Thermocouple Cable

Thermocouple Cables

Thermocouple cables are used to connect thermocouples to measuring instruments. Therefore, it must be made of the same material as the thermocouple. Otherwise, the extra thermocouple voltage will eventually lead to distorted measurement. The products are mainly used in various temperature measuring devices and have been widely used in nuclear power, petroleum, chemical, metallurgy, electric power, and other sectors.

ZMS cable is the leading manufacturer. Our thermocouple wire products are available in high value-added high-grade stainless steel and special alloys, steel strip-based systems, and industrial heating solutions. We manufacture many types of thermocouple wires. Including k-type thermocouple wire, j-type thermocouple wire, t-type thermocouple wire, etc.

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Thermocouple Wire

More Thermocouple Cable Products

The role of the thermocouple compensation wire cable is to extend the cold end of the hot electrode, i.e., the mobile thermocouple, to connect with the display instrument to form a temperature measurement system. Thermocouple compensation wire is generally used in thermocouples. We can provide 2 wire 3 wire 4 wire thermocouple cables, and the best thermocouple cable prices. Also, we provide customization service for thermocouple extension wire, you can provide the following detailed parameters: 1. conductor size and type. 2. insulation and sandwich material. 3. shielding material. 4. color.

k type thermocouple wire

KX Type Thermocouple Extension Wire

1. FB insulation + FB insulation + SS braid
2. Conductor: NiCr-NiSi
3. Color: Red +, Black – 
4. Size: 2*7*0.2mm
(FB means fiberglass, SS means Stainless steel)

KC Type Compensation Wire

1. PVC insulation + Cooper wire braid
2. Conductor: Cu-CuNi
3. Color: Red +, Blue –
4. Size: 2*1mm

JX Type Thermocouple Extension Wire

1. PVC insulation + Silicone rubber
2. Conductor: Fe-CuNi
3. Colour: Red +, Purple –
4. Size: 2*7*0.3mm

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TX Type Thermocouple Extension Wire

1. PVC insulation + PVC insulation
2. Conductor: Cu-CuNi
3. Colour: Red +, White –
4. Size: 2*7*0.1mm

EX Type Thermocouple Extension Wire

1. PVC insulation + Silicone rubber
2. Conductor: Iron-CuSi
3. Color: Red +, Purple –
4. Size: 2*7*0.5mm

NC Type Compensation Wire

1. FB insulation+Cooper wire braid+FB insulation
2. Conductor: Fe-CuNi
3. Color: Red +, Yellow –
4. Size: 2*7*0.2mm

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SC Type Compensation Wire

1. PVC insulation+SS braid+Silicone rubber insulation
2. Conductor: Cu-CuNi
3. Color: Red +, Green –
4. Size: 2*7*0.2mm

Pt100 Thermocouple Grade Wire

1. PVC insulation + PTFE insulation
2. Conductor: Cu-CuNi
3. Color: Red, Blue, Blue
4. Size: 3*7*0.2mm

Calibration of thermocoupleModel numberConductor
S or RSC or RCCu-CuNi 0.6
KKCCu-CuNi 40
KXNiCr 10-NiSi 3
NNCFe-CuNi
NXNiCrSi -NiSiMg
EEXNiCr 10-CuNi 45
JJXFe-CuNi45
TTXCu-CuNi 45
WRe3-WRe25WReCCu-CuNi

More Thermocouple Wire Types

  • K type thermocouple wire is a temperature sensor, Type K thermocouple extension wire is usually used with display instruments, recording instruments, and electronic regulators. type K thermocouple typically consists of the main components such as temperature sensing element, mounting fixture, and junction box.
  • Because the oxidation resistance of type K thermocouples wire is stronger than other base metal thermocouples, it is most widely used in temperatures above 500°C.
  • Type K thermocouple compensating cable are more resistant to oxidation than other combinations (except Type N), so they are recommended for use in oxidizing or inert atmospheres.
  • Type K thermocouples offer calibration accuracy, stability, oxidation resistance, high thermoelectric potential, and a reasonable price.
    Thermothal P/Thermothal N thermocouples meet all international standards.
  • The N-type combination wire is a significant improvement over the K-type combination in terms of electromotive force drift and transient changes in electromotive force. In addition, the N-type has a longer life than the K-type duplex thermocouple due to the improved oxidation resistance of the Nisil negative leads.
  • The thermoelectric potential output value of Nicrosil/Nisil is lower than that of K-type, so it is not possible to directly replace K-type with N-type unless the existing instrumentation is modified. However, temperature measurement and control are particularly important in the aerospace, nuclear, and semiconductor industries, so it is unlikely that these industries will turn a blind eye to longer life and better thermoelectric potential stability. And for the industry as a whole, one also needs to save on the inspection, maintenance, and calibration costs of thermocouple-sensing high-temperature measurement devices.
  • Type E thermocouple extension wire is the type with the largest electric potential output value of any common thermocouple, and it is sometimes used in thermal power generators (thermopiles). It operates at temperatures up to 900°C and has excellent stability over a range from low temperatures to 300°C.
  • The positive pole of this type of shielded thermocouple wire is Thermothal P like the K type, while the negative pole is Cuprothal (EN).
  • The combination of copper (positive element) and Cuprothal (TN) (negative element) allows this thermocouple to be used in a variety of laboratory and industrial environments in the temperature range of -185°C to +370°C.
  • Given the limited oxidation resistance of copper, it is not recommended that this model be used outside of this temperature range. Since any good quality pure electrolytic copper (i.e. pure electrolytic copper according to ASTM standard B3) produces a uniform and constant electric potential with no differences from batch to batch (especially when temperatures are above -185°C), we generally offer only the negative element (Cuprothal (TN).
  • The N-type combination wire is a significant improvement over the K-type combination in terms of electromotive force drift and transient changes in electromotive force. In addition, the N-type has a longer life than the K-type due to the improved oxidation resistance of the Nisil negative leads.
  • The thermoelectric potential output value of Nicrosil/Nisil is lower than that of K-type, so it is not possible to directly replace K-type with N-type unless the existing instrumentation is modified. However, temperature measurement and control are particularly important in the aerospace, nuclear, and semiconductor industries, so it is unlikely that these industries will turn a blind eye to longer life and better thermoelectric potential stability. And for the industry as a whole, one also needs to save on the inspection, maintenance, and calibration costs of thermocouple-sensing high-temperature measurement devices.

International Thermocouple Color Code—Thermocouple and Extension Grade Wires

Thermocouple extension and compensating cable are pairs of conductors, each made of a different material. The thermocouples must be selected according to the relevant temperature, the operating environment, and the physical characteristics of the components.
These materials are manufactured according to the internationally recognized standard specified in IEC 584 1,2, which is based on the international practical temperature standard ITS 90. The maximum operating temperature depends on the thickness of the thermocouple conductors. Thermocouple types can be subdivided into 2 groups, base metals and rare (precious metals).
A major advantage of thermocouple type J (Iron (JP)/Cuprothal® (JN)) is the ability to work in both oxidizing and reducing atmospheres. Covering the iron with copper prevents corrosion during the shelf life. Although the traditional J-type is still popular in temperature measurement, it is less important in mineral insulated forms due to its limited temperature range – 200C to +750°C. Type J is still mainly in use, based on the widespread use of older instruments calibrated for this type. Their sensitivity rises to 55µV/°C.

What is The Insulation Material of The Thermocouple Insulation Cable?

thermocouple cables of different materials
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The Primary Factors Affecting Thermocouple Life

Temperature: If the temperature rises by 50°C, then the thermocouple life will be shortened by about 50%.
Diameter: If the wire diameter doubles, then the thermocouple life will be extended by 2 to 3 times.
Thermal cycling: If the thermocouple is subjected to thermal cycling from room temperature to over 500°C, then the life of the former will be reduced by about 50% compared to a thermocouple used continuously at the same temperature.
Protection: If the thermocouple is covered with a protective sleeve and placed in a ceramic insulator, then its life will be significantly extended.

Thermocouple Compensation Wire Instructions For Use

Select thermocouple compensation wire to know the thermocouple compensation wire in the ambient temperature and site mining conditions, according to the site ambient temperature situation to choose the appropriate compensation wire sheath, the general ambient temperature in -25 ~ 105 ℃, choose polyvinyl fluoride sheath, the ambient temperature in -60 ~ 205 ℃, choose polytetrafluoroethylene as compensation wire sheath, and in -60 ~ 260 ℃, choose Polytetrafluoroethylene as a thermocouple compensation wire sheath. So in the selection must pay attention to the site mine situation.

Which insulation material?Useable temperature rangeApplication notes
PVC-10°C to 105°CGood general purpose insulation for ‘light’ environments. Waterproof and very flexible.
PFA (Extruded)-75°C to 250°CResistant to oils, acids, other adverse agents and fluids. Good mechanical strength and flexibility. PTFE better for steam/elevated pressure environments.
PTFE (taped & wrapped)-75°C to 250/300°CResistant to oils, acids, other adverse agents and fluids. Good mechanical strength and flexibility.
Glass fibre (Varnished)-60°C to 350/400°CGood temperature range but will not prevent ingress of fluids. Fairly flexible but does not provide good mechanical protection.
High temperature glass fibre-60°C to 700°CWill withstand temperature up to 700°C but will not prevent ingress of fluids. Fairly flexible, doesn’t provide good protection against physical disturbance.
Ceramic Fibre0 to 1000°CWill withstand high temperature, up to 1000°C. Will not protect against fluids or physical disturbance.
Glass fibre (varnished) stainless steel overbraid-60°C to 350/400°CGood resistance to physical disturbance and high temperature (up to 400°C). Will not prevent ingress of fluids.
For maximum accuracy extension cables should be used and terminals and connectors should be of thermocouple materials to maintain continuity.

Notes On Thermocouple Compensation Wire

1. Selection of Thermocouple Compensation Wire

Thermocouple compensation wire must be used according to the type of thermocouple used and the occasion used to make the correct choice. For example, k-type couples should choose k-type couples compensation wire, according to the use of the occasion, choose the operating temperature range. Usually, kx working temperature of -20 ~ 100 ℃, a wide range of -25 ~ 200 ℃. The error of the ordinary level is ± 2.5℃, and the precision level is ± 1.5℃.

2. Contact Connection

With the thermocouple terminal 2 joints as close as possible, try to keep the temperature of the two joints the same. Connected with the instrument terminals as much as possible at the same temperature, the instrument cabinet has a fan, and the contact point should be protected from the fan blowing directly to the contact point.

3. Use a Length

Because the thermocouple signal is very low, microvolts level, if the distance used is too long, the attenuation of the signal and the environment of strong electrical interference coupled, enough to make the signal distortion of the thermocouple, resulting in inaccurate measurement and control temperature, in control of serious temperature fluctuations.
According to our experience, usually using the thermocouple compensation wire length control within 15 meters is better, if more than 15 meters, it is recommended to use the temperature transmitter for signal transmission. A temperature transmitter is the temperature of the corresponding potential value into DC current transmission, strong anti-interference.

4. Wiring

Armored multicore thermocouple cable or compensation wiring must be away from power lines and interference sources. In places where crossing can not be avoided, also as far as possible to use the crossway, not parallel.

5. Shielded Compensation Wire

In order to improve the anti-interference thermocouple connection line, you can use shielded compensation wire. For the scene with more interference sources, the effect is better. However, the shield must be strictly grounded, otherwise, the shield not only does not play the role of shielding but enhances the interference.

Thermocouple Compensation Wire Temperature Measurement Principle

The role of the thermocouple compensation wire is to extend the hot electrode that moves the cold end of the thermocouple, and display instrumentation connected to form a temperature measurement system. Products are mainly used in a variety of temperature measurement devices and have been widely used in petroleum, chemical, metallurgical, electric power, and other sectors.
Generally speaking, the thermocouple may be tens of meters away from the temperature measurement table. And the cold end of the thermocouple (out of the line end) temperature and temperature measurement table ambient temperature are different (even up to tens of degrees).
If you use ordinary copper wire, according to the thermocouple principle, the wiring will produce temperature difference potential, which will produce measurement errors.
Long-distance transmission wire pressure drop problem, because the temperature meter input impedance is high. The temperature difference potential generated by the thermocouple (millivolt level) transmission current (micro-A level) is very small, the pressure drop loss on the wire is very small, in general, within the error range. So there are thermocouple transmitters, input thermocouple signal, and output 4-20ma so that you can do not want to compensate for the wire, you can also be transmitted over long distances.
If the use of compensation wire (must match the thermocouple index number), is selected metal material and can produce the smallest possible temperature difference potential at the wiring to minimize the temperature measurement error. In other words, the cold end of the thermocouple is moved to the temperature measurement table.

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