Boost Accuracy With Extending Thermocouple Wires

Many industrial applications require thermocouple sensors to be run over long distances from their sensor heads. When extended using copper instrument wire, dissimilar metal junctions must be adjusted for in your controller system.

For your own protection, thermocouple extension wires that meet special or standard limit accuracy can help. At IOthrifty we carry extension grade thermocouple cable that meets these standards – please see color-coded extension grade thermocouple cable available as an example of these.

Choosing Thermocouple Wire

Thermocouples play an invaluable role in many industrial applications, from manufacturing to gourmet cooking and space missions. These sensors act as sentinels to continuously monitor temperature variations across all industries for increased operational efficiency.

The thermocouple system itself consists of two metals that possess natural affinity for heat, generating voltages that can be read by an instrument and used to gauge temperature differences between hot and cold junctions. Due to their small voltage outputs, however, thermocouples need to be amplified; therefore it is vital that you select an appropriate thermocouple wire for your specific application.

There are various kinds of thermocouple wires, each with their own characteristics and tolerances. Selecting an appropriate one depends on factors like temperature range, electrical environment and accuracy requirements.

Thermocouple wires can be divided into two categories based on their accuracy specifications: standard or special limits of error (SLE). SLE wires use purer thermocouple alloys to improve accuracy compared to its counterpart; both types have identical temperature ratings with an increased sensitivity for SLE thermocouples rated to the same temperature limits; to make sure you choose the appropriate one, consult with a reliable manufacturer and review their selection guides and FAQs.

Using Thermocouple Extension Wire

Thermocouple extension wire is constructed using similar materials as its sensor lead, making it compatible with Type K, J or T sensors without altering their voltage output. Insulated with similar colors to match its sensor it features an interchangeable connector so the polarities remain unaltered; thermocouple cable tends to be more durable than standard electrical insulation and can run much further distances than traditional instrumentation wire.

When using thermocouple extension wire, it is important to remember that no two lengths will have exactly the same alloy percentages, even when they belong to the same type. These small variations in alloy percentages are the source of some error in temperature signals produced by thermocouples.

Due to these variations, it is crucial that thermocouple extension cables be utilized instead of using regular copper instrument wire. If you are running over long distances from your thermocouple, using shielded compensation wire such as KX-HS-FFP-2*2*1.5 may extend measurements; just ensure the shielding does not interfere with measurements and affect voltage output – otherwise this method won’t meet accuracy requirements of thermocouples with greater accuracy requirements.

Using Thermocouple Extension Cable

Using non-TC wire to extend a thermocouple creates errors by creating additional dissimilar metal junctions which cause error voltages that distort readings. Error voltage amplitude depends on temperature at each junction which may differ from actual measurement temperatures.

Add precision by extending your thermocouple using cables crafted with alloys similar to those found within its main body. Extension cables come in various diameters, insulation materials and conductor styles (solid or stranded), with limits of error as outlined by manufacturers.

These cables typically include labels with the same code letters used to identify your thermocouple, while thermocouple extension wires feature one red and one white wire with color codes based on your thermocouple type.

These cables offer similar thermoelectric characteristics as thermocouples but over a shorter range of temperatures, due to using core metals from your thermocouple in an economical copper-nickel alloy form. Videre, compensating cables may be less expensive; you should only need them for short distances of 100ft or less from thermocouple head to instrument as this will minimize induced errors caused by longer wire runs.