THERMO

COUPLE
 Thermocouples
A thermocouple is defined as a thermal junction that functions
based on the phenomenon of the thermoelectric effect, i.e. the
direct conversion of temperature differences to an electric voltage.
It is an electrical device or sensor used to measure temperature.
A thermocouple can measure a wide range of temperatures. It is a
simple, robust, and cost-effective temperature sensor used in
various industrial applications, home, office, and commercial
applications.
 Seebeck Effect

In 1821, German physicist Thomas Johann Seebeck found that a

magnetic field is produced when two different metals are connected
at one end and create a temperature difference between two ends.
This voltage is very small (in terms of mV) and depends on the type
of metal used in the thermocouple.
 How does a Thermocouple Work?
• A thermocouple consists of two plates of different metals. Both
plates are connected at one end and make a junction.
• The junction is placed on the element or surface where we want to
measure the temperature. This junction is known as a hot junction.
And the second end of the plate is kept at a lower temperature
(room temperature). This junction is known as cold junction or
reference junction.
Principle of operation
 Thermocouple Types

According to different types of combinations of alloys, the

thermocouples are available in different types. The type of
thermocouple is chosen according to the application, cost,
availability, stability, chemical properties, output, and temperature
ranges.
 K type

The K type thermocouple is the most common type of

thermocouple, and it has the widest temperature measuring range.
The positive lead of Type K thermocouple is composed of
approximately 90% nickel and 10% chromium. The negative lead is
composed of approximately 95% nickel, 2% aluminum, 2%
manganese, and 1% silicon.
The positive lead is colored yellow and it is a non-magnetic
material. The negative lead is colored red and it is a magnetic
material. And the overall jacket is colored yellow.
The temperature range of type K thermocouple is -200˚C to
+1260˚C (-328 F to +2300 F). It is inexpensive and widely used in
the general-purpose applications where temperature sensitivity
requires approximately 41μV/˚C.
The accuracy of type K thermocouple is ±2.2 C% (0.75%). The
accuracy of thermocouple also depends on the deviation in alloys.
 Type T Thermocouple

This type of thermocouple is suitable to measure the low

temperature. The positive lead is composed of copper and the
negative lead is composed of constantan (45% nickel and 55%
copper).
The sensitivity of the type T thermocouple is 43 µV/°C. This
thermocouple is suitable to works in an oxidizing atmosphere. The
temperature range of this thermocouple is between -200°C to
350°C.
 Type J Thermocouple
This type of thermocouple is a low cost and most used
thermocouple. The positive lead is made of iron and a negative lead
is made of constantan (45% nickel and 55% copper).
The positive lead is colored white and the negative terminal is
colored red. And the overall jacket is colored black.
The temperature range of type J thermocouple is between -210˚C to
750˚C (-346F to 1400F). This type of thermocouple has a smaller
temperature range and short life span compared to type K
thermocouple. But this type of thermocouple is well suited for the
oxidizing atmospheres.
The accuracy of this type of thermocouple is ±2.2˚C (0.75%). This
type of thermocouple is not recommended for lower temperature
applications. And the sensitivity of this type of thermocouple is
approximately 50μV/˚C.
 Type E Thermocouple
This type of thermocouple has higher accuracy and stronger signal
than type K and J thermocouple at moderate temperature ranges.
And it is a more stable type thermocouple than type K. The type E
thermocouple produces the highest EMF per degree than other types
of a thermocouple.
The positive lead is composed of nickel-chromium (90% nickel and
10% chromium) and a negative terminal is composed of constantan
(95% nickel, 2% aluminum, 2% manganese, and 1% silicon). The
positive lead is colored purple and negative lead-colored red.
The temperature range of this type of thermocouple is between
-270˚C to 870˚C (454 to 1600F). And standard accuracy is ±1.7˚C
%.
This type of thermocouple is used where high accuracy and fast
response required. It is not used for vacuum or low oxygen
applications and Sulphuric environment. The cost of type E
thermocouple is more than the type J and K thermocouple.
 Type N Thermocouple
Type N thermocouple is designed by the Defense Science and
Technology Organization (DSTO) of Australia, by Noel A. Burley.
The accuracy and temperature limits of type N thermocouple is the
same as the type K thermocouple.
The temperature range of type N thermocouple is between -270 °C
and 1300 °C. Sensitivity is slightly lower than type K thermocouple
and it is 39μV/˚C.
Type N thermocouple is composed of Nicrosil and Nisil. Where
Nicrosil is a combination of Nickel, Chromium, and Silicon. And it
made positive wire. The Nisil is a combination of Nickel and
Silicon. And it made negative wire.
This thermocouple is the best alternative of type K thermocouple
for low oxygen conditions. This type of thermocouple is suitable to
use in vacuum, oxidizing atmosphere, inert atmosphere, or dry
atmosphere
 Type S Thermocouple
Type S thermocouples are used for higher temperature applications.
Because of high accuracy and stability, sometimes it is used for low
temperature also.
The temperature range of type S thermocouple is between 630 °C to
1064 °C. The positive lead is composed of 90% platinum, 10%
Rhodium, and the negative led is composed of Platinum.
Generally, this type of thermocouple is used in the application like
Pharmaceutical and Biotech industries where the high temperature
should be measure with high accuracy.
 Type R Thermocouple
Type R thermocouple is also composed of Platinum and Rhodium.
But the output range and stability of type R thermocouple is slightly
more than the type S thermocouple.

The positive lead pf type R thermocouple is composed of 87%

Platinum and 13% Rhodium. And the negative lead is composed of
Platinum. The temperature range of this thermocouple is between 0
°C to 1600 °C.
 Type B Thermocouple
Type B thermocouples are also made up of a combination of
Platinum and Rhodium. The positive lead of a thermocouple is
composed of 70% Platinum and 30% Rhodium. And the negative
lead is composed of 94% Platinum and 6% Rhodium.

Type B thermocouple is used to measure the temperature up to

1800°C. But the output of this thermocouple is lower compared to
type R and S thermocouples.
Seebeck Effect
Circuit construction
 Standard Calibration Setup

Ice-point

The result of the calibration is a table of EMF versus T

values. The integral is never directly evaluated.
Instead a polynomial curve fit to the calibration data
gives:
E  F T   b T 2  .....  b T
0j n
2 j n
 Material EMF versus Temperature

Chromel

Iron
emf Copper
Platinum-Rhodium
With reference to
the
characteristics of
Alumel
pure Platinum

Constantan
Temperature
Thermocouple temperature vs.Voltage graph
Seebeck coefficient vs. Temperature
 Applications
1. Steel industry
2. Gas appliance safety
3. Thermopile radiation sensors
4. Manufacturing
5.Power production
6.Thermoelectric cooling
7.Process plants
8.Thermocouple as vacuum gauge
A thermocouple (the right most tube) inside the burner
assembly of a water heater.
Thermocouple connection in gas appliances. The end ball (contact) on the left is insulated
from the fitting by an insulating washer. The thermocouple line consists of copper wire,
insulator and outer metal (usually copper) sheath which is also used as ground.
Type
Advantages
 Bio Medical Application

heating of pacemaker leads during magnetic resonance

imaging (MRI)
 Estimation of brain protection during cardiopulmonary
surgery
cryogen spray cooling
 thermal treatment using cryotherapy of breast fibro
adenomas
 RTD vs Thermocouple

RTD (Resistance Thermometer Detectors) and Thermocouple both devices are

used to measure the temperature. And it is difficult to conclude which is better
for overall performance as a temperature sensor.

But if you specify some performance parameters like cost, range of

temperature, ruggedness, and speed of measurement, the thermocouple has a
better performance compared to RTD.

The cost of a thermocouple is much less (almost 2.5 to 3 times) compared to

RTD. And also, the cost of installation is cheaper. The RTD is designed to
measure a limited range of temperatures.

The advantage of an RTD is that it is more accurate compared to the

thermocouple. And the repeatability of measurement is more compared to the
thermocouple. Hence, RTD is preferred in the application where the most
accurate temperature is required.

So, both devices have their advantages and disadvantages. The thermocouple
has a wide range of temperature measurements, cheaper, and durable. On the
other hand, RTD has better accuracy and reliable measurement.
 RTD VS THERMISTOR

The Thermistor and the RTD both are the temperatures measuring device. The

major difference between the RTD and the Thermistor is that the RTD is made of
metal, whereas the semiconductor material is used for Thermistor.  The other
differences between the Thermistor and RTD are explained below in the
comparison chart.
As the Thermistor is made of semiconductor material, they have both the
negative and positive temperature coefficient. But most of them thermistor have
a negative temperature coefficient, i.e., their resistance decreases with the
increases in temperature. The negative temperature coefficient can be large
enough for several percentage increases in temperature because of the
Thermistor can detect the small changes in temperature.
The RTD is made of pure metal like platinum, nickel, etc., which has a positive
temperature coefficient. The positive temperature coefficient means their
resistance increases with the temperature, which is the main function of RTD.
The RTD is used for measuring the large variation in temperature.