Choosing the right type and style of thermocouple

Beaded Wire Thermocouple

A beaded wire thermocouple is the simplest form of thermocouple. It consists of two pieces of thermocouple wire joined together with a welded bead. Because the bead of the thermocouple is exposed, there are several application limitations. The beaded wire thermocouple should not be used with liquids that could corrode or oxidize the thermocouple alloy. Metal surfaces can also be problematic. Often metal surfaces, especially pipes are used to ground electrical systems The indirect connection to an electrical system could impact the thermocouple measurement. In general, beaded wire thermocouples are a good choice for the measurement of gas temperature. Since they can be made very small, they also provide very fast response time.

Thermocouple Probe

A thermocouple probe consists of thermocouple wire housed inside a metallic tube. The wall of the tube is referred to as the sheath of the probe. Common sheath materials include stainless steel and Inconel. Inconel supports higher temperature ranges than stainless steel, however, stainless steel is often preferred because of its broad chemical compatibility. For very high temperatures, other exotic sheath materials are also available. View our line of high temperature exotic thermocouple probes.

The tip of the thermocouple probe is available in three different styles. Grounded, ungrounded and exposed. With a grounded tip the thermocouple is in contact with the sheath wall. A grounded junction provides a fast response time but it is most susceptible to electrical ground loops. In ungrounded junctions, the thermocouple is separated from the sheath wall by a layer of insulation. The tip of the thermocouple protrudes outside the sheath wall with an exposed junction. Exposed junction thermocouples are best suited for air measurement.

Surface Probe

Measuring the temperature of a solid surface is difficult for most types of temperature sensors. In order to assure an accurate measurement, the entire measurement area of the sensor must be in contact with the surface. This is difficult when working with a rigid sensor and a rigid surface. Since thermocouples are made of pliable metals, the junction can be formed flat and thin to provide maximum contact with a rigid solid surface. These thermocouples are an excellent choice for surface measurement. The thermocouple can even be built in a mechanism which rotates, making it suitable for measuring the temperature of a moving surface.

What is an MI cable?

MI cable is a specialized type of cable used in high temperatures or harsh environmental conditions because it has low flammability, even when operating at high temperatures. It resists oxidation and enables precise measurement.

Mineral insulated cable consists of copper wires inside a copper, stainless steel, or Inconel sheath, insulated by packed minerals such as magnesium oxide (MgO). Magnesium oxide makes an excellent electrical insulation material because it resists oxidation and ionizing radiation, and it is both chemically and physically stable at high temperatures. After the cable has been packed with MgO insulation, it may be rolled under pressure to achieve the desired diameter. The outer sheath protects the internal thermocouple wire from heat, chemical or other environmental damage. The metal sheath may be covered with an additional colored plastic sheath to add in identification and to add an additional layer of protection from corrosion.

An MI cable may contain any number of wires, but the most common configurations include 1, 2 or 3 pairs of conductors. Specialized MI cables may include additional thermocouples in customized configurations. MI cable is available in a variety of diameters and lengths, depending on the specific requirements. Many MI cables are calibrated using sensitive, fast and highly accurate dry block probe calibrators.

RTD and thermocouple sensors manufactured from MI cable are used extensively in heat treating metals, solid waste incinerators, sintering powdered metals, firing ceramic materials, gas or oil fired furnaces, fuel fired heat exchangers, box furnaces and nuclear or hydrocarbon based energy plants.