Temperature Technical Reference

Thermocouple Connector Guide

Thermocouple Connector Guide

Thermocouple Connectors ensure the Temperature measurement signal (millivolts) from the thermocouple sensor or lead wire is accurately transmitted to the display or control Instrumentation. 

The 3 Things you should know in selecting the correct thermocouple connector.

1 -  Ensure the Thermocouple Alloys within the connector Match those in the thermocouple sensor and or lead wires. It sounds very basic, although  have seen well established organizations make this mistake and the resulting issues. 

  • Different pairings of Thermocouple Alloys are used in the primary thermocouple connectors. It is common for these alloy pairs to be referred as Calibrations and use letters to designate the type of thermocouple.
  • J, K, T, Eand N calibrations represent the most commonly used designs, sometimes referred as Base Metal thermocouples. Type C, R/S, U (B) thermocouples are utilized in much more specific, and many times higher temperature ranges or applications.                      

2 - Color Coding system is used to help identify and match the connectors to the thermocouple sensors and wire. This Coloring System can be confusing and there are several specific important points to understand in this methodology.

  • The USA color coding is Different than the international guidelines and other countries across the globe.
  • The thermocouple wire leads you attach to the connector achieved is primarily achieved by Coloring the InsulationTypically these insulations are high temperature plastics or fibers. 
  • The IEC (International Electrotechnical Commission) match the insulation color of the Positive thermocouple wire and the color of the outer jacket insulation to the color of the Thermocouple Connector.
  • The USA or ANSI has some Exceptions to the insulated thermocouple wire color code system. 
  • For example thermocouple grade wire has a Brown colored outer insulation jacket, although the color code on Extension Grade thermocouple wire will match the connector with one exception
  • Type J thermocouple connectors are Black although the insulation on the positive wire is White.
  • Again Thermocouple Color Codes can be confusing and we provided a chart and other details in this document along with other technical reference on the Evolution Sensors website. 

3 -  The Functional Temperature range of the thermocouple connector is a Critical selection point to consider in your temperature measurement application.

  • The metal alloy pins within the thermocouple connector can be capable of operating temperatures from Below Zero to above 2,000F.
  • The Functional temperature range of thermocouple connector is determined by the Connector Body Materials. 
  • These materials are typically ThermoplasticsThermosets or Ceramics providing an overall range from - 40 F to 1200 F (-40 C to 650 C). Each material provides specific temperature range and mechanical capabilities along with cost considerations.

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    Surface Temperature Sensors

    Surface Temperature Sensors

    Surface Temperature Sensors are one the most utilized temperature measurement technologies applied in the Development of New Products, the Refinement of Manufacturing Processes along with providing Reliability Analysis and Predictive Maintenance data on existing products or processes.

    This sensor technology is used in an extremely diverse number of applications, such as the surface temperature of a Power Source or CPU for Electronic Control Systems or a Complex Composite Aerospace Parts in an Automated Heat Treating Process or the Motor of a Power Generation System and literally tens of thousands of other applications.

    Many times measuring the surface temperature is only one of a few technologies available for to provide critical and insightful data in a Non Destructive and or Extreme Condition Testing without causing additional test variables related to structural and mechanical integrity or contamination of the product. 

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    What is an RTD Element? How are they Made and Used with RTD Sensors and Probes.

    What is an RTD Element? How are they Made and Used with RTD Sensors and Probes.

    RTD Element is the core temperature sensing technology utilized in RTD sensors and probes. This sensing element is based on Resistance Temperature Detector technology, meaning a change in temperature results in a measurable and consistent resistance change.

    The technology of these elements have earned an excellent reputation of Accuracy and Repeatability for themselves as well for RTD probes assemblies. Depending on the design selected the elements can provide excellent performance in the temperature range of -320 F to 1,562 F (-196 to 850 C) along with some speciality designs reaching 1,832 F (1,000 C)

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    What are RTD Sensors and Probes

    What are RTD Sensors and Probes

    RTD is a Temperature Sensor with an excellent reputation for Accuracy and Repeatability. The sensor is based on Resistance Temperature Detector technology, meaning a change in temperature results in measurable resistance change in the sensor output.

    RTD's typically have been viewed as being the Second Most Utilized Temperature Sensor throughout industry. Thermocouples are thought to be most utilized temperature sensor design, although RTD's appear to be growing at a faster rate. In fact we have noted an increasing amount of automation industry and equipment builders choosing a RTD sensor design as their Primary Temperature Sensor Solution.

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    Surface Mount RTD Temperature Sensors

    Surface Mount RTD Temperature Sensors
    With a temperature range of -90 to 500 F (-70 to 260 C) and the use of Class A Accuracy RTD elements, the excellent performance and reliability of our Bolt DownStick On or Screw Down Surface Mount RTD Temperature Sensors provide the solution for diverse industry applications. Customers in Semiconductor to Alternate Energy, Laboratories and beyond have experience the benefits of these designs.

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    Thermocouple Connector - Miniature Time Saver Series

    Thermocouple Connector - Miniature Time Saver Series

    Our Time-Saver Thermocouple Connector Series, can Reduce your Assembly Time by 2 Minutes on each connector and provide a Very Secure and Rugged Stainless-Steel Clamping System for your lead wire.

    The connector cap has an integral stainless steel bracket with a pre-assembled wire clamp design. All the screws are stainless steel combination heads and with the simple turn of a screw the clamp quickly and easily accommodate designs as small as 40 gage parallel jacketed wire and as large as 20 gage parallel jacketed wire. .

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