`

THERMOCOUPLE

Introduction
A thermocouple is an electrical device consisting of two different conductors forming electrical
junctions at differing temperatures. A thermocouple produces a temperature-dependent voltage as
a result of the thermoelectric effect, and this voltage can be interpreted to measure temperature.
Thermocouples are a widely used type of temperature sensor.
Commercial thermocouples are inexpensive, interchangeable, are supplied with standard
connectors, and can measure a wide range of temperatures. In contrast to most other methods of
temperature measurement, thermocouples are self-powered and require no external form of
excitation. The main limitation with thermocouples is accuracy; system errors of less than one
degree Celsius (C) can be difficult to achieve.
Thermocouples are widely used in science and industry; applications include temperature
measurement

for kilns, gas

turbine exhaust,

diesel,

and

other

industrial

processes.

Thermocouples are also used in homes, offices and businesses as the temperature sensors in
thermostats, and also as flame sensors in safety devices for gas-powered major appliances.

Principle
When different metals are joined at the ends and there is a temperature difference between the
joints a magnetic field is observed.
In practical use the voltage generated at a single junction of two different types of wire is what is
of interest as this can be used to measure temperature at very high and low temperatures. The
magnitude of the voltage depends on the types of wire used. Generally, the voltage is in the
microvolt range and care must be taken to obtain a usable measurement. Although current flows
very little, power can be generated by a single thermocouple junction. Power generation using
multiple thermocouples, as in a thermopile, is common. As shown in figure.

Types and range of thermocouple

Thermocouple Type

Composition

Temperature Range

Platinum 30% Rhodium (+)

2500-3100 degrees F

Platinum 6% Rhodium (-)

1370-1700 degrees C

W5Re Tungsten 5% Rhenium (+)

3000-4200 degrees F

W26Re Tungsten 26% Rhenium (-)

1650-2315 degrees C

Chromel (+)

200-1650 degrees F

Constantan (-)

95-900 degrees C

Iron (+)

200-1400 degrees F

Constantan (-)

95-760 degrees C

Chromel (+)

200-2300 degrees F

Alumel (-)

95-1260 degrees C

Nickel (+)

32-2250 degrees F

Nickel (-)

0-1287 degrees C

Nicrosil (+)

1200-2300 degrees F

Nisil (-)

650 -1260 degrees C

Platinum 13% Rhodium (+)

1600-2640 degrees F

Platinum (-)

870-1450 degrees C

Platinum 10% Rhodium (+)

1800-2640 degrees F

Platinum (-)

980-1450 degrees C

Copper (+)

negative 330-660 degrees

F
negative 200-350 degrees
C

C
E
J
K
M
N
R
S
T

Constantan (-)

Applications
3

Type K (-270 to +1370C / -454 to +2498F)

The Type K is a 'general purpose' thermocouple with a wide temperature range. With a variety of
probe types available, it is suitable for use across many industries and processes.

Testing temperatures associated with process plants e.g. chemical production and

petroleum refineries
Testing of heating appliance safety

Type J (-210 to +1200C / -346 to +2192F)

The Type J is a popular thermocouple that is commonly used to monitor temperatures of inert
materials and in vacuum applications. This thermocouple is susceptible to oxidization so is not
recommended for damp conditions or low temperature monitoring. (Note the accuracy of this
sensor may be permanently impaired if used above 760C.)

Monitoring in a vacuum and for inert metals

Hot processes including plastics and resin manufacture

Type T (-270 to +400C / -454 to +752F)

The Type T is used widely in the food industry, mainly due to the high level of accuracy it
provides and because it performs well in the presence of moisture without oxidizing. If in general
a lower range temperature measurement is required, the Type T is popular choice.

Monitoring in food processing and production to identify potential food safety hazards

and comply with HACCP regulations

Suitable for low temperature and cryogenic applications

Type N (-270 to +1300C / -454 to +2372F)

`
The Type N also has a wide temperature range, but is better suited to high temperature monitoring than
the Type K because it is more stable and resists oxidization .

Temperature profiling in ovens, furnaces and kilns

Temperature measurement of gas turbine and engine exhausts
Monitoring of temperatures throughout the production and smelting process in the steel,
iron and aluminum industry