Thermocouple module.

The thermocouple module was specially developed as an interface for high-temperature measurement chains. It is ideally suited for use in demanding environments such as blast furnaces in steel production as well as in large industrial plants and test cabinets. In addition to the ODU-MAC® White-Line and Silver-Line, it is now also available in the Blue-Line and thus in all modular connectors.

The operation of the high temperature measuring module is simple and effective. It creates a voltage between two wires made of different materials called a thermocouple. When temperatures are applied to the temperature sensor, the voltage generated varies due to the thermoelectric effect. These voltage changes enable extremely accurate temperature determination.

Compact and flexible.
An outstanding feature of the new 6 contacts ODU-MAC® module is its versatile configurability. It can be flexibly combined with other media in the connector. Despite its compact design, it can be equipped with up to three thermocouples. Customers benefit from a reliable solution designed for at least 5,000 mating cycles.

Quickly ready for use.
The thermocouple pin and socket crimp contacts of the ODU-MAC® module are available in K and T types. The stamped contacts are mounted as usual using the clip principle and are further facilitated by the coloured marking. If the thermocouple module is integrated into the connector together with the thermoelectric cables, you get a ready-to-use solution.

@PresseBox #ODU #PAuto 

Thermocouple or pyrometer?

Whether to use thermocouples or a portable pyrometer for temperature measurement in liquid metal applications is a decision long-debated in the industry. Now, AMETEK Land can help make the decision with its new download, ‘Thermocouples vs Cyclops L Portable Pyrometers – Frequently Asked Questions and Other Information’ (pdf)

Prasath Venkatasamy, Global Industry Manager – Metals at AMETEK Land, said: “Making the decision to use thermocouples or the Cyclops L can have significant implications for ongoing costs, operator safety, and measurement accuracy. This new FAQ document helps metal manufacturers to cut through the confusion and find the information they need to make the choice that best suits their application.”

AMETEK Land provides a detailed comparison of the two solutions, outlining their benefits and drawbacks in liquid metal temperature measurements.

For example, thermocouples are highly accurate across a wide temperature range, offer a good response time and have a low cost of ownership. However, they have limited accuracy at very high temperatures, can be affected by several factors, and require regular tip replacement, increasing the cost of consumables.

Portable pyrometers, on the other hand, use a non-contact measurement from a safe distance, deliver a faster, better response time and have a wide temperature range measurement. They need a clear line of sight to the object being measured and can be affected by dust, smoke, steam, or other gases in the environment.

AMETEK Land’s Cyclops 055L portable pyrometer is highlighted as a solution for liquid metal measurements during the casting process to support metal quality, offering a rapid return on investment.

The Cyclops 055L model has an additional Meltmaster processing output, designed for molten metal measurements, which helps overcome variations in the radiation emitted from the metal stream, providing a valid estimation of the true temperature.

Alongside the frequently asked questions (FAQs) from customers about thermocouples and pyrometers in general, the download has full information about the Cyclops 055L, including specifications and accessories.

@landinst  #PAuto #LiquidMetal

Measuring temperature!

There is more than one way to measure temperature in an application. 

The easiest option is certainly the cable probe. But the higher the demands on the probe, the faster the simple cable probe reaches its limits. Operating temperature, installation situation, flexibility and reproducibility are just some of the influencing factors. Therefore, the cable probe and the mineral insulated resistance thermometer (also called resistance thermometers or mineral insulated probe) are compared and areas of application are shown. 

The classic cable probe

Simply constructed cable temperature probes without bringing potting compund and heat-conductive paste as well as certain insulation elements in, are quite simple to manufacture. They consist of a cable, at whose end a sensor element (e.g. platinum sensor) is connected. The entire measuring insert (this is the name given to the sensor incl. insulation and possible shrink tubing installed on the cable) is inserted into a protective sleeve that protects it against environmental influences. With the help of the already mentioned casting compounds, a high IP protection class (up to IP68) can also be achieved with these probes. The use of heat-conductive paste also ensures that quick response times are achieved. The fixation by means of pinching or rolling ensures a secure connection between the sleeve and the cable. Depending on the raw material prices and the structure of the measuring insert, the classic cable probe can be a very cost effective way of measuring temperature. A small number of parts and work steps also ensures a low price in production.

B+B Thermo-Technik GmbH has provided innovative measurement technology for the past 35 years. They are partners for the measurement and automation technology. The company is a specialist for all areas in the temperature, humidity and pressure measurement.

However, depending on the requirements, this simple execution of temperature measurement also reaches its limits. Although the cable probes can be cast waterproof up to a maximum permanent temperature of approx. 350 °C, there is still the possibility that water vapor could get inside the probe. Particularly when using glass fiber lines, which are used at high ambient temperatures (>260 °C), moisture can penetrate the measuring insert and impair its function.

Reproducibility is also only possible to a limited extent. The location of the sensor varies minimally from probe to probe, which can lead to slight deviations in the measured values.

Last but not least, the installation situation often requires a structural adjustment of the temperature probe. The protective sleeve of cable probes is rigid and therefore offers only a few options for flexibility. More space is required, especially for probes with a thread, so-called screw-in probes. But this is, depending on the installation space. not available

In such cases, a sheath resistance thermometer can be used.

The mineral insulated resistance thermometer
Similar to the structure of a mineral insulated thermocouple, the mineral insulated resistance thermometer consists of two conducters, but not made of thermocouple material but made out of copper. These are enclosed by magnesium oxide and a stainless steel sleeve (e.g. Inconel 600). In the measuring technology industry, this is known as a sheathed slotted line. It is shortened to the required length and the sensor element (e.g. Pt1000) is welded to the exposed copper wires.

Using this process, it is possible to always put the sensor elements in the same position, even if 2 sensor elements are installed in a probe, which must be at the same height and radial position. Deviations when changing a probe are therefore also excluded.

Another stainless steel sleeve encloses the sensor elements and is welded to the end of the sheathed slotted line. Now the sensor elements are embedded in tightly compressed magnesium oxide. At the end the probe is closed with a pastille.

Thanks to the magnesium oxide, the sensors are cast vapor-tight and, thanks to their structure, can withstand high pressures and temperatures of up to 600 °C without any problems. Due to the robust construction, the probes are shockproof and durable. Another big benefit: The sheathed slotted line can be bent and can therefore be individually adapted to the application and construction.

All these advantages and properties mean that significantly more and higher quality basic materials are required for a mineral insulated resistance thermometer. The manufacturing processes are also more complex, which means that the price is higher than that of a simple cable probe. In comparison to a high-quality cable probe (with R glass fibre cable), there is almost no difference in price.

@bb_sensors @PresseBox #PAuto

Hermetic connector with T/C contacts.

The range of circular connector with thermocouple contacts from Esterline Connection Technologies – SOURIAU, now includes a version with hermetic receptacle to meet specific requirements for aircraft, and applications in harsh environments.

This connector range supplements and complements SOURIAU's current range of hermetic connectors and thermocouple contacts. The specific thermocouple contacts can be fitted in connectors that comply with EN 3646, MIL-DTL-26482, MIL-DTL-38999, and EN 2997. In civil and military aviation, for example, they are used to connect temperature sensors placed around aircraft engines and brake systems.

A specific contact technology
In temperature measurement chains, nickel-chrome (NiCr) and nickel-aluminium (NiAl) are soldered at the sensor inside the transducer and must have material continuity up to the analysis electronics. A connector's contacts must meet this requirement in order for it to be added to the measuring chain. SOURIAU ensures material continuity by fitting a nickel-chrome contact and a nickel-aluminium contact in each of its thermocouple connectors, thus rendering them neutral in the measuring chain.

Hermetic contacts and receptacles

Available connectors SOURIAU's hermetic connectors with thermocouple contact are now available in three versions:  EN 2997, MIL-DTL-38999 Series III, and EN 3646. They are the perfect match with SOURIAU's existing range of hermetic connectors and removable contacts designed for use in increasingly harsh environments.

Receptacles fitted on equipment must be hermetic at two points. The first point relates to the method used to attach the receptacle, which is possible by laser or TIG welding or by fitting a special O-ring. The second point is at the contacts inside the receptacle. Here, the conventional insulator is replaced by a glass insulator. A sintered pad of the same size as the shell and corresponding to the contact layout is inserted and melted at 1000°C in an autoclave. The heating and cooling cycles in the process are interspersed with stabilization periods. As a result, the glass contracts to form a fully hermetic seal within the shell and around each contact. Each connector undergoes rigorous quality control in the form of a helium leak test in order to guarantee the specific leakage rate of less than 10-7 atm-cc/sec required for hermetic connectors.

Contact layout and arrangement
Most connectors are fitted with a pair of nickel-chrome/nickel-aluminium contacts to form a thermocouple pair. SOURIAU can provide connectors with two pairs or more of thermocouple contacts for customers that require signal acquisition redundancy.
Two standard arrangements of three and five contacts are available based on standard definitions. As in any hermetic connector, the matching contacts are typically made of ferronickel.
SOURIAU can customize the location of contacts inside the cavity to the customer’s requirements.

 @SouriauSunbank #PAuto

T/c simulator.

Pickering Interfaces has introduced their first Millivolt Thermocouple Simulator Module.

PXI Thermocouple Simulator Modules (series 41-760) are ideal for simulating the operation of a thermocouple. They are available in a choice of 8, 16, 24 or 32 channels—each channel providing a low-voltage output across two connector pins capable of providing ±20mV with 0.7µV resolution, ±50mV with 1.7µV resolution and ±100mV with 3.3µV resolution, covering most thermocouple types.

These new thermocouple simulators use two wire outputs with a remote output reference sense to ensure the modules deliver accurate low-level voltages, even if the system has common mode voltages present. In addition, each simulation channel is also able to provide an open circuit setting to simulate faulty wiring connections to a sensor. For improved accuracy, each channel of the Low Voltage Source carries accurate calibration data stored on the module. The module also includes a calibration multiplexer for module test and verification purposes.

The 41-760 simulator modules can be connected straight into the thermocouple measurement system. To aid in this, Pickering offers a connector solution that has 8, 16, 24 or 32 copper twisted pairs terminated with mini copper thermocouple plugs. Pickering can also supply connector blocks that convert the module’s 78-pin connector to terminal blocks to ease user wiring, or design alternative customized interconnections solutions.

The introduction of the PXI thermocouple simulator modules builds on Pickering Interfaces growing PXI simulation product line that includes standard and precision programmable resistors, including RTD and strain gauge simulation.

@Pickeringtest  #PAuto #TandM 

Ten thermocouple channel model for glass tempering!

Datapaq is extending its Furnace Tracker product range with the addition of a new ten thermocouple channel model, designed specifically for use in low height furnaces. The data logger stores up to 18,000 readings per channel at intervals from 0.05 seconds to 10 minutes. Ceramic coated and laser welded, the 29mm (1.14in) high thermal barrier ensures long operational life.

The ten and four channel Furnace Tracker systems for glass tempering furnaces accurately measure temperatures from all types of glass, including hard and soft-coated low-E glass. Thus, users can optimize cycle times and reduce energy costs. The accompanying user-friendly software features comprehensive analysis and archiving functions and enables users to see quickly and easily what is really happening inside the furnace.

Mini wireless thermocouple connector/datalogger

Omega’s new MWTC-D Series of Miniature Portable Wireless Thermocouple Connectors and data logger records over 65,000 process temperature data points and are available in standard J, K, T, E, R, S, B, C, or N thermocouple calibration. Each battery powered, compact connector transmits and/or records process & ambient temperature data back to a mating wireless receiver up to 90 m (300’) away. All readings are displayed on your PC screen in real time using the free provided software. The recording can begin either at power up, or at a pre-set time & date. Multiple wireless connectors (Up to 48 units) can transmit to one MWTC-REC receiver. This product is used in chemical, automotive and oil & gas industries to monitor and log temperature process data.

Making T/cs with ease

Click image to see welder in operation!

BEL Thermocouple Welder Model TLWELD9, from Tester Store, is designed for manufacturers and for laboratory use in the production of commercial grade thermocouple junctions, and for users of large numbers of exposed junction thermocouple such as test and development laboratories where multipoint temperature sensing of test pieces are required.

It has a safety welding pen design and eliminates the use of pliers. No special skills are needed and most people will be capable of producing quality work with minimal practice.

The instrument is operated via the front panel. It is a portable welding machine that allow the thermocouple wires to bond into freestanding beads. The Operator only takes a few seconds to bond the standard thermocouple wire into a temperature sensor.

This model is suitable for welding any type thermocouple wires from AWG40-AWG19 (0.1~1.1 mm) in diameter. A satisfactory thermocouple junction is produced without using argon. In just three steps a quality bonded thermocouple wire sensor can be welded. It has been selected by many famous laboratories throughout the world.

USB T/C input module

The new UTC-USB universal thermocouple connector from OMEGA is an easy way to convert thermocouple signals and display actual temperature readings on your PC through a standard USB port (Integral cable provided).

It features their patented universal input connection, so you can quickly attach both standard and miniature size thermocouple plugs.

This discrete device accepts 8 different thermocouple types and provides automatic cold junction compensation and linearisation. Free software is included that lets you select the thermocouple type and units. You can then use your PC to display, chart record and log the temperature data.