1

2
Selection of the Measuring Junction

Sheathed thermocouples are available in 3 junction types: grounded, ungrounded, and exposed.
Each design offers specific advantages as well as disadvantages and must considered carefully
when placing an order.

Grounded

The thermo-elements are welded into the end cap using the same
weld rod as the sheath material. Fast time response. Recommended for high-pressure
applications, liquids, moisture, contaminating atmospheres, and most general uses. -Least
expensive.

Ungrounded

The thermo-elements are welded together and are electrically

3
isolated from the sheath. Recommended for applications where stray EMF’s from electrical
apparatus would affect the reading. -More expensive.

Exposed

The thermo-elements are welded together outside of the sheath.

This provides the fastest time response, but exposes the elements to contamination. Electrically
isolated from the sheath.

Inconel® is the registered trademark of INCO Alloys International.

Inconel® Maximum temperature 2150°F (1175°C) and is the most widely used thermocouple sheath
material. Good high temperature strength, corrosion resistance and is resistant to chloride-ion stress
corrosion, cracking and oxidation. Do not use in sulfur bearing environments

Hastelloy X is the registered trademark of Haynes International.

Hastelloy X Maximum temperature 2200°F (1205°C) widely used in aerospace applications. Resistant to
oxidizing, reducing and neutral atmospheric conditions. Excellent high temperature strength.

4
Standard Test Method for Calibration of Thermocouples
National Institute of Standards and Technology (NIST)

NIST reference functions and tables of thermocouple electromotive force (emf) versus temperature have
been adopted as standards by the American Society for Testing and Materials ( ASTM) and the
International Electrotechnical Commission (IEC) . All letter-designated thermocouple types are
manufactured to match these standards to within specified tolerances. Furthermore, calibrations of
individual thermocouples are often expressed in terms of the deviation in emf of the test thermocouple
from the emf value given by the reference function.

International Temperature Scale of 1990 (ITS-90)

The International Temperature Scale of 1990 (ITS-90) published by the Consultative Committee for
Thermometry (CCT) of the International Committee for Weights and Measures (CIPM) is an equipment
calibration standard for making measurements on the Kelvin and Celsius temperature scales. ITS–90 is an
approximation of the thermodynamic temperature scale that facilitates the comparability and
compatibility of temperature measurements internationally.

5
Terminology

Electromotive force, thermoelectric voltage - synonymous terms that describe the net value of
electrochemical potential that is generated by a thermocouple with reference junctions at 0 °C and
measuring junctions at the indicated temperature. The electromotive force is abbreviated "emf" and is
denoted by the symbol E.

International Temperature Scale of 1990 (ITS-90) - an internationally accepted definition of

temperature, including the assignment of temperatures to various natural fixed-points, such as the
freezing point of gold; specification of thermometer types; and specification of interpolation methods
between fixed points. The ITS-90 replaces earlier, obsolete scales that were adopted in 1927, 1948, and
1968. The symbol t90 or T90 is used to designate temperature on the ITS-90. Appendix A gives further
information.

Inverse function - a mathematical function giving temperature as a function of voltage. The

thermocouple reference functions cannot be inverted exactly with a finite number of coefficients;
consequently the inverse functions are only approximate, to within the errors stated in the tables of
coefficients.

Inverse function coefficients, or inverse coefficients - the numerical parameters used in the inverse
functions. Polynomial coefficients are denoted di for the ith power of thermoelectric voltage.

Measurement junction - that junction of dissimilar metals in a thermoelectric circuit that is placed at the
location of the unknown temperature that is to be determined.

6
Reference function - the mathematical function giving the thermoelectric voltage as a function of
temperature. This function defines the response of a specific letter-designated thermocouple type.

Reference function coefficients, or coefficients - the numerical parameters used in the reference
functions. Polynomial coefficients are denoted ci for the ith power of temperature. For type K, there are
additional coefficients a0, a1, and a2.

Reference junctions - those junctions in a thermoelectric circuit that are maintained at a fixed, known
temperature, which is often 0 °C.

Thermocouple - a pair of dissimilar electrical conductors joined at one end (the measuring junction).
When the other ends of the thermocouple are maintained at a known reference temperature, the
thermoelectric voltage produced by the thermocouple is a repeatable function of the temperature of the
measuring junction.

Thermoelectric voltage - see Electromotive Force.

************************************
* This section contains coefficients for type K thermocouples for
* the two subranges of temperature listed below. The coefficients
* are in units of °C and mV and are listed in the order of constant
* term up to the highest order. The equation below 0 °C is of the form
* E = sum(i=0 to n) c_i t^i.
*
* The equation above 0 °C is of the form
* E = sum(i=0 to n) c_i t^i + a0 exp(a1 (t - a2)^2).
*
* Temperature Range (°C)
* -270.000 to 0.000
* 0.000 to 1372.000
************************************
name: reference function on ITS-90
type: K
temperature units: °C
emf units: mV
range: -270.000, 0.000, 10
0.000000000000E+00
0.394501280250E-01
0.236223735980E-04
-0.328589067840E-06
-0.499048287770E-08
-0.675090591730E-10
-0.574103274280E-12
-0.310888728940E-14
-0.104516093650E-16
-0.198892668780E-19
-0.163226974860E-22
range: 0.000, 1372.000, 9
-0.176004136860E-01
0.389212049750E-01
0.185587700320E-04
-0.994575928740E-07
0.318409457190E-09
7
 -0.560728448890E-12
0.560750590590E-15
-0.320207200030E-18
0.971511471520E-22
-0.121047212750E-25
exponential:
a0 = 0.118597600000E+00
a1 = -0.118343200000E-03
a2 = 0.126968600000E+03

************************************
* This section contains coefficients of approximate inverse
* functions for type K thermocouples for the subranges of
* temperature and voltage listed below. The range of errors of
* the approximate inverse function for each subrange is also given.
* The coefficients are in units of °C and mV and are listed in
* the order of constant term up to the highest order.
* The equation is of the form t_90 = d_0 + d_1*E + d_2*E^2 + ...
* + d_n*E^n,
* where E is in mV and t_90 is in °C.
*
* Temperature Voltage Error
* range range range
* (°C) (mV) (° C)
* -200. to 0. -5.891 to 0.000 -0.02 to 0.04
* 0. to 500. 0.000 to 20.644 -0.05 to 0.04
* 500. to 1372. 20.644 to 54.886 -0.05 to 0.06
********************************************************
Inverse coefficients for type K:

Temperature -200. 0. 500.

Range: 0. 500. 1372.

Voltage -5.891 0.000 20.644

Range: 0.000 20.644 54.886

0.0000000E+00 0.000000E+00 -1.318058E+02

2.5173462E+01 2.508355E+01 4.830222E+01
-1.1662878E+00 7.860106E-02 -1.646031E+00
-1.0833638E+00 -2.503131E-01 5.464731E-02
-8.9773540E-01 8.315270E-02 -9.650715E-04
-3.7342377E-01 -1.228034E-02 8.802193E-06
-8.6632643E-02 9.804036E-04 -3.110810E-08
-1.0450598E-02 -4.413030E-05 0.000000E+00
-5.1920577E-04 1.057734E-06 0.000000E+00
0.0000000E+00 -1.052755E-08 0.000000E+00

Error -0.02 -0.05 -0.05

Range: 0.04 0.04 0.06

8
rational polynomial function approximation for Type K thermocouples is used for computing
temperature from measured thermocouple potential. The calibration equation

Computing type K cold junction voltages

9
10
 .

IEC 584-1, P ART4: K:

This is most commonly used thermocouple ind is are commonly known as chromel/Alumel
thermocouple

These are designed primarily for use in Oxidising atmosphere at temperatures described above.

Great care should be taken when using for any other atmosphere.

These thermocouple will get oxidised when used continuously at temp above 1000 Deg C and cause
drift.

For temp range from 250 to 600 Deg C stability is suspect. Other base metal thermocouples are better
bet at this temp range.

thermocouple: acc. to DIN IEC 584 (type L: DIN 43 710)

11
tolerances: acc. to DIN IEC 584, classification 1 and 2 and partly classification 3

insulation resistance: 20 M at room temperature and a test voltage of 500 V d.c.

protection classification: IP 54 acc. to EN 60529

in case of Silicone seals in the heads of higher protection.

Accuracy for thermocouples in accordance with

IEC-EN 60584-2 and ASTM E230-ANSI MC96.1

Tolerance classes for thermocouples to IEC 584-2 : 1982

Thermocouple Wire Types and Codes IEC 584-3 : 1989

12
13
International harmonised standards
IEC 65B (CO) 76 (1989)

Base metal insulated thermocouple cables and thermocouples (draft)

14
IEC 584-1:1995

Thermocouples, Reference tables

IEC 584-2:1982

Thermocouples, Tolerances

IEC 584-3:1989

Extension and compensating cables. Tolerances and identification system.

IEC 654-1 (1979)

Operating conditions for industrial-process measurement and control equipment.

Part 1: Temperature, humidity and barometric pressure

IEC 751:1983

Industrial platinum resistance thermometer sensors

ANSI American National Standards Institute

BSI British Standards Institution

BS British Standards Institution Standards

DIN Deutsche Institut fur Normung

EN CEN/CENELEC European Standards

IEC International Electrotechnical Commission

IEEE IEEE Standards

IPTS-68 International Practical Temperature Scale of 1968

ISO International Organisation for Standardisation

ITS-90 International Temperature Scale of 1990

Calibration: Checking/ measuring accuracy against an external reference/standard

Calibrator :Device used for or in calibration

Drift :Change in the value of a parameter due to operational influence (e.g. temperature variation /
ageing)
15
Dry Block Calibrator :A thermal device which does not use a fluid medium as a temperature source

Fixed Points Temperatures defined by physical laws, change of state of (Temperature) pure materials

Simulator Instrument which produces electrical signals emulating those of sensors

Tolerances: Stated uncertainties

Uncertainties:Possible inaccuracies

Process :The system being monitored or controlled

Process Variable: The parameter monitored or controlled

Proportional Band :The control band within which power is regulated between 0 and 100% usually
express as a percentage of the overall temperature range

Set-point: Desired process temperature set by the operator

Data Acquisition : Gathering data from a process, usually electronic, usually automatic

SCADA :Abbreviation of Supervisory Control and Analogue Data Acquisition

Cold junction :Reference junction of a thermocouple

Cold Junction: Compensation for thermocouple reference junction

Compensation (CJC): temperature variations

Exposed Junction :A thermojunction not protected by sheath material. Used when fast thermal
response is required

http://us.flukecal.com/Thermocouple-Temperature-Calculator

http://us.flukecal.com/Thermocouple-Table-Voltage-Calculator

http://www.instrumentationtoolbox.com/2011/05/converting-thermocouple-milivolts-to.html

16
http://us.flukecal.com/Thermocouple-Temperature-Calculator

http://us.flukecal.com/Thermocouple-Table-Voltage-Calculator

International harmonised standards

17
IEC 65B (CO) 76 (1989)

Base metal insulated thermocouple cables and thermocouples (draft)

IEC 584-1:1995

Thermocouples, Reference tables

IEC 584-2:1982

Thermocouples, Tolerances

IEC 584-3:1989

Extension and compensating cables. Tolerances and identification system.

IEC 654-1 (1979)

Operating conditions for industrial-process measurement and control equipment.

Part 1: Temperature, humidity and barometric pressure

IEC 751:1983

Industrial platinum resistance thermometer sensors

ANSI American National Standards Institute

BSI British Standards Institution

BS British Standards Institution Standards

DIN Deutsche Institut fur Normung

EN CEN/CENELEC European Standards

IEC International Electrotechnical Commission

IEEE IEEE Standards

IPTS-68 International Practical Temperature Scale of 1968

ISO International Organisation for Standardisation

ITS-90 International Temperature Scale of 1990

18
TYPE K THERMOCOUPLE (Chromel / Alumel)-200°C to
+1260°C / -328°F to +2300°F
Chromel {90% nickel and 10% chromium} Alumel {95% nickel, 2% manganese, 2%
aluminium and 1% silicon}

This is the most common thermocouple type that provides the widest operating temperature
range. Type K thermocouples generally will work in most applications because they are nickel
based and have good corrosion resistance.

•1.Positive leg is non-magnetic (Yellow), negative leg is magnetic (Red).

Composed of a positive leg, which is approximately 90% nickel, 10% chromium and a negative leg, which
is approximately 95% nickel, 2% aluminum, 2% manganese and 1% silicon.Type K Thermocouples are the
most common general purpose thermocouple with a sensitivity of approximately 41µV/°C, chromel
positive relative to alumel. It is inexpensive, and a wide variety of probes are available in its -200°C to
+1260°C / -328°F to +2300°F range. Type K was specified at a time when metallurgy was less advanced
than it is today, and consequently characteristics vary considerably between samples. One of the
constituent metals, nickel, is magnetic; a characteristic of thermocouples made with magnetic material is
that they undergo a step change in output when the magnetic material reaches its Cure Point (around
354 °C for type K thermocouples).

Type K Thermocouple ( Chromel/Alumel)

Type K thermocouples usually work in most applications as they are nickel based and exhibit
good corrosion resistance. It is the most common sensor calibration type providing the widest
operating temperature range. Due to its reliability and accuracy the Type K thermocouple is used
extensively at temperatures up to 2300°F (1260°C). This type of thermocouple should be
protected with a suitable metal or ceramic protection tube, especially in reducing atmospheres. In
oxidizing atmospheres, such as electric furnaces, tube protection is not always necessary when
other conditions are suitable; however, it is recommended for cleanliness and general mechanical
protection. Type K will generally outlast Type J because the JP wire rapidly oxidizes, especially
at higher temperatures.

Temperature Range:
•Thermocouple grade wire, −454° to 2,300°F (−270 to 1,260°C)

•Extension grade wire, −32° to 392°F (0 to 200°C)

19
•Melting Point, 2550°F (1400°C)

Accuracy (whichever is greater):

•Standard: ± 2.2C% or ±.75%

•Special Limits of Error: ± 1.1C or 0.4%

Deviations in the alloys can affect the accuracy of

thermocouples. For type K thermocouples the tolerance
class one is given as ± 1.5 K between -40 and 375 °C.
However, deviations between thermocouples coming
from the same production are very small and a much
higher accuracy can be achieved by individual
calibration.

Metallurgical changes can cause a calibration drift of 1

to 2°C in a few hours, increasing to 5 °C over time. A special grade of Type K is available that
can maintain special limit accuracy up to ten times longer than the regular grade

A coupling of Chromel and Alumel wires, has a range of -270 °C to 1260 °C and an output of -6.4 to 54.9
mV over maximum temperature range

Type K Limits Of Error

Thermocouple wire sensitivities and margins of error are considerations when selecting a type. Type K
has a higher margin of error than other types of thermocouple wire; manufacturers that choose this type
are generally willing to sacrifice accuracy for the wide range of sensitivity. Type K has a margin of error
related to a percentage of the temperature measured. It is roughly 0.75‰ or 2.2°C, whichever is greater.

20
Type K Thermoelectric Voltage
Type K has an exponentially increasing voltage the differences in voltages become easier to
measure and more accurate at higher temperatures. At very cold temperatures minus 260° C to
minus 250° C type K thermocouple voltages differ only one or two thousandths of a millivolt for
every degree Celsius. At extremely high temperatures around 1,350°C voltage differs about 3.3
hundredths of a millivolt per degree Celsius.

Type K Thermocouple Wire Coating

Uncoated wire probes respond more quickly to temperature. Coated wires display different
response times in different media. Some test subject chemicals might damage exposed probes
and wires. A 1/4-inch wide, sheathed, ungrounded type K thermocouple responds to temperature
changes in water in about 2.25 seconds. A bare thermocouple wire responds in just over 0.6
seconds.

Type K Thermocouple Junctions

Grounded hermocouple

This is the most common junction style. A

thermocouple is grounded when both thermocouple wires and the sheath are all welded together
to form one junction at the probe tip. Grounded thermocouples have a very good response time
because the thermocouple is making direct contact with the sheath, allowing heat to transfer
easily. A drawback of the grounded thermocouple is that the thermocouple is more susceptible to
electrical interference. This is because the sheath often comes into contact with the surrounding
area, providing a path for interference.

Ungrounded Thermocouple
A thermocouple is
ungrounded when
the thermocouple
wires are welded
together but they are
insulated from the
sheath. The wires are often separated by mineral insulation.

21
Exposed Thermocouples (or "bare wire thermocouples")

A thermocouple is exposed when the

thermocouple wires are welded together and directly inserted into the process. The response time
is very quick, but exposed thermocouple wires are more prone to corrosion and degradation.
Unless your application requires exposed junctions, this style is not recommended.

Type K Thermocouple Conductor Gauge

Thermocouple conductors come in a variety of sizes. Depending on your application, the gauge
selected will affect the thermocouple's performance. The larger the gauge size, the more thermal
mass the thermocouple will have with a corresponding decrease in response. The larger the
gauge size the greater the stability and oper-ating life. Conversely, a smaller gauge size will have
a quicker response, but may not deliver the stability or oper-ating life required.

Type K Thermocouple Sheath

316 Stainless Steel

Maximum temperature: 1650. Best corrosion resistance of the austenitic stainless steel grades.
Widely used in the food and chemical industry. Subject to damaging carbide precipitation in
900°F to 1600°F (482°C to 870°C).
316L Stainless Steel
Maximum temperature: 1650°F (900°C). Same as 316 SST (04) except low carbon version
allows for better welding and fabrication.

304 Stainless Steel

Maximum temperature: 1650°F (900°C). Most widely used low temperature sheath material.
Extensively used in food, beverage, chemical and other industries where corrosion resistance is
required.
Industry: Subject to damaging carbide precipitation in 900 to 1600°F (480 to 870°C) range.
Lowest cost corrosion resistant sheath material available.
304L Stainless Steel
22
Maximum temperature: 1650°F (900?C). Low carbon version of 304 SST (02). Low carbon
content allows this material to be welded and heated in the 900 to 1600°F (480 to 870°C) range
without damage to corrosion resistance.
310 Stainless Steel
Maximum temperature: 2100?F (1150?C). Mechanical and corrosion resistance, similar to but
better than 304 SS. Very good heat resistance.

This alloy contains 25% chromium, 20% nickel. Not as ductile as 304 SS.

321 Stainless Steel

Maximum temperature: 1600°F (870°C). Similar to 304 SS except titanium stabilized for
intergranular corrosion.

This alloy is designed to overcome susceptibility to carbon precipitation in the 900 to 1600°F
(480 to 870°C) range. Used in aerospace and chemicalapplications.
446 Stainless Steel
Maximum temperature: 2100°F (1150°C). Ferritic stainless steel which has good resistance to
sulfurous atmospheres at high temperatures.

Good corrosion resistance to nitric acid, sulfuric acid and most alkalies. 27% chromium content
gives this alloy the highest heat resistance of any ferritic stainless steel.
Inconel 600
Maximum temperature: 2150°F (1175°C). Most widely used thermocouple sheath material.
Good high temperature strength, corrosion resistance, resistance to chloride-ion stress corrosion
cracking and oxidation resistance to high temperatures.

Do not use in sulfur bearing environments. Good in nitriding environments.

Inconel 601
Maximum temperature: 2150°F (1175°C) continuous, 2300°F (1260°C) intermittent. Similar to
Alloy 600 with the addition of aluminum for outstanding oxidation resistance. Designed for high
temperature corrosion resistance.

This material is good in carburizing environments, and has good creep rupture strength. Do not
use in vacuum furnaces! Susceptible to intergranular attack by prolonged heating in 1000 to
1400°F (540 to 760°C) temperature range.
Inconel 800
Maximum temperature: 2000°F (1095°C). Widely used as heater sheath material. Minimal use in
thermocouples. Superior to Alloy 600 in sulfur, cyanide salts and fused neutral salts.

Susceptible to intergranular attack in some applications by exposure to the temperature range of

1000 to 1400°F (540 to 7607deg C).

23
How to measuere temperature with a Type K Thermocouple

A thermocouple circuit contains the two alloy junctions, wire sand connectors and a voltage
measuring device. When the two junctions are experiencing different temperatures, measurable
current flows through the circuit. The current is related to the temperature differential. Because
the measurement is relative, one of the temperatures must be known in order to calculate an
absolute temperature. In early thermocouples, one junction was kept at 0° C by immersing it in
an ice water bath. Today, one of the junctions, the "cold junction," is electrically compensated to
maintain a standard. The other junction, the "hot junction," is exposed to the environment to be
measured.

24