9/7/2024

Lecture 8 : Thermocouple

Assistant Prof. Dr. Mahmood Aldobali

EMI DR. ADEL RAWEA

Thermocouple
• The thermocouple can be defined as a kind of temperature sensor that is used to measure the
temperature at one specific point in the form of the EMF or an electric current.
• This sensor comprises two dissimilar metal wires that are connected together at one junction.
The temperature can be measured at this junction, and the change in temperature of the metal
wire stimulates the voltages.
• The amount of EMF generated in the device is very minute (millivolts), so very sensitive
devices must be utilized for calculating the e.m.f produced in the circuit.
• The common devices used to calculate the e.m.f are the voltage balancing potentiometer and
the ordinary galvanometer. From these two, a balancing potentiometer is utilized physically
or mechanically.

Thermocouple

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Thermocouple Working Principle

• The thermocouple principle mainly depends on the three effects namely Seebeck,
Peltier, and Thompson.
• See beck-effect
• This type of effect occurs among two dissimilar metals. When the heat offers to any one
of the metal wires, then the flow of electrons supplies from hot metal wire to cold
metal wire. Therefore, direct current stimulates the circuit.
• Peltier-effect
• This Peltier effect is opposite to the Seebeck effect. This effect states that the
difference of the temperature can be formed among any two dissimilar conductors by
applying the potential variation among them.
• Thompson-effect
• This effect states that as two disparate metals fix together & if they form two joints
then the voltage induces the total conductor’s length due to the gradient of
temperature. This is a physical word that demonstrates the change in rate and direction
of temperature at an exact position.

Construction of Thermocouple
• The construction of the device is shown below. It comprises two different metal wires and that are
connected together at the junction end. The junction thinks as the measuring end. The end of the
junction is classified into three type’s namely ungrounded, grounded, and exposed junction.
Ungrounded-Junction
In this type of junction, the conductors are separated from the protecting cover. The
applications of this junction mainly include high-pressure application works. The main
benefit of using this function is to decrease the stray magnetic field effect.
Grounded-Junction
In this type of junction, the metal wires, as well as the protection cover, are connected. This
function is used to measure the temperature in the acidic atmosphere, and it supplies
resistance to the noise.
Exposed-Junction
The exposed junction is applicable where a quick response is required. This type of junction
is used to measure the gas temperature. The metal used to make the temperature sensor
depends on the calculating range of temperature.
Generally, a thermocouple is designed with two different metal wires namely iron and
constantan that detect elements by connecting at one junction that is named as a hot
junction.
This consists of two junctions, one junction is connected by a voltmeter or transmitter , and Construction of
Thermocouple
the cold junction and the second junction are associated in a process that is called a hot
junction.

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Thermocouple Work
• The thermocouple diagram is shown in the below picture. This circuit can be built with two different metals, and
they are coupled together by generating two junctions. The two metals are surrounded by the connection through
welding.
• The junctions are denoted by P & Q, and the temperatures are denoted by T1, & T2. When the temperature of
the junction is dissimilar from each other, then the electromagnetic force generates in the circuit.
• If the temperate at the junction end turns into an equivalent, then the
equivalent, as well as reverse electromagnetic force, is produced in the
circuit, and there is no flow of current through it. Similarly, the
temperature at the junction end becomes imbalanced, then the potential
variation is induced in this circuit.
• The magnitude of the electromagnetic force induced in the circuit relies
on the sorts of material utilized for thermocouple making. The entire flow
of current throughout the circuit is calculated by the measuring tools.
• The electromagnetic force induced in the circuit is calculated by the
following equation
E = a (∆Ө) + b (∆Ө)2
Where ∆Ө is the temperature difference among the hot thermocouple
junction end as well as the reference thermocouple junction end, a & b are
constants. Thermocouple circuit

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Thermocouple Types
• In before going with a discussion of thermocouple types, it has to be considered that
thermocouple needs to be protected in a protective case to isolate from the atmospheric
temperatures. This covering will significantly minimize the corrosion impact on the device.
• So, there are many types of thermocouples. Let us have a detailed look at those.
• Type K – This is also termed as Nickel-Chromium/Nickel-Alumel type of thermocouple.
• It is the most generally used type. It has the features of enhanced reliability, preciseness, and
inexpensive and can operate for extended temperature ranges.

The temperature ranges are:

Thermocouple grade wire – -454F to 2300F (-2700C to 12600C)
Extension wire (00C to 2000C)
This K-type has an accuracy level of
Standard +/- 2.2C or +/-0.75% and the special limits are +/- 1.1C
or 0.4%
Thermocouple Type K

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Thermocouple Types
• Type J – It is a mix of Iron/Constantan. This is also the most used type of thermocouple. It has
the features of enhanced reliability, preciseness, and inexpensive. This device can be operated
only for lesser temperature ranges and has a short lifespan when operated at a high range of
temperatures.
The temperature ranges are:

Thermocouple grade wire – -346F to 1400F (-2100C to 7600C)

Extension wire (00C to 2000C)

This J-type has an accuracy level of

Standard +/- 2.2C or +/-0.75% and the special limits are +/- 1.1C
or 0.4%
Thermocouple Type J

Thermocouple Types
• Type T – It is a mix of Copper/Constantan. The T type thermocouple holds increased stability
and is generally implemented for lesser temperature applications like ultra-low temperature
freezers and cryogenics.

The temperature ranges are:

Thermocouple grade wire – -454F to 700F (-2700C to 3700C)

Extension wire (00C to 2000C)

This T-type has an accuracy level of

Standard +/- 1.0C or +/-0.75% and the special limits are +/- 0.5C Thermocouple Type T
or 0.4%

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Thermocouple Types
• Type E – It is a mix of Nickel-Chromium/Constantan. It has a greater signal ability and
improved accuracy when compared with that of Type K and J thermocouples when operated at
≤ 1000F

The temperature ranges are:

Thermocouple grade wire – -454F to 1600F (-270C to 870C)

Extension wire (00C to 2000C)

This T-type has an accuracy level of

Standard +/- 1.7C or +/-0.5% and the special limits are +/- 1.0C or Thermocouple Type -E
0.4%

Thermocouple Types
• Type N – It is considered as either Nicrosil or Nisil thermocouple. The temperature and
accuracy levels of type N are similar to type K. But this type is more expensive than type K.

The temperature ranges are:

Thermocouple grade wire – -454F to 2300F (-2700C to 3920C)

Extension wire (00Cto 2000C)

This T-type has an accuracy level of

Standard +/- 2.2C or +/-0.75% and the special limits are +/- 1.1C Thermocouple Type -N
or 0.4%

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Thermocouple Types
• Type S – It is considered as either Platinum/Rhodium or 10%/Platinum thermocouple. The S
type of thermocouple is extremely implemented for high-temperature range applications such
as in Biotech and pharmacy organizations. It is even used for lesser temperature range
applications due to its increased preciseness and stability.
The temperature ranges are:

Thermocouple grade wire – -58F to 2700F (-500C to 14800C)

Extension wire (00C to 2000C)

This T-type has an accuracy level of

Standard +/- 1.5C or +/-0.25% and the special limits are +/- 0.6C
or 0.1%

Thermocouple Type -N

Thermocouple Types
• Type R – It is considered as either Platinum/Rhodium or 13%/Platinum thermocouple. The S
type of thermocouple is extremely implemented for high-temperature range applications. This
kind is included with a higher amount of Rhodium than Type S that makes the device more
costly. The features and performance of type R and S are nearly similar. It is even used for
lesser temperature range applications due to its increased preciseness and stability.

The temperature ranges are:

Thermocouple grade wire – -58F to 2700F (-500C to 14800C)

Extension wire (00C to 2000C)

Thermocouple Type -R
This T-type has an accuracy level of

Standard +/- 1.5C or +/-0.25% and the special limits are +/- 0.6C
or 0.1%

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Thermocouple Types
• Type B – It is considered as either 30% of Platinum Rhodium or 60% of Platinum Rhodium
thermocouple. This is widely used in the higher range of temperature applications. Of all the
above-listed types, type B has the highest temperature limit. At the increased temperature
levels, the type B thermocouple will hold increased stability and accuracy.
The temperature ranges are:
Thermocouple grade wire – 32F to 3100F (00C to 17000C)
Extension wire (00C to 1000C)
This T-type has an accuracy level of
Standard +/- 0.5%
The types S, R, and B are considered noble metal thermocouples.
These are chosen because they can function even at high-
temperature ranges providing great accuracy and a long lifetime.
But, when compared with base metal types, these are more Thermocouple Type -B
expensive

What is the Difference Between Thermostat and Thermocouple?

Feature Thermocouple Thermostat

Range of Temperature -454 to 32720F -112 to 3020F

Price Range Less High

Stability Provides less stability Provides medium stability

Sensitivity Thermocouple has less sensitivity Thermostat offers the best stability

Linearity Moderate Poor

System cost High Medium

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What is the Difference Between RTD and Thermocouple?

RTD Thermocouple
RTD is extensively suitable for measuring less The thermocouple is suitable for measuring a
range of temperature which are between (- higher range of temperature which are
2000C to 5000C) between (-1800C to 23200C)
For a minimal range of switching’s, it exhibits These have minimal stability and also results
increased stability are not precise when tested multiple times

It has more accuracy than a thermocouple Thermocouple has less accuracy

The sensitivity range is more and can even The sensitivity range is less and these cannot
calculate minimal temperature changes calculate minimal temperature changes
Thermocouples provide a quick response than
RTD devices have a good response time
that of RTD
The output is linear in shape The output is non-linear in shape

These are more expensive than thermocouple These are economical than RTDs

Advantages & Disadvantages

• The advantages of thermocouples include the following.
• Accuracy is high
• It is Robust and can be used in environments like harsh as well as high vibration.
• The thermal reaction is fast
• The operating range of the temperature is wide.
• Wide operating temperature range
• Cost is low and extremely consistent
• The disadvantages of thermocouples include the following.
• Nonlinearity
• Least stability
• Low voltage
• Reference is required
• least sensitivity
• The thermocouple recalibration is hard

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Applications
• Some of the applications of thermocouples include the following.

• These are used as the temperature sensors in thermostats in offices, homes,

offices & businesses.
• These are used in industries for monitoring temperatures of metals in iron,
aluminum, and metal.
• These are used in the food industry for cryogenic and Low-temperature
applications. Thermocouples are used as heat pumps for performing
thermoelectric cooling.
• These are used to test temperature in chemical plants, petroleum plants.
• These are used in gas machines for detecting the pilot flame.

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