Thermocouple

A thermocouple is created whenever two dissimilar metals touch and

the contact point produces a small open-circuit voltage as a function of
temperature. This thermoelectric voltage is known as the Seebeck
voltage, named after Thomas Seebeck, who discovered it in 1821. The
voltage is nonlinear with respect to temperature. However, for small
changes in temperature, the voltage is approximately linear, or
ΔV=σ * ΔT
where ΔV is the change in voltage, σ is the Seebeck
coefficient, and ΔT is the change in temperature.
Material EMF versus Temperature
Chromel With reference to
the characteristics
of pure Platinum
Iron
emf Copper
Platinum-Rhodium

Alumel

Constantan
Temperature
Emf output of a thermocouple

Thermo electric power

mV/deg A

t1 t2
Temperature
 Thermocouple Effect
• Any time a pair of dissimilar wires is joined
to make a circuit and a thermal gradient is
imposed, an emf voltage will be
generated.
– Twisted, soldered or welded junctions
are acceptable. Welding is most
common.
– Keep weld bead or solder bead
diameter within 10-15% of wire
diameter
– Welding is generally quicker than
soldering but both are equally
acceptable
– Voltage or EMF produced depends on:
• Types of materials used
• Temperature difference between
the measuring junction and the
reference junction
 Thermocouple types
Several types of thermocouples are available; these thermocouples are
designated by capital letters that indicate their composition.
The ISA in the USA started the standards on Thermocouple
nomenclature that includes the letter conventions used to describe
certain alloy wire pairs. This is now carried on around the World and
ASTM Committee E20 on Temperature provides the standard ASTM
E230 that is now the American National Standard for the letter
designation, the calibration tables, the color coding and recommended
use limits of the most common types of thermocouple wire pairs
 Thermocouple types

TC Type Colour Range C Conductors – Positive Conductors – Negative

K Yellow/Red -270 to1372 Chromel Alumel

N Orange/Red -270 to 1300 Nicrosil Nisil

J White/Red -210 to 1200 Iron Constantan

E Purple/Red -270 to1000 Chromel Constantan

T Blue/Red 0 to 400 Copper Constantan

R Black/Red -50 to 1768 Platinum-13% rhodium Platinum

S Black/Red -50 to 1768 Platinum-10% rhodium Platinum

B Grey/Red 0 to 1700 Platinum-30% rhodium Platinum-6% rhodium

 Thermocouple calibration curves
• The curves of
thermocouple voltage
versus temperature for
00C reference show the
different sensitivities
and nonlinearities.
Laws of thermoelectric circuits :
Law of Homogeneous circuit
An electric current can not be sustained in a circuit of a
single homogeneous metal, however varying in section,
by the application of heat alone.
 Law of Intermediate Metals
Insertion of an intermediate metal
into a thermocouple circuit will not
affect the emf voltage output so
long as the two junctions are at the
same temperature and the material is
homogeneous.
– Permits soldered and welded joints.
– Permits insertion of measuring device,
provided that all intermediate junctions are
at same temperature.
 Law of Intermediate Temperatures
T2 T1 If a thermocouple circuit develops a
net emf1-2 for measuring junction
temperatures T1 and T2, and a net
emf2-3 for temperatures T2 and T3, then
T3 T2 it will develop a net voltage of emf1-3 =
emf1-2 + emf2-3 when the junctions are
at temperatures T1 and T3.

T3 T1
emf1-2+ emf2-3= emf1-3
– Permits cold junction compensation.
 Thermocouple

Grounded - In grounded thermocouples, the conductors are contained in a sheath with mineral
insulation, but the actual hot junction is welded to the end of the sheath (see figure #1). This
provides a
great deal of ruggedness and environmental protection without sacrificing too much response time.
The
disadvantage of this construction is that there is no protection if stray voltages come in contact with
the
sheath.
Exposed - In this construction, the conductors actually extend beyond the sheath or there is no
sheath at all (see figure #3). This provides excellent response time, but no protection from the
environment
or stray voltages. Exposed thermocouples are relatively fragile.
Ungrounded (Insulated) - The ungrounded construction is similar to the grounded construction
except the hot junction is totally contained within the sheath (see figure #2). This provides complete
 Thermocouple Advantages and
Disadvantages

• Advantages: • Disadvantages:
– Self Powered (does not – Extremely Low
require a current or Voltage output (mV)
voltage source) – Not very stable
– Rugged – Not very linear
– Inexpensive – Needs a reference
– Simple point
– Wide range
– Fast response