Thermocouples are the most common temperature sensing device. They work by generating a voltage (EMF) based on the Seebeck effect from the junction of two dissimilar metals. Thermocouples are inexpensive, can withstand tough conditions, and provide point temperature measurements over a wide range from -250°C to +2500°C. They have limitations such as non-linearity and needing cold junction compensation, but remain popular for industrial and scientific temperature measurement applications.

1. Thermocoupl
e
Akhil Mahajan

2. Outline
• How to measure temperature?
• Comparisons
 What Is A Thermocouple Sensor?
 Basic Working Principle
 Practical Thermocouple Construction
 Thermocouple Materials
 Standard Thermocouple Types
 Thermocouple Color Codes
 Characteristics
 Major Specifications
 Capabilities and Limitations
 Selecting A Temperature Sensor

3. How to Measure
Temperature?
• What is temperature?
• What effects may temperature cause on material or structure?
• Examples:
– Resistance
– Volume
– EMF (Electromotive Force, Thomas Seebeck effect 1821 from the joint of
two dissimilar metals)
– Thermal radiation (astronomy, the temperature of a star)
– Appearance (color)
• Existing sensors:
– RTD (Resistance Temperature Device), thermistor
– Thermometer (thermal expansion device, use mercury or organic fluid or
bimetallic device)
– Thermocouple
– Infrared radiator
– Liquid crystal (change of state device)

4. Thermocouples are among the easiest temperature sensors
to use and obtain and are widely used in science and
industry.
Thermocouples are the most common temperature sensing
device. They can be made in very tough designs, they are
very simple in operation and measure temperature at a
point. Over different types they cover from -250C to
+2500C.
Accurate temperature measurements can be made with
thermocouples sensors at low cost with shop-built probes
and ordinary low-level voltmeters.

5. Basic Working Principle
The principle of operation is on the Seebeck effect. A temperature
gradient along a conductor creates an EMF. If two conductors of
different materials are joined at one point, an EMF is created
between the open ends which is dependent upon the temperature
of the junction. As T1 increases, so does V. The EMF also
depends on the temperature of the open ends T2.
The junction is placed in the process, the other end is in iced
water at 0C. This is called the reference junction.
( is the Seebeck coefficient for small delta T)

6. Practical Thermocouple Construction
A thermocouple construction consist of two conductors,
welded together at the measuring point and insulated from each
other long the length. It will usually have an outer protection
sheath.
Cont.

7. Thermocouple Construction
 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

8. Reference Temperature Systems
 Ice Baths
◦ Accurate and inexpensive
 Electronically Controlled References
◦ Require periodic calibration and are
generally not as stable as ice baths, but are
more convenient.

9. Zone
boxes
◦ A zone of uniform temperature
that insures all connections made
within the zone are at the same temperature.

10. Thermocouple Materials
The three most common thermocouple materials for moderate
temperatures are Iron-Constantan (Type J), Copper-
Constantan (Type T), and Chromel-Alumel (Type K).
1-) The first named element of the pair is the positive element.
2-) The negative wire is color coded red.
All three types (J, K, and T) are available as insulated
duplexed pairs from 0.001-inch diameter on up. For accuracy,
and minimum system disturbance, the smaller the wire the
better, but wire smaller than 0.003-inch diameter is very
fragile.

11. Standard Thermocouple Types
Iron-Constantan: Iron-Constantan (Type J, color coded white and red)
generates about 50 µV/°C (28 µV/°F). The Iron wire is magnetic.
Junctions can be made by welding or soldering, using commonly
available solders and fluxes. Iron-Constantan thermocouples can
generate a galvanic EMF between the two wires and should not be
used in applications where they might get wet.
Chromel Alumel: Chromel-Alumel (Type K, color coded yellow and
red) generates about 40 µV/°C (22 µV/°F). The Alumel wire is
magnetic. Junctions can be made by welding or soldering, but high
temperature silver-solders and special fluxes must be used.
Chromel-Alumel thermocouples generate electrical signals, while
the wires are being bent, and should not be used on vibrating
systems, unless strain relief loops can be provided.
Copper-Constantan: Copper-Constantan (Type T, color coded blue and
red) generates about 40 µV/°C (22 µV/°F). Neither wire is magnetic.
Junctions can be made by welding or soldering with commonly
available solders and fluxes. Copper-Constantan thermocouples are
very susceptible to conduction error, due to the high thermal
conductivity of the copper, and should not be used unless long runs
of wire (100 to 200 wire diameters) can be laid along an isotherm.

12. Thermocouple Material Vs EMF
Types T, J, and K are most commonly used thermocouples

13. Thermocouple Color Codes
Thermocouple wiring is color coded by
thermocouple types. Different countries utilize
different color coding. Jacket coloring is sometimes
a colored stripe instead of a solid color as shown.

14. Major Specifications
Type J: Iron / Constantan:Useful range of temperature is 0-750
0C. Can be used in vacuum, oxidizing, reducing and inert
atmospheres.Possible problems: Oxidizes rapidly due to the
iron wire. The use of the stainless steelmetal sheathed MgO
style of construction has overcome some of this problem and
is much preferred over the beaded bare wire style of
thermocouple.
Type E: Chromel / Constantan Useful range of temperature is –
200-900 0C. The type E thermocouple has the highest millivolt
(EMF) output of all established thermocouple types. Type E
sensors can be used in sub-zero, oxidizing or inert pplications
but should not be used in sulfurous, vacuum or low oxygen
atmospheres.

15. Major Specifications……
Type R and S: Platinum / Platinum-Rhodium Useful range of
temperature is 0-1450 0C. Both the R and S thermocouples are
used for very high temperatures. These couples are relatively
expensive compared to other thermocouples since they are
made of platinum. These thermocouples must not touch the
sheath if a metal sheath is used for construction. Normally a
ceramic protective tube and ceramic beads are used for
construction for both high temperature reasons and to prevent
contamination of the noble metal.
Type T: Copper / Constantan Useful range of temperature is -200-
350 0C. Type T sensors can be used in oxidizing (below 700F),
reducing or inert applications.
Type K: Chromel / Alumel Useful range of temperature is -200-
1250 0C. Type K sensors are recommended for use in oxidizing
or completely inert environments. type K has better oxidation
resistance then types E, J and T.

16. Characteristics
Thermocouples have non-linear characteristics given
by an approximating polynomial.
For example for type J (range 1, -210 to 760°C) the
characteristic is given by
where V is in and T in °C
The output signal from a thermocouple is up to 50mV.

17. Temperature Conversion Table
(I)
• The type of thermocouple is associated with the type of metal joints.
• Constanan is a generic name of copper-nickel alloy. Its composition
is not the same when used in types E, J and T.

18. Temperature Conversion Table (II)
• Hand-held portable thermocouple readout has done this voltage-
temperature conversion in the circuit for users.
• Have to match the right type of thermocouple specified in the
readout.

19. 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.

20. Law of Intermediate
Temperatures
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 it will develop a net voltage of
emf1-3 = emf1-2 + emf2-3 when the
junctions are at temperatures T1 and
T3.
emf1-2+ emf2-3= emf1-3
T2
T3 T1
T3 T2
T1

21. Capabilities and Limitations
Capabilities:
- Wide Range
- Fast Response
- Passive
- Inexpensive
Limitations:
- CJC
- Non-Linear

22. How to Select Thermocouple?
• Junction protection: sheath or not.
• Tip size: big or small
• Thermocouple type (T, J, K, E, S, R):
–Temperature range (cryogenic or high temperature)
–Corrosion (noble metal is more inert to chemical
attack)
• Termination: wire or connector
• Cost

23. How to Use Thermocouple (TC)?
• The tip of TC should be buried inside the material and gets
to the test point as close as possible.
• Use thermally conductive epoxy or thermal interface material
to mount TC.
• The extension cord should match the type of TC. Otherwise,
additional Emf errors would be produced at junctions.
• To reduce the noise, the TC wires can be wrapped with
aluminum foil as a EMI shield.
• To calibrate any signal drifting, use fixed points such as
water boiling point (100°C at 1atm) and ice melting point (0
°C at 1atm) for calibration.

24. Figure showing how to use thermocouple

25. Comparison of Temperature
Sensors

26. Temperature Measurement
Errors
 Conduction
 Convection
 Radiation
 Response Time
 Noise
 Grounding issues and shorts,
especially on metal surfaces