1. Instruments & Electrical Measurements Lecture 3

2. Basically thermocouple consists of two different metals which are placed in contact with each other as shown in the diagram

3. First part is called the heater element because when the current will flow through this, a heat is produced and thus the temperature will increased at the junction. At this junction an electromotive force (EMF) is produced which is approximately proportional to the temperature difference of hot and cold junctions.
The emf produced is a DC voltage which is directly proportional to root mean square value of electric current. A permanent magnet moving coil instrument is connected with the second part to read the current passing through the heater. One question must be arise in our mind that why we have used only a permanent magnet coil instrument?

4. Answer to this question is very easy it is because PMMC instrument has greater accuracy and sensitivity towards the measurement of DC value. The thermocouple type instruments employ thermocouple in their construction. Thermocouple type instruments can be used for both ac and DC applications. Also thermocouple type of instruments has greater accuracy in measuring the current and voltages at very high frequency accurately.

7. Construction of Thermocouple Type Instrument Now let us look at the construction of Thermocouple type Instruments. Broadly speaking the thermocouple type of instruments consists of two major parts which are written below: (a) Thermo electric elements: The thermocouple type of instruments consists of thermo electric elements which can be of four types:

8. Contact Type: It has a separate heater which is shown in the diagram.
The action of thermocouple type instruments can be explained briefly as,

9. At the junction the electrical energy is being converted to thermal energy in the heater element. A portion of the heat is transferred to the hot junction while most of the heat energy is dissipated away.
o The heat energy which is transferred to hot junction is again converted to electrical. Only a portion of electrical energy is converted into mechanical energy which is used to produce a deflecting torque. The overall efficiency of the system is low thus the instrument consumes high power. So there is a requirement of highly accurate and sensitive DC instrument.

10. 2. Non Contact Type: In non contact type there is insulation between the heating element and the thermocouple i.e. there no direct contact between two. Due to this these instruments are not much sensitive as compared contact type.
3. Vacuum Thermo-elements: These types of instruments are mostly employed for the measurement of electric current at very high frequency of the order of 100 Mega hertz or more as these instruments retain their accuracy even at such high frequency.

11. 4. Bridge Type: These bridges are manufactured on the AC ratings usually from 100 mili amperes to 1 amperes. In this two thermocouple are connected to form a bridge which is shown in the figure given below:

12. There is no requirement of heating element, the electric current which directly passing through the thermocouple raises the temperature which is directly proportional to the I2R losses. The bridge works on balanced condition at which there will be no current in the arm ab. The connected meter will show the potential difference between the junctions a and b.

13. Advantages of Thermocouple Type Instruments
1. The thermocouple type of instruments accurately indicates the root mean square value of current and voltages irrespective of the waveform. There is a wide varieties of range of thermocouple instruments are available in the market.
2. Thermocouple type of instruments give very accurate reading even at high frequency, thus these types of instruments are completely free from frequency errors.

14. Gross errors can be avoided by using two suitable measures and they are written below: 1. A proper care should be taken in reading, recording the data. Also calculation of error should be done accurately. 2. By increasing the number of experimenters we can reduce the gross errors. If each experimenter takes different reading at different points, then by taking average of more readings we can reduce the gross errors.

15. 3. The measurement of quantity under these instruments is not affected by stray magnetic fields.
4. These instruments are known for their high sensitivity.
5. Usually for measuring the low value of current bridge type of arrangement is used i.e. ranging from 0.5 Amperes to 20 Amperes while for measuring the higher value of current heater element is required to retain accuracy.

16. Disadvantages of Thermocouple Type Instruments
Instead of many advantages these type of instruments posses one disadvantage, The over load capacity of thermocouple type of instrument is small, even fuse is not able to the heater wire because heater wire may burn out before the fuse blows out.

17. Types of Thermocouples:
1-Type K Thermocouple (Nickel-Chromium / Nickel-Alumel): The type K is the most common type of thermocouple. It’s inexpensive, accurate, reliable, and has a wide temperature range. Temperature Range:
Thermocouple grade wire, –454 to 2,300F (–270 to 1260C)
Extension wire, 32 to 392F (0 to 200C)
Accuracy (whichever is greater):
Standard: +/- 2.2C or +/- .75%
Special Limits of Error: +/- 1.1C or 0.4%

18. 2. Type J Thermocouple (Iron/Constantan): The type J is also very common. It has a smaller temperature range and a shorter lifespan at higher temperatures than the Type K. It is equivalent to the Type K in terms of expense and reliability.
Temperature Range:
Thermocouple grade wire, -346 to 1,400F (-210 to 760C)
Extension wire, 32 to 392F (0 to 200C)
Accuracy (whichever is greater):
Standard: +/- 2.2C or +/- .75%
Special Limits of Error: +/- 1.1C or 0.4%

19. 3. Type T Thermocouple (Copper/Constantan): The Type T is a very stable thermocouple and is often used in extremely low temperature applications such as cryogenics or ultra low freezers. Temperature Range:
Thermocouple grade wire, -454 to 700F (-270 to 370C)
Extension wire, 32 to 392F (0 to 200C)
Accuracy (whichever is greater):
Standard: +/- 1.0C or +/- .75%
Special Limits of Error: +/- 0.5C or 0.4%

20. 4. Type E Thermocouple (Nickel-Chromium/Constantan): The Type E has a stronger signal & higher accuracy than the Type K or Type J at moderate temperature ranges of 1,000F and lower. See temperature chart (linked) for details. Temperature Range:
Thermocouple grade wire, -454 to 1600F (-270 to 870C)
Extension wire, 32 to 392F (0 to 200C)
Accuracy (whichever is greater):
Standard: +/- 1.7C or +/- 0.5%
Special Limits of Error: +/- 1.0C or 0.4%

21. 5. Type N Thermocouple (Nicrosil / Nisil): The Type N shares the same accuracy and temperature limits as the Type K. The type N is slightly more expensive. Temperature Range:
Thermocouple grade wire, -454 to 2300F (-270 to 392C)
Extension wire, 32 to 392F (0 to 200C)
Accuracy (whichever is greater):
Standard: +/- 2.2C or +/- .75%
Special Limits of Error: +/- 1.1C or 0.4%

22. NOBLE METAL THERMOCOUPLES (Type S,R, & B): Noble Metal Thermocouples are selected for their ability to withstand extremely high temperatures while maintaining their accuracy and lifespan. They are considerably more expensive than Base Metal Thermocouples.   
6. Type S Thermocouple (Platinum Rhodium - 10% / Platinum): The Type S is used in very high temperature applications. It is commonly found in the BioTech and Pharmaceutical industries. It is sometimes used in lower temperature applications because of its high accuracy and stability. Temperature Range: Thermocouple grade wire, -58 to 2700F (-50 to 1480C)
Extension wire, 32 to 392F (0 to 200C)
Accuracy (whichever is greater): Standard: +/- 1.5C or +/- .25%
Special Limits of Error: +/- 0.6C or 0.1%

23. 7. Type R Thermocouple (Platinum Rhodium -13% / Platinum): The Type R is used in very high temperature applications. It has a higher percentage of Rhodium than the Type S, which makes it more expensive. The Type R is very similar to the Type S in terms of performance. It is sometimes used in lower temperature applications because of its high accuracy and stability. Temperature Range:
Thermocouple grade wire, -58 to 2700F (-50 to 1480C)
Extension wire, 32 to 392F (0 to 200C)
Accuracy (whichever is greater):
Standard: +/- 1.5C or +/- .25%
Special Limits of Error: +/- 0.6C or 0.1%

24. 8. Type B Thermocouple (Platinum Rhodium – 30% / Platinum Rhodium – 6%): The Type B thermocouple is used in extremely high temperature applications. It has the highest temperature limit of all of the thermocouples listed above. It maintains a high level of accuracy and stability at very high temperatures. Temperature Range:
Thermocouple grade wire, 32 to 3100F (0 to 1700C)
Extension wire, 32 to 212F (0 to 100C)
Accuracy (whichever is greater):
Standard: +/- 0.5%
Special Limits of Error: +/- 0.25%

25. Thank you