Thermocouple Type-K: 3 Wires & Ceramic Shield?

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SUMMARY

The discussion centers on the unique configuration of a Type-K thermocouple featuring three wires, with the third wire serving as a grounding connection via a thermowell. This design is intended to prevent static charge buildup, enhancing measurement accuracy. The thermocouple's exposed junction type allows for faster response times compared to shielded types, which are typically encased in protective materials. The conversation also touches on troubleshooting methods for a non-functional electric tube furnace utilizing this thermocouple.

PREREQUISITES
  • Understanding of thermocouple types, specifically Type-K thermocouples
  • Knowledge of thermowell applications and grounding techniques
  • Familiarity with temperature measurement and control systems
  • Basic troubleshooting skills for electric furnaces and thermocouples
NEXT STEPS
  • Research the differences between grounded and ungrounded thermocouples
  • Learn about thermowell designs and their impact on thermocouple performance
  • Investigate troubleshooting techniques for electric tube furnaces
  • Explore the specifications and applications of Type-K thermocouples in industrial settings
USEFUL FOR

Engineers, technicians, and researchers involved in temperature measurement, furnace operation, and thermocouple applications will benefit from this discussion.

  • #31
Averagesupernova said:
My guess the third wire is to help with noise imunity while preventing the whole thermocouple from floating. I would think there would be better noise immunity when this third wire is grounded back at the amplifier/transmitter than just grounding it at the weld. I would think of it as a shielded twisted pair microphone cable.

A propensity for noise issues depends on controller instrumentation amp design as well as TC construction and wiring. I ran into this when replacing an ancient Barber-Coleman MACO V control system with a (then, only recently introduced) Allen-Bradley SLC500 PLC equipped with a half dozen 1747-NT4, 4 channel thermocouple input modules. Temperature measurements drifted by a degree or so, some more than others, and apparently at random, but closer investigation revealed it depended on how many zones were simultaneously calling for heat. Turned out the -NT4 module was more sensitive to common mode noise than the MACO V (several years later A-B introduced an -INT4 module with better isolation), and a quick fix was to swap out the original grounded thermocouple probes for ungrounded ones. Another option was to replace all the TC extension wire runs with shielded TC extension cable, ground the shield at the TC plug negative connection (in the process introducing an ongoing maintenance issue), and bond the negative TC extension wire at the module's analog common.

1747-NT4_Input.jpg
TC input wiring

It was a long walk to get here, but most other manufacturers also recommend bonding a grounded thermocouple's cable shield to the source (TC) rather than at the instrument side. The cable shield for an ungrounded TC is grounded at the input module.

Ungrounded thermocouples aren't a panacea, and don't necessarily help with noise. Many TC instrumentation amps connect the inverting input to ground through a high resistance. It they don't, any charge that builds up on the wires through op amp reverse bias leakage, static, etc. has nowhere to go, and affects measurements.

AD_TC_Figure 6_Circuit.jpg


Figure 6 was borrowed from an excellent Analog Devices technical article, "Two Ways to Measure Temperature Using Thermocouples Feature Simplicity, Accuracy, and Flexibility" regarding their TC amplifiers.

In the OP's situation I'd bet there is a screw within reach of the TC ground wire with witness marks indicating prior connection.
 
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