DO NOT PHOTOCOPY - SEE PRINTING RESTRICTIONS IN "ABOUT THIS LIBRARY" TABLE OF CONTENTS 2.2.

6 Thermocouple assembly A thermocouple assembly is an assembly consisting of a thermocouple element and one or more associated parts such as terminal block, connection head, and protecting tube. 1) Terminal block: A terminal block is a block of insulating material that is used to support and join the terminations of conductors. (See Figure 2.) PREVIOUS PAGE

Figure 2 Thermocouple element with terminal block

2) Connection head: A connection head is a housing enclosing a terminal block for an electrical temperature sensing device and usually provided with threaded openings for attachment to a protecting tube and for attachment of conduit. (See Figures 3 and 4.)

Figure 3 Thermocouple element with connection head

Figure 4 Connection head

3) Connection head extension: A connection head extension is a threaded fitting or an assembly of fittings extending between the thermowell or angle fitting and the connection head. The connection head extension length is the overall length of the connection head extension and is assigned the symbol N. (See Figure 11.) 4) Protecting tube: A protecting tube is a tube designed to enclose a temperature sensing device and protect it from the deleterious effects of the environment. It may provide for attachment to a connection head but is not primarily designed for pressure-tight attachment to a vessel. A bushing or flange may be provided for the attachment of a protecting tube to a vessel. (See Figures 5, 6, 7, and 8.)

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The protecting tube length is the overall length of a protecting tube and is assigned the symbol P. (See Figure 5.)

Figure 5 Protecting tube

Figure 6 Protecting tube with mounting bushing

Figure 7 Protecting tube with mounting flange

Figure 8 Thermocouple element with protecting tube and connection head

The protecting tube diameter is the outside diameter of a protecting tube and is assigned the symbol M. A protecting tube has one end closed unless it is specified as open end. (See Figure 9.)

Figure 9 Open end protecting tube

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5)

Thermowell: A thermowell is a pressure-tight receptacle adapted to receive a temperature sensing element and provided with external threads or other means for pressure-tight attachment to a vessel. A lagging extension is that portion of a thermowell above the threads, intended to extend through the lagging of a vessel. The lagging extension length is the length from the lower end of the external threads of the well to the outer end of the portion intended to extend through the lagging of a vessel, less one inch allowance for threads, and is assigned the symbol T. (See Figure10.)

Figure 10 Well

Figure 11 Thermocouple assembly with thermowell

The immersion length of a thermowell, protecting tube, or thermocouple element is the length from the free end to the point of immersion in the medium which is being measured and is assigned the symbol R. (See Figure 12.) The insertion length of a thermowell, protecting tube or thermocouple element is the length from the free end to, but not including, the external threads or other means of attachment to a vessel and is assigned the symbol U. (See Figures 10 and 12.)

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Figure 12 Immersion and insertion lengths for thermocouple assembly with thermowell
2.2.7 Angle type thermocouple assembly An angle type thermocouple assembly is an assembly consisting of a thermocouple element, a protecting tube, an angle fitting, a connection head extension, and a connection head. 2.2.8 Other forms of thermocouples and thermocouple elements 1) Coaxial thermocouple element: A coaxial thermocouple element consists of a thermoelement in wire form within a thermoelement in tube form and electrically insulated from the tube except at the measuring junction. Sheathed thermocouple: A sheathed thermocouple is a thermocouple having its thermoelements, and sometimes its measuring junction, embedded in mineral oxide insulation compacted within a metal protecting tube.

2)

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Symbols
Symbols Thermocouple element length Thermocouple element diameter Connection head extension length Protecting tube length Protecting tube diameter Lagging extension length Immersion length Insertion length A Y N P M T R U

2.3 Wire sizes

2.3.1 Thermocouples The wire sizes normally used for non-sheathed thermocouples are as follows: For J, K, and E: 8, 14, 20, 24, and 28 AWG* For T: 14, 20, 24, and 28 AWG* For R, S and B: 24 AWG* only 2.3.2 Extension wires The wire sizes normally used for extension wire, either singly or in pairs, are 14, 16, and 20 AWG*. Sixteen (16) gage is most commonly used. Twenty (20) gage and smaller may be used when bundled and reinforced to provide strength for pulling. These sizes apply to all types of extension wires.

2.4 Upper temperature limits

Table 7 gives the recommended upper temperature limits for the various thermocouples and wire sizes. These limits apply to protected thermocouples in conventional closed-end protecting tubes. They do not apply to sheathed thermocouples having compacted mineral oxide insulation. In any general recommendation of thermocouple temperature limits, it is not practical to take into account special cases. In actual operation, there may be instances where the temperature limits recommended can be exceeded. Likewise, there may be applications where satisfactory life will not be obtained at the recommended temperature limits. However, in general, the temperature limits listed are such as to provide satisfactory thermocouple life when the wires are operated continuously at these temperatures. Various factors affecting thermocouple life are discussed in Appendix C.

*American Wire Gage, also known as B&S (Brown & Sharpe)

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Table 7 Recommended upper temperature limits for protected thermocouples. Upper temperature limit for various wire sizes (AWG), Deg C
Thermocouple Type B E J K R&S T 370 260 870 760 1260 650 590 1090 540 480 980 No. 8 Gage No. 14 Gage No. 20 Gage No. 24 Gage 1700 430 370 870 1480 200 200 430 370 870 No. 28 Gage

2.5 Tolerance of initial calibration

Tables 8, 9 and 10 give the standard and special tolerance of initial calibration for thermocouples and thermocouple extension wires. The tolerance of initial calibration is defined as the allowable deviation of the thermocouple and extension wire in its initial condition as supplied by the manufacturer from the standard EMF-temperature tables. Once the thermocouple is in use its calibration will change. The magnitude and direction of the change are dependent on temperature, time and environmental conditions affecting the thermocouple and may not be accurately predicted. The tolerances for each type of thermocouple apply only over the temperature range for which the wire size in question is recommended (see Table 7). These tolerances should be applied only to standard wire sizes. The same tolerances may not be obtainable in special sizes. These tolerances do not include installation or system errors. See Appendix C, paragraph C4.1 for the thermocouple installations and errors. Where tolerances are given in percent, in Table 8, the percentage applies to the temperature being measured. For example, the standard tolerance of Type J over the temperature range 277 to 760C is +3/4 percent. If the temperature being measured is 538C, the tolerance is +3/4 percent of 538, or +4.0C. To determine the tolerance in degrees Fahrenheit, multiply the tolerance in degrees Celsius times 1.8.

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Table 8 Initial calibration tolerances for thermocouples Reference Junction 0C TOLERANCES

Thermocouple Type B E J K R or S T Temperature Range, C 870 to 1700 0 to 900 0 to 750 0 to 1250 0 to 1450 0 to 350 Cryogenic Ranges E* K* T* 200 to 0 200 to 0 200 to 0 +1.7C or +1% +2.2C or +2% +1C or +1.5% ** ** ** Standard (whichever is greater) +0.5% + 1.7C or +0.5% +2.2C or +0.75% +2.2C or +0.75% +1.5C or +0.25% +1C or +0.75% +1C or +0.4% +1.1C or +0.4% +1.1C or +0.4% +0.6C or +0.1% +0.5C or +0.4% Special (whichever is greater)

*Thermocouples and thermocouple material are normally supplied to meet the tolerances specified in the table for the normal specified range. The same materials, however, may not fall within the cryogenic tolerances in the second section of the table. If materials are required to meet the cryogenic tolerances, the purchase order must so state. Selection of materials usually will be required. Tolerances indicated in this table are not necessarily an indication of the accuracy of temperature measurements in use after initial heating of the materials. **Little information is available to justify establishing special tolerances for cryogenic temperatures. Limited experience suggests the following tolerances for Types E and T thermocouples: Type E 200 to 0C +1C or +0.5% (whichever is greater) Type T 200 to 0C +0.5C or +0.8% (whichever is greater) These tolerances are given only as guide for discussion between purchaser and supplier. Due to the characteristics of the materials, cryogenic tolerances for Type J thermocouples and special cryogenic tolerances for Type K thermocouples are not listed.

Table 9 Initial calibration tolerances for thermocouple extension wires Reference Junction 0C Tolerances
Extension Wire Type EX JX KX TX Temperature Range, C 0 to 200C 0 to 200C 0 to 200C 0 to 100C Standard 1.7C 2.2C 2.2C 1.0C Special 1.1C 0.5C

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3 Non-ceramic insulation of thermocouple and extension wires

The normal function of thermocouple and extension wire insulation is to provide electrical insulation. If this function is not provided or is compromised in any way, the indicated temperature may be in error. Insulation of this type (non-ceramic) may be affected adversely by moisture, abrasion, flexing, temperature extremes, chemical attack, and nuclear radiation. Each type of insulation has its own limitations. A knowledge of these limitations is essential if accurate and reliable measurements are to be made. A number of coatings are presently available commercially. The strong points as well as limitations are discussed in ASTM Special Technical Publication STP-470B, "Manual on the Use of Thermocouples in Temperature Measurement." In summary, this type of insulation should be selected only after considering possible exposure temperatures and heating rates, the number of temperature cycles, mechanical movement, moisture, routing of the insulated wire, and chemical deterioration.

Table 10 Initial calibration tolerances for thermocouple compensating extension wire Reference Junction 0C
Thermocouple Type
B

Compensating Wire Type

BX***

Temperature Range, C
0 to 100

Tolerances

{
R, S SX** 0 to 200

+0.000 mV 0.033

(+0C)* (-3.7C)*

+ .057 mV

(+5C)*

*Due to the non-linearity of the Types, R, S, and B temperature-EMF curves, the error introduced into a thermocouple system by the compensating wire will be variable when expressed in degrees. The degree C tolerances given in parentheses are based on the following measuring junction temperatures: Measuring Junction Temperature Type Wire BX Greater than 1000C SX Greater than 870C **Copper (+) versus copper nickel alloy (). ***Copper versus copper compensating extension wire, usable to 100C with maximum errors as indicated, but with no significant error over 0 to 50C range. Matched proprietary alloy compensating wire is available for use over the range 0 to 200C with claimed tolerances of +0.033 mV. (+3.7C*).

4 Temperature-EMF tables for thermocouples

4.1 Scope and purpose
This section applies to the temperature-EMF relationships of materials used for temperature measurement thermocouples. Its purpose is to provide reference tables of temperature-EMF values for Type B, E, J, K, R, S, and T thermocouples, in a form convenient for industrial and laboratory use.

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4.2 Introduction
The values in these tables are based upon the International Practical Temperature Scale of 1968 (IPTS-68) and the U.S. legal electrical units. All the data in Tables 11 to 17 have been extracted from "Thermocouple Reference Tables Based on the IPTS-68," National Bureau of Standards Monograph 125. These tables differ slightly from previous tables for the following reasons: improved measurements and data analysis techniques, slight changes in commercial thermocouple materials, and also changes in the temperature scale and electrical units. The significance of these factors, as well as the origin of each of the tables, is discussed in the NBS reference noted above, and it should be consulted for details. These tables give values of EMF to three decimal places (0.001 mV) for one degree Celsius (C) temperature intervals. If greater precision is required, the NBS reference noted above should be consulted. It includes tables giving values of EMF to four decimal places (0.0001 mV) and analytical functions for each thermocouple type that allow a direct and precise calculation of the EMFtemperature relationship. Tables for each type of thermocouple giving values of EMF as a function of temperature in degrees Fahrenheit (F) can be found in ANSI/ASTM Standard E230, "Temperature-Electromotive Force (EMF) Tables for Thermocouples." Tables giving EMF-temperature values (in both C and F) for single-leg thermoelements referenced to platinum (NBS Pt-67) are also given in the above ANSI/ ASTM standard.

4.3 Use of temperature-EMF tables

These temperature-EMF reference tables serve two very useful purposes in that they provide a means for converting the generated EMF of certain thermocouple material combinations into equivalent temperatures, and they enable the calibration and checking of thermocouples and thermocouple extension wire. If the reference junction is maintained at 0C, the appropriate temperature or EMF data may be read directly from the tables. When it is not practical to maintain the reference junction temperature at 0C, these tables may still be used by applying an appropriate correction. The value of the correction may be obtained from these tables. An example to illustrate how to obtain and apply this correction follows. Let us suppose a Type J thermocouple was used in an installation to determine the temperature of a fluid medium and an EMF output of 18.070 mV was observed. Also, a mercury thermometer in close proximity to the thermocouple reference junction produced a reading of 20C. To use the Type J Table to obtain a value for the temperature of the fluid medium, the observed EMF output of the thermocouple must first be corrected to compensate for the difference between the reference junction temperature actually used and 0C. The correction is the EMF value given by the Type J Table at the reference junction temperature actually used (20C). As shown below, this EMF value (1.019 mV) is algebraically added to the observed EMF output to obtain the value of EMF that the thermocouple would produce if the reference junction were at 0C. Observed Type J Thermocouple Output: Correction Factor (Table value at reference temperature actually used) for reference junction at 20C: Corrected Output: 18.070 mV

1.019 mv 19.089 mV

The corrected output of 19.089 mV is then used to determine from the Type J Table the equivalent temperature value of 350C. NEXT PAGE
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