Thermocouple wire sensors are the fundamental sensing element before installation into a sheath or housing. Thermometrics supplies thermocouple wire sensors in bare, PTFE-insulated, glass-braid, and ceramic-fiber constructions — as individual thermocouple pairs, duplex insulated cable, and extension-grade wire for runs from sensor to instrument.
| Type | Description | Insulation | Max Temp | Application |
|---|---|---|---|---|
| TC-TW-PTFE | Duplex TC Wire — PTFE Insulated | PTFE individual + overall PFA jacket | 260°C continuous | General process; chemical-resistant runs; moisture-prone locations |
| TC-TW-FG | Duplex TC Wire — Fibreglass Insulated | E-glass braid individual + overall braid | 480°C continuous | Oven and dryer leads; furnace door penetrations |
| TC-TW-CF | Duplex TC Wire — Ceramic Fibre Insulated | High-alumina ceramic fibre braid | 1200°C max | Thermocouple leads inside furnaces, kilns, combustion zones |
| TC-TW-SS | Duplex TC Wire — SS Overbraid | PTFE or FG + 304SS overbraid | 260–480°C | Mechanical protection; abrasion-prone installations |
| TC-EXT-PTFE | Extension-Grade TC Cable — PTFE | PTFE insulated, 20 AWG extension conductors | 260°C | Sensor-to-panel runs (not for sensing — extension grade conductors) |
| TC-EXT-PVC | Extension-Grade TC Cable — PVC | PVC, colour-coded per ANSI MC96.1 | 105°C | Indoor/conduit runs, control panels, standard plant wiring |
| TC-NM-R | Noble Metal TC Wire — Type R (Pt-13%Rh/Pt) | Alumina twin-bore insulation | 1480°C | Calibration labs, noble metal assemblies, furnace Type R elements |
| TC-NM-S | Noble Metal TC Wire — Type S (Pt-10%Rh/Pt) | Alumina twin-bore insulation | 1480°C | Primary standard thermometry, glass furnace control elements |
| Parameter | Base Metal Wire | Noble Metal Wire |
|---|---|---|
| Types Available | K, J, T, E, N | R, S, B (Pt-Rh alloys) |
| Standard | ASTM E230 / IEC 60584 | ASTM E230 / IEC 60584 |
| Tolerance | Standard; Special Limits available | Class 1; NIST-traced on request |
| AWG Sizes | 20, 24, 28, 30, 36, 40 AWG | 24, 28 AWG |
| Lot Certification | Standard with order | NIST-traceable EMF test |
| Colour Code | ANSI MC96.1 (US) or IEC 60584-3 | ANSI/IEC on request |
| Custom Stranding | Solid or 7-strand | Solid only |
Thermocouple-grade wire uses the actual thermocouple alloys (e.g., Chromel/Alumel for Type K) and is calibrated to sensing tolerances per ASTM E230. Extension-grade wire uses lower-cost alloys with the same Seebeck coefficient within a limited temperature range (typically 0°C to 200°C) and is only intended for the run from the sensor to the instrument panel. Never use extension-grade wire in the sensing zone — it introduces calibration error outside its rated range. Thermometrics supplies both grades; extension cables are colour-coded to match the sensing type per ANSI MC96.1.
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