temperature sensors are not used to their
limits. They can be cheap, long lasting and are often designed in
an easy-to-use form.
There are three basic design forms they are produced from:

1. Flexible Cable Temperature Sensors

2. Rigid Metal Tube Temperature Sensors
3. Mineral Insulated Temperature Sensors

1. Flexible Cable Temperature

Sensors

Flexible cable temperature sensors are made from readily available

temperature sensor cables. They can be a number of different types of
sensors including resistance thermometers, thermistors, integrated
circuits or thermocouples.

The measuring point is usually protected by a metal pocket or plastic

coating. The temperature limit is determined by the maximum
temperature of the cable.
 Moderate and Light Use
Temperature Sensors

These sensors can be cheap to make. Both ends of the sensor

can be highly customised to your needs e.g. fast response
measuring tip and a plug termination for connecting to equipment.

Measuring Point Protection and Connection to the

process

Flexible cable sensors can have a variety of hot end

configurations, meaning the sensor can be protected in a variety
of ways and also attached to your process in a number of ways.
Below are some options for measuring point protection with links
to some example temperature sensor designs.

The following sensors are only examples. The designs and

materials of the thermocouples, resistance thermometers (RTDs)
and protection sheaths can vary according to your personal
requirements.

Metal Pocket

A metal pocket is the most common

hot end protection for a cable
temperature sensor. The sensor
and cable are secured into a metal
tube which is closed at the hot end.
This provides protection for the
sensor and also an easy way to
immerse the sensor into a process.
 Moderate and Light Use
Temperature Sensors

Ceramic Pocket

A ceramic pocket is very similar to a

metal pocket but not as common.
Generally you will use a ceramic
pocket over a metal pocket if you
are measuring a higher
temperature.

Eye

A temperature sensor can be

attached to a washer, eyelet
or ring. This can they be
easily attached to a process
with a screw or bolt.

Pipe Clamp

A ceramic pocket is very similar to a

metal pocket but not as common.
Generally you will use a ceramic
pocket over a metal pocket if you
are measuring a higher
temperature.
 Moderate and Light Use
Temperature Sensors

Ceramic Pocket

A ceramic pocket is very similar to a

metal pocket but not as common.
Generally you will use a ceramic
pocket over a metal pocket if you
are measuring a higher
temperature.

Eye

A temperature sensor can be

attached to a washer, eyelet
or ring. This can they be
easily attached to a process
with a screw or bolt.

Pipe Clamp
A temperature sensor can be
attached to an adjustable pipe
clamp/clip for measuring the
temperature of pipes. This type of
cable temperature sensor is often
used in HVAC applications to find
out the temperature differential
between two pipes.
 Moderate and Light Use
Temperature Sensors

Screw Tip

A temperature sensor can be

embedded within a bolt which then
can be easily attached to a process.

Leaf
A temperature sensor can be
attached to a small foil leaf. This
is useful for measuring the
temperature between to objects
or in small spaces such as
between heater bands.

Bayonet

A temperature sensor can be

attached to a bayonet
fitting/connector. This can be
spring-loaded to keep the
measuring point in contact with the
process. Bayonet thermocouples
are often used in plastic extruders
and injection moulding machines.
 Moderate and Light Use
Temperature Sensors

Exposed Junction Cable Temperature Sensors

Some applications are so mild that the sensors require no hot

junction protection or even insulation. These are the cheapest
temperature sensors to manufacture. They are no less reliable or
accurate than any other sensors, but they are clearly vulnerable
to dust, dirt or abuse.

We would recommend them for short-term or limited use only

unless suitable housing is used. They can be so cheap that they
are disposable.

Exposed Junction Cable Temperature Sensor Example:

Exposed Junction Designs

Exposed junction sensors come in a number of different options.

From very basic sensors, to sensors with some insulation.

Bare Elements without Insulation

Basic temperature sensor elements like these are supplied

uninsulated and generally need further assembly into sheaths or
equipment. They can be supplied as replacement elements for
broken sensors if it is economical to do so.
 Moderate and Light Use
Temperature Sensors

Temperature Sensors with Basic Insulation

Ceramic Insulators
The next level of complexity for a basic temperature sensor is to
add some insulation. This ceramic insulation can come in a
number of options. Either a single length of ceramic is used, or a
number of small sections of ceramic insulator are used to add a
small amount of flexibility, finally, fish spine ceramic beads can be
used as insulation.

Wire Insulation with No Outer Sheath

Rather than ceramic insulation, plastics or glass fibre can be
used on each wire to insulate the temperature sensor conductors.
Each leg or wire can be either left loose or twisted together.

These basic sensors can still have further protection added or

further assembly conducted into equipment. The maximum
operating temperature of the sensor will be dictated by the type of
insulated used.
Wire Insulation with Outer Sheath
The final level of insulation that a basic sensor can have is
instead of having individual wires or wires twisted together, the
insulated wires can be protected by an outer sheath to form a
cable temperature sensor.

This still is a very inexpensive component for equipment

manufacturers to install. A variety of options of cable type and
sizing means this is a very flexible design that can be tailored to
your exact needs.
 Moderate and Light Use
Temperature Sensors

2. Rigid Metal Tube Temperature Sensors

Sensors mounted in rigid metal tubes provide an inexpensive
sensor which is reasonably robust. Sensors can be supplied
straight or bent according to your specification. As the sensor is
produced and fixed into a metal tube a seal can be placed in the
tube.

There is therefore no pot seal or other increase in diameter at the

cold end of the sensor. Any commercially available metal tube
can be used and many sensor types inserted into the tube. This
gives a huge range of combinations.

The tube can have process fittings welded, head connection

components attached, or deformed for a variety of application
reasons. As the sensor is not being exposed to the toughest
conditions it is usually made of Stainless Steel, although other
materials are available.

Rigid Metal Tube Temperature Sensor Example:

 Moderate and Light Use
Temperature Sensors

Rigid Metal Tube Designs

Below are some rigid metal tube temperature sensors designs.

The designs and materials of the thermocouples, resistance

thermometers (RTDs) and protection sheaths can vary according to
your personal requirements, below are only some examples.

Lead and Flexible Tails

This is the simplest design. The metal tube

transitions to flexible temperature sensor cables,
with or without a pot seal. Instead of tails a plug
or socket can be fitted.

Temperature Transmitter

The rigid metal tube is attached to a standard

DIN plate which is then connected to a
temperature transmitter. The transmitter
converts the sensor signal to a format
favoured by instrumentation such as 0-20 mA.

This enables to sensor to be easily attached

to an instrument. This is still an inexpensive
sensor design and is often used in pocket or
head assemblies. A compression fitting can
also be added. The cold end maximum
temperature will be determined by the
operating temperature of the transmitter.
 Moderate and Light Use
Temperature Sensors

Terminal Head
A wide variety of terminal heads
can be added to the cold end of a
temperature sensor. We can
provide many standard designs
such as KNE, KS, DIN B, ALA, and
BUZ.

A terminal head protects the

terminations from both physical
damage and isothermal errors.
Most heads are IP rated between
IP65 and IP67. Within the head
either loose tails, temperature
transmitter or ceramic block is
fitted. Temperature sensors with
terminal heads are most suited for
quick replacement in plants.

Terminal Block

Similar to a sensor with a temperature

transmitter. The rigid tube is attached to a
standard DIN plate, but a ceramic block is
mounted instead of a transmitter.

It is a very inexpensive design that is suitable

for pockets, heads and quick replacements. It
can be spring-loaded to ensure good thermal
contact with your process.
 Moderate and Light Use
Temperature Sensors

Sensor with Handle

A rigid tube sensor can be attached

to a plastic handle. This enables
the sensor to be easily used either
in an industrial environment or as
an insertion probe for food
manufacture and processing.

After the handle leads and tails

can be terminated with a plug to
easily connect to instrumentation or
hand-held readouts. The sensor
can be supplied with reduced or
pointed tips for easier process
insertion.

3. Mineral Insulated Cable Sensors

Mineral Insulated Metal Sheathed (MIMS) Temperature Sensor
Cable has conductors surrounded by an inert tightly packed
powder (Magnesium Oxide). The powder is held in place by a
metal sheath. Insulation resistance of over 100MΩ is possible
between each conductor and between the sheath and any
conductor.

For use in moderate applications, an mineral insulated cable is

used because it is readily available, tougher than flexible cables,
easily bent into unusual shapes and remains there, and is a
generally very robust product.
 Moderate and Light Use
Temperature Sensors

All mineral insulated sensors we supply conform to IEC

61515:2016 – Mineral insulated metal-sheathed thermocouple
cables and thermocouples.

Mineral Insulated Sensor Example:

 Moderate and Light Use
Temperature Sensors

Mineral insulated temperature sensors exhibit the following

features:

High integrity construction suited to high temperatures and

high mechanical forces
High accuracy and stability throughout the life
Fast response
Available in diameters between 0.25mm and 10.8mm
Units can be bent, twisted, or even flattened to suit an
application
Very long sensors can be supplied coiled and easily
straightened on site
The seamless metal tube is available in a number of alloys to
suit many applications – All common conductors can be
sourced
Hot junctions can be insulated, grounded or exposed

Mineral Insulated Cable Designs

Below are mineral-insulated temperature sensors designs. Links

are available to datasheets for each sensor design.

The designs and materials of the thermocouples, resistance

thermometers (RTDs) and protection sheaths can vary according
to your personal requirements, below are only some examples.
 Moderate and Light Use
Temperature Sensors

Basic Seal

A basic seal is the easiest, cheapest

and most simplistic cold end design. It
does not offer any cold end protection
and is only suitable for assembly into
your own high-volume equipment or to
fit your own cold end fitting.

The mineral insulated cable is sealed

with epoxy with the temperature
sensor conducts bare above the seal.

Lead and Flexible Tails

This is a simple design. The

mineral insulated cable
transitions to flexible
temperature sensor cables,
with or without a pot seal.
Instead of tails a plug or
socket can be fitted.
 Moderate and Light Use
Temperature Sensors
Temperature Transmitter
The mineral insulated cable is attached to a
standard DIN plate which is then connected
to a temperature transmitter.

The transmitter converts the sensor signal

to a format favoured by instrumentation
such as 0-20 mA. This enables to sensor to
be easily attached to an instrument. This is
still an inexpensive sensor design and is
often used in pocket or head assemblies.

A compression fitting can also be added.

The cold end maximum temperature will be
determined by the operating temperature of
the transmitter.
Terminal Head
A wide variety of terminal heads can be added
to the cold end of a temperature sensor. We
can provide many standard designs such as
KNE, KS, DIN B, ALA, and BUZ.

A terminal head protects the terminations from

both physical damage and isothermal errors.
Most heads are IP rated between IP65 and
IP67. Within the head either loose tails,
temperature transmitter or ceramic block is
fitted. Temperature sensors with terminal
heads are most suited for quick replacement in
plants.
 Moderate and Light Use
Temperature Sensors
Terminal Block
Similar to a sensor with a temperature
transmitter. The mineral insulated cable is
attached to a standard DIN plate, but a
ceramic block is mounted instead of a
transmitter.

It is a very inexpensive design that is

suitable for pockets, heads and quick
replacements. It can be spring-loaded to
ensure good thermal contact with your
process.

Standard Plug

A standard plug at the cold end of a

mineral-insulated temperature sensor
enables the sensor to be easily replaced
or moved. It can be plugged into various
instrumentation.

The plug is attached to the mineral

insulated cable with a pot seal. Standard
plugs are colour coded to enable
identification of the type of temperature
sensor they are connected to.
 Moderate and Light Use
Temperature Sensors
Miniature Plug

A miniature plug at the cold end of a mineral insulated

temperature sensor enables the sensor to be easily
replaced or moved. It can be plugged into various
instrumentation. The plug is attached to the mineral
insulated cable with a pot seal. Standard plugs are colour
coded to enable identification of the type of temperature
sensor they are connected to.
 5
Harsh Use
Temperature
Sensors
 Harsh Use Temperature
Sensors

These sensors are often being used close to their physical limits.
The nature of the materials used in these sensors leads to more
limited design shapes, larger sizes, thicker sections and limited
material selection. The main process resisting component is the
most important choice. There are three basic design forms for
these sensors:

1. Ceramic sheaths
2. Tough metal sheaths for high temperatures
3. Tough metal sheaths for chemical environments

1. Ceramic Sheaths

Ceramic materials reach the highest temperatures that are often

seen in the industry. Below is a summary of ceramic protection
sheath materials:
 Harsh Use Temperature
Sensors
Ceramic Sheath Designs

The sheaths are sometimes used alone but usually have either a
metal shank attached or a shank and head. This provides a full
enclosure for a sensor insert and allows a process connection to
be used without the risk of damage to the ceramic.
Sheaths are available in the following forms:

Ceramic Protection Sheath With Ceramic Protection Sheath

Platinum Thimble & Head With Shank and Head
 Harsh Use Temperature
Sensors

Ceramic Protection Sheath

Ceramic Protection Sheath With

Shank
 Harsh Use Temperature
Sensors
2. Tough Metal Sheaths for High Temperatures

Some applications are at temperatures where special alloys can

provide adequate sensor life, and be more robust than a ceramic
sheath. The tube used will usually be seamless and have a welded
disc at the cold end.

The sensor diameter will be typically 20 to 30 mm. As the sheath is

weldable, simple process connections can be easily fixed in place.
Below is a summary of metal sheath materials for high-
temperature applications:
 Harsh Use Temperature
Sensors

High Temperature Metal Sheath Designs

High temperature metal sheaths are available in the following

forms:

Fabricated Metal Protection Fabricated Metal Protection

Sleeve with Head Sleeve for Air Sensors
 Harsh Use Temperature
Sensors

Fabricated Metal Protection Fabricated Metal Protection

Sleeve with Flange Sleeve with Process Thread
 Harsh Use Temperature
Sensors

Fabricated Metal Protection Fabricated Metal Protection

Sleeve with Reduced Tip Sleeve
Harsh Use Temperature
Sensors

Right Angle Metal Protection

Sleeve
 Harsh Use Temperature
Sensors

Tough Metal Sheaths For Chemical Environments

The materials used for these sensors must withstand the

chemicals and the pressure associated with Chemical Plants. The
potential for accidents is high, this demands material certification,
pressure testing and a range of other contractual requirements.

The starting materials can be commercially available alloys,

special melts and forged grades. Very often sheaths and sensors
are built to customers' own drawings.
 Harsh Use Temperature
Sensors

Tough Metal Sheath Forms

This is a selection of what we can offer. We have many other

materials available, including fabrications with sheet cladding or
polymer coating.

Solid Drilled Pocket with Flange Solid Drilled Pocket with

Process Thread
 Harsh Use Temperature
Sensors

Solid Drilled Pocket with Stub Solid Drilled Pocket – Weld In

Flange
 6

Summary
 Summary

There can seem like there are many things that need to be taken into
account when designing a temperature sensor. The key is to
determine what are the critical factors which relate to your process or
product and dismiss the rest. If you over-engineer your temperature
sensor it won’t be economical.

In order to make the process as easy as possible answer the

questions below and send your answers to us to help you get the
sensor for your application:

What is your temperature range?

What are your accuracy requirements?
How many sensors do you need?
What are the size requirements or restrictions? Diameters?
Lengths?
How long does it need to last?
Do you require calibration?
When do you need it?
Is it light use at ambient temperature, or harsh use at extremes of
temperature, under attack?
How do you want to measure your process/product? (Hot end)
How does it connect to your equipment/instrumentation? (Cold
end)

Some of these might be “don’t know” or irrelevant but we’re here to

help.

+44 (0) 1246 261999

Made By Peak Sensors Limited
pslsales@peaksensors.com
UK Temperature Sensor Manufacturer & Supplier
peaksensors.com