A foolproof guide to temperature sensors, thermocouples, and resistance thermometer- Contact temperature measurement explained through general Q&A

A foolproof guide to temperature sensors, thermocouples, and resistance thermometer- Contact temperature measurement explained through general Q&A

This book provides an easy-to-understand explanation of the principles, wiring, errors, selection, and inspection of contact-type temperature measurement. It is a practical Q&A that answers common questions that can be confusing in the field.

Basics (Temperature Sensor Overview)

What is the difference between contact and contactless? Basics

Contact types (thermocouples, resistance thermometer, etc.) measure the temperature by touching the object. Non-contact types (radiation thermometer) estimate the surface temperature from infrared rays. The type you should use depends on the response speed, ease of installation, and thermal coupling with the object.

Basic resistance thermometer)differences between typical elements (thermocouples/

Thermocouples detect temperature by electromotive force, while resistance thermometer detect temperature by changes in resistance value. Thermocouples are advantageous for high temperatures and wide ranges, while resistance thermometer are advantageous for accuracy and stability.

What is a sensor's "response time"? The basics

This is the time it takes for step temperature change to reach 63% (or 90%). The smaller and thinner the temperature sensor is, and the lower the thermal capacity and thermal resistance, the faster the change will be.

How to use (general)

Tips for correct installation

The target temperature is thermally contacted and the influence of the surroundings is reduced by using heat insulating material or thermally conductive grease. For fluids, the temperature is near the center of the flow path, and for solids, it is at a representative point.

What about the settings on the measuring device? display

Correctly match the sensor type (thermocouple type/ resistance thermometer element/wire type), unit, filter, alarm, and scaling.

Wiring (general)

Basics of noise suppression wiring

shield and twist the cable, keep it away from power lines and inverters, and ground a single-point earth. For long distances, it is effective to use a converter (4–20 mA/IO-Link, etc.).

How to choose an extension cable ?

For thermocouples, balance the material and diameter of the compensating wire, and for resistance thermometer, check the polarity and contact resistance of the connector.

Environmental impact (general)

Effects of vibration, humidity, and chemical atmosphere environment

vibration can cause disconnection and poor contact, moisture can reduce insulation, and corrosive gases can cause coating deterioration. Protect with protective tubes, terminal boxes, and the correct IP rating.

Troubleshooting (general)

display is unstable/ slow

Possible causes include insufficient thermal capacity, mismatched response time, improper filter settings, and noise interference. Review the installation and organize the wiring route.

Inspection and calibration (general)

Simple on-site inspection

Use freezing point/boiling point, thermostatic chamber, and dry block to compare with a reference sensor. Adjust span/zero if necessary.

Selection guidelines (general)

Thermocouple or resistance thermometer, which to choose ?

Range / Temperature (high temperature is thermocouple), Accuracy and stability (in Japanese history) resistance thermometer (See Section 2.1.2.), response (Micro is thermocouple/thin type) resistance thermometer (See Section 2.1.2.), environment (Compare with (vibration- corrosion resistant). Also take into account the presence of transducers and cable lengths.

Reference materials (public information)

  • Thermocouple Basics and Types: IEC 60584-1/JIS (Type Symbols and Tolerances)
  • Basics of resistance thermometer: IEC 60751/JIS (Pt100/Pt1000, Class A/B, etc.)
  • Wiring and noise countermeasures: Instrumentation wiring guidelines, transmitter manuals from various manufacturers
  • Inspection and calibration: Use of dry blocks, thermostatic chambers, and reference resistance

*For detailed values and the latest information on specifications, please refer to the respective specifications sheets and product instruction manuals.

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