Thermocouple Wires

Thermocouples operate using the Seebeck effect, which creates an electromotive force when dissimilar metals are heated. They come in various shapes, sizes and colors with specific alloy combinations that define each type.

Thermocouple wires (conductors) are insulated conductors that carry temperature information from an outdoor sensor to a computer system. They're typically color coded and marked with letters that identify their type.
Insulation

Thermocouple wires are flexible and insulated cable that sense temperature, feeding that information back to a temperature controller or monitor. Their operation relies on the Seebeck effect, which generates an electromotive force (emf) between dissimilar metals at different temperatures through two conductors that have distinct alloy compositions - hence their many different thermocouple wire types with unique alloy compositions and voltage versus temperature tables.

Different insulation materials provide unique advantages in specific applications and environments; making the right selection can improve overall performance while lengthening cable lifespan. Some popular choices for heat resistant cables include heat resistant PVC, Teflon, fiberglass and ceramic fibre insulation materials.

Consider environmental conditions and potential corrosion when selecting insulation for thermocouple wires. Moisture, chemicals and vibration can interfere with their accuracy and cause false readings; make sure you verify connections regularly as part of a scheduled calibration regime to maintain accurate temperature monitoring systems.
Conductors

Thermocouple wires come in pairs with each conductor being of differing metal alloy composition and use the Seebeck effect to generate electron flow between dissimilar metal alloys at various temperatures to generate small voltage measurements that can be recorded. Extension cables often feature metal sheathing for added corrosion protection. Stainless steel sheathing may also protect insulation against further degradation over time.

According to their application, some thermocouple wires use precious metals such as platinum and platinum/rhodium for accurate measurement results and exceptional durability. These thermocouple wires are ideal for measuring in harsh and high-temperature environments.

For most applications, a standard grade thermocouple works just fine. To maximize performance and ensure best results, opt for an Special Limits of Error (SLE) thermocouple wire with extended temperature range and high precision that matches the needs of your application. When selecting one for future expansion and compatibility with existing equipment. Consult a full set of calibration tables, letter designations, color codes and suggested use limits when selecting an SLE thermocouple cable that's right for you.
Connectors

Thermocouple connectors connect thermocouple probes with their respective measuring instrument, control system or digital indicator in order to ensure accurate temperature measurements on display. They come in various designs, utility and shape options.

As a general guideline, thermocouple connections should use special connectors. This is because thermocouples rely on the junction voltage between two different metals and any third-metal present could introduce unwanted voltage into the circuit.

Connectors should use the same alloy as thermocouple wire or extension cable connectors. Failure to do so may lead to green rot, an oxidation process which reduces output from chromel alloy and causes thermocouple readings to dip low; eventually this could even cause it to fail completely! In order to prevent this scenario from arising all connectors should be regularly examined, cleaned and calibrated as part of an ongoing maintenance schedule.
Extending Thermocouple Wire

Thermocouple wires emit type k thermocouple cable an extremely low voltage signal that is highly vulnerable to interference, so it is vital that they be placed away from power cables, motors and other electrical devices that could compromise its transmission.

As soon as you extend a thermocouple, its accuracy will become compromised due to changes in temperature along its path. You can lessen its effects by employing special construction thermocouple extension wire or RTD cable; Pyromation offers various sizes and types to meet all of your process needs.

A thermocouple extension wire is composed of thermoelectric alloy materials similar to that used in its thermocouple, so its properties and thermal EMF behavior remain consistent across its entirety. Furthermore, many applications call for the addition of a connector head which provides protection for terminal connections while helping eliminate loose ends which could otherwise lead to errors caused by loose connections. Some varieties even come equipped with Standard Limits of Error (SLE) and Special Limits of Error (SPE) classifications for additional flexibility in your applications.