Instruction

TEMP-PRO
An ISO 9001 CERTIFIED Company
Inc. Manual

INSTRUCTION AND INSTALLATION

MANUAL

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 Sensor
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company
Catalog

TYPE Oil Tight Removable Sensor

▲
NPT SENSOR
DIRECT (METAL SHEATHED)
MOUNTING
BUSHING

5/16" DIA
MAX

THREAD
ENGAGEMENT
✽
D
CONDUIT PENETRATION
PORT DEPTH

▲ MgO insulation for thermocouple, AL2O3 insulation for R.T.D.

* This dimension to be specified when thermowell is not required.

HEAD MOUNT ING BUSHING SENSOR

LINE CONDUIT PIPE # OF SHEAT H
MAT 'L MAT 'L DIA. T YPE MEASURING JUNCT ION
# PORT SIZE WIRES MAT 'L

1 C.I. 3/4 C.S. 1/2 3/16 J 316 GROUNDED

2 ALUM. 1/2 304 SS 3/4 1/4 K 2 INC. UNGROUNDED

BLOCK NOT OTHER OTHER

3 5/16 E 3 OTHER ADVISE EXPOSED
ONLY REQ'D ADVISE ADVISE
NOT NOT NOT
4 T 4 OTHER ADVISE
REQ'D REQ'D REQ'D
100 OHM
5 NOT APPLICABLE
PLAT.
OTHER
6 6
ADVISE

P/N 03 ——

Complete using the line number for each column in sequence from left to right.

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 Instruction
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company Manual

INSTRUCTION MANUAL

Operation And Maintenance Instructions

1. General Information
The Temp-Pro Thermocouple assembly you have selected is a precision temperature sensing unit
which offers accurate readings under your specified industrial field conditions. Reasonable care,
however, must be exercised in handling these sensors. Specified operating limits (see Table 1 on
page 2) must not be exceeded. Rough handling, bending, or dropping of the sensor must be avoided.

2. Unpacking and Inspection

Immediately upon receipt, the sensors should be examined for possible in-transit damage and for
physical conformance to specifications, In the case of damage, file a claim with the carrier and
notify Temp-Pro Inc. without delay.

3. Thermocouple Assemblies and Technical Requirements

3.1. EMF Values: Each thermocouple has been manufactured to meet the EMF vs. Temperature
characteristics specified by NIST (National Institute of Standards and Technologies). These tables
are available at Temp-Pro and can be supplied to you upon request.

3.2. Calibration: Temp-Pro has a calibration Laboratory for calibration and verification of
Temperature vs. EMF of the thermocouples supplied to the customers and provides calibration data
when requested by the customer.

3.3. General Information: General information related to commonly used thermocouples in

industries are shown in Table 1 (page 2) including the temperature range, color coding, tolerances,
etc.

3.4. Insulation Resistance (IR) Test of the Thermocouples: This is the most common test done
on UNGROUNDED Thermocouples (and RTDs). See test method under MEASURING IR on page 6
of this manual.

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 Instruction
TEMP-PRO An ISO 9001 CERTIFIED Company
Inc. Manual
TABLE 1

INITIAL CALIBRATION TOLERANCES TO THERMOCOUPLE

THERMOCOUPLE TYPE ºC ºF

ANSI
COLOR TEMPERATURE STANDARD SPECIAL TEMPERTURE STANDARD SPECIAL
WIRE ALLOYS TYPE
CODE RANGE LIMITS LIMITS RANGE LIMITS LIMITS
SYMBOL

-200º to -650º ±1.5% ±0.8% -330º to -85º ±1.5% ±0.8%

Copper (+) vs. Blue
T -65º to +130º ±1º ±0.5º -85º to +270º ±1.8º ±0.9º
Constantan (-) Red
+130º to +350º ±0.75% ±0.4% +270º to +660º ±0.75% ±0.4%

*Iron (+) vs. White 0º to +285º ±2.2º ±1.1º +32º to +545º ±4º ±2º
J
Constantan (-) Red +285º to +750º ±0.75% ±0.4% +545º to +1400º ±0.75% ±0.4%

-200º to -170º ±1% ±1º -330º to -270º ±1% ±1.8º

Chromel™ (+) vs. Yellow -170º to +250º ±1.7º ±1º -270º to +480º ±3º ±1.8º
E
Constantan (-) Red +250º to +340º ±1.7º ±0.4% +480º to +640º ±3º ±0.4%
+340º to +900º ±0.5% ±0.4% +640º to +1600º ±0.5% ±0.4%

-200º to -110º ±2% -330º to -165º ±2%

Chromel™ (+) vs. Yellow -110º to 0º ±2.2º -165º to +32º ±4º ±2º
K
*Alumel™ (-) Red 0º to +285º ±2.2º ±1.1º +32º to +545º ±4º ±0.4%
+285º to +1250º ±0.75% ±0.4% +545º to +2300º ±0.75%

Nicrosil (+) vs. 0º to 285º ±2.2º ±1.1º +32º to +545º ±4º ±2º
N
Nisil (-) +285º to +1250º ±0.75% ±0.4% +545º to +2300º ±0.75% ±0.4%

Platinum -
0º to +600º ±1.5º ±0.6º +32º to +1110º ±2.7º ±1.1º
10% Rhodium (+) S
+600º to +1450º ±0.25% ±0.1% +1110º to +2650º ±0.25% ±0.1%
vs. Platinum (-)

Platinum -
0º to +600º ±1.5º ±0.6º +32º to +1110º ±2.7º ±1.1º
13% Rhodium (+) R
+600º to +1450º ±0.25% ±0.1% +1110º to +2650º ±0.25% ±0.1%
vs. Platinum

Platinum -
30% Rhodium (+)
B +870º to +1700º ±0.5% ±0.25% +1600º to +3100º ±0.5% ±0.25%
vs. Platinum -
6% Rhodium (-)

Tungsten (+) vs.

Tungsten WR +400º to 2300º ±1% +800º to +4200º ±1%
-26% Rhenium (-)

Tungsten -
3% Rhenium (+)
W3 +400º to 2300º ±1% +800º to +4200º ±1%
vs. Tungsten -
25% Rhenium (-)

Tungsten -
5% Rhenium (+)
W5 +400º to +2300º ±1% +800º to +4200º ±1%
vs. Tungsten -
26% Rhenium (-)

* Magnetic
™ Trademark, Hoskins Manufacturing Co.
T not ANSI type symbol
NOTE: Percent limits apply directly to temperature in degrees Celsius, but for degrees Fahrenheit equivalents are applied to the
number of degrees Fahrenheit above or below the ice point (+32 degrees Fahrenheit).

[i.e., Limit (degrees F) = (Temperature (degrees F) - 32 (degrees F)) * Percentage]

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 Instruction
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company Manual
4. Resistance Thermometer Detector (RTD) Assembly and Technical
Requirements

4.1. Outputs and Measurements: The output of RTD is resistance and can be measured with a
Digital Multimeter.

4.2. General Information: General Information about different types of RTDs are shown in
Table 2 below.

TABLE 2

RESISTANCE TEST READING

ELEMENT TEMP. COEF. OHMS AT OHMS AT

TYPE (TCR) 0° C 25° C

Platinum (DIN) .00385 100.00 109.73

Platinum .00392 100.00 109.91

Nickel .00426 90.38 99.11

Nickel .006720 120.00 140.20

C opper .004274 9.04 10.00

Nickel - Iron .005188 604.00 676.00

4.3. Temperature vs. Resistance: Temperature vs. Resistance of the most commonly used RTDs
are shown in Table 3 on page 5.

4.4. Insulation Resistance of the RTDs: The Insulation Resistance Test of RTD is similar to
Thermocouple except, use maximum 100 VDC as an applied voltage when using a megohmmeter
(see Measuring IR on page 6)

4.5. Maintenance of RTDs, including Platinum RTDs: Normally, RTDs do not require
maintenance. Should there be any apparent change in response time or drift in signal output,
remove sensor from the assembly (or thermowell) and check for any deposits of foreign materials
on the tip of the probe, or on the terminal screws inside the enclosure.

4.6. Checking Failure Conditions: If any failure occurred during the operation, check operating
conditions against sensor specifications (verify the output against those in Table 3, on page 5, for
the RTD type).

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 Instruction
TEMP-PRO An ISO 9001 CERTIFIED Company
Inc. Manual
4.7. Calibration of RTD: To determine the Resistance vs. Temperature characteristic of an RTD,
the unit must be calibrated at a fixed temperature. The most commonly used fixed calibration
environment is the ICE BATH. For instructions and the calibration method, see Figure 1 below:

Figure 1: RTD Resistance Measurement Calibration Method

4.8. Bench Test of RTD. Use a Digital Multimeter for resistance measurement and a megohmmeter
for Insulation Resistance Measurement.

4.8.1. Wipe dry external surfaces of sensor.

4.8.2. Refer to wiring diagram on the drawing and connect Digital Multimeter leads across
opposite terminals of the platinum resistance winding extension wires. Resistance should
read approximately 110 ohms at room temperature and 100 ohms in the ice bath. See the
RTD calibration set-up and instruction, Figure 1 on page 4.

4.8.3. Test Insulation Resistance by connecting one megohmmeter lead to wires on terminal
(all wires shorted together) and the other to the external sheath (metal protection casing) of
the sensor. Resistance reading should exceed 5 megohms unless otherwise specified (applied
voltage should not exceed 100 VDC). See also Insulation Resistance Test of the
Thermocouples, Measuring IR, on page 7 of this instruction manual.

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 Instruction
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company Manual
TABLE 3
T EMPERAT URE RESISTANCE CHARACT ERIST ICS

T EMPERAT URE RESISTANCE IN OHMS

DEGREES PLAT INUM WINDINGS NICKEL WINDINGS COPPER WINDINGS
°C °F *ALPHA .00385 *ALPHA .00392 *ALPHA .00426 *ALPHA .006720 *ALPHA .004274

-130 -202 47.93 47.28

-110 -166 56.13 55.52
-90 -130 64.25 63.71
-70 -94 72.29 71.86 68.27 73.10
-60 -76 76.28 75.92 71.19 79.62
-50 -58 80.25 79.96 74.24 86.17 7.10
-40 -40 84.21 83.99 77.39 92.76 7.49
-30 -22 88.17 88.01 80.56 99.41 7.88
-20 -4 92.13 92.02 83.77 106.15 8.26
-10 +14 96.07 96.02 87.04 113.00 8.65
+-0 +32 100.00 100.00 90.38 120.00 9.04
+10 +50 103.90 103.97 93.80 127.17 9.42
+20 +68 107.79 107.93 97.31 134.52 9.81
+30 +86 111.67 111.88 100.91 142.06 10.19
+40 +104 115.54 115.82 104.60 149.79 10.58
+50 +122 119.40 119.75 108.39 157.74 10.97
+60 +140 123.24 123.66 112.28 165.90 11.35
+70 +158 127.07 127.56 116.27 174.27 11.74
+80 +176 130.89 131.45 120.36 182.85 12.12
+90 +194 134.70 135.33 124.55 191.64 12.51
+100 +212 138.50 139.20 128.85 200.64 12.90
+110 +230 142.28 143.06 133.26 209.86 13.28
+120 +248 146.06 146.90 137.78 219.30 13.67
+130 +266 149.82 150.73 142.40 228.96 14.06
+140 +284 153.57 154.55 147.11 238.85 14.44
+150 +302 157.32 158.36 151.91 248.97 14.83
+160 +320 161.04 162.16 156.79 259.37 15.22
+170 +338 164.76 165.94 161.89 269.92 15.61
+180 +356 168.47 169.71 167.13 280.79 16.00
+190 +374 172.16 173.47 172.46 291.96 16.39
+200 +392 175.84 177.22 177.95 303.46 16.78
+210 +410 179.51 180.96 183.55 315.31 17.17
+220 +428 183.17 184.69 189.40 327.53 17.56
+230 +446 186.82 188.40 195.35 340.14 17.95
+240 +464 190.46 192.10 201.55 353.14 18.34
+250 +482 194.06 195.80 208.00 366.53 18.73
+260 +500 197.70 199.47 214.60 380.31
+280 +536 204.88 206.80 228.45 409.07
+300 +572 212.03 214.07 242.70 439.43
+320 +608 219.13 221.30
+340 +644 226.18 228.48
+360 +680 233.19 235.62
+380 +716 240.15 242.70
+400 +752 247.06 249.74
+420 +788 253.93 256.74
+440 +824 260.75 263.68
+460 +860 267.52 270.58
+480 +896 274.25 277.43
+500 +932 280.93 284.24
+520 +968 287.57 291.00
+540 +1004 294.16 297.71
+560 +1040 300.70 304.37
+580 +1076 307.20 310.99
+600 +1112 313.65 317.56
+620 +1148 320.05 324.08
+640 +1184 326.41 330.56
+660 +1220 332.72 336.99
+680 +1256 338.99 343.37
+700 +1292 345.21 349.70
+720 +1328 351.38 355.99
+740 +1364 357.51 362.23
+760 +1400 363.59
+780 +1436 369.62
+800 +1472 375.61
+820 +1508 381.55
+840 +1544 387.45

* TCR = Temperature Coefficient of Resistance = Ohm / Ohm / Degree Celsius

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 Instruction
TEMP-PRO An ISO 9001 CERTIFIED Company
Inc. Manual
Measuring IR
T/C TERMINAL HEAD
TERMINAL (POST)

MEASURING
JCT. (TIP)
SHEATH

INDICATING SCALE SHOWS

INSULATION RESISTANCE

MEGGER INSULATION TESTER

Insulation Resistance may be performed to test ungrounded thermocouples or RTD's. Measuring IR need
not be of the highest precision, in that low IR should be grounds for rejection. Precision instrumentation
is not therefore required, although calibration must be dependable, and any recognized megohmmeter is
satisfactory.

To measure IR, you would use an IR tester, which is a portable instrument that's essentially a resistance
meter, or ohmmeter, with a built in hand cranked or line-operated DC generator that develops high DC
voltage. This voltage (usually 500V or more) causes a small current to flow through and over the
insulation's surface. The tester provides a direct reading of IR in ohms or megohms. Test is made with
clips connected to the sheath and to all leads tied together. Insulation resistance may be expected to be
in excess of 1000 megohms at room temperature and not less than 20 megohms at 200 degrees Celsius.

The above picture shows a typical megohmmeter test instrument hook-up to measure insulation resistance.
You can use an IR meter and obtain measurements. A high resistance value would indicate a "good"
insulation, while a relatively low resistance value would point to a "poor" insulation. In actual
applications, resistance values can be higher or lower due to the effects of factors such as temperature,
humidity, the moisture content of the insulation, and even the person doing the testing. Therefore, the
IR reading can be very different for the same wire tested on different days.

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 Instruction
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company Manual
Installation of Thermocouples or RTDs

5. Installation Instruction
5.1. Complete unit: Complete unit may be secured into process location without sensor
disassembly, in the case of those with threaded or flanged thermowells or fittings.

5.2. Weld-in Thermowell Assembly: On a weld-in thermowell assembly, the sensor inset must be
removed before welding in place, to prevent possible damage by overheating during welding.

6. RTD Spring-Loaded:
Removal And Assembly Instructions Into Thermowell
(Refer to Figure 2 on page 8)

6.1. To remove RTD inset, take off connection head cover and loosen the two terminal block
retaining screws until they are disengaged from the connection head.

6.2. Withdraw inset from connection head without further disassembly, and place in a safe location
to prevent bending and possible damage.

6.3. With an ohmmeter, check and verify resistance of the unit. A 100 ohm platinum RTD should
have a resistance of about 110 ohms at room temperature between red and blue and/or black and
white respectively. There should be no continuity between the leadwires and the sheath of the
probe.

6.4. Screw the RTD connection head and extension into the existing thermowell.

6.5. Replace the RTD inset (reverse of §6.1).

6.6. Connect extension leads to the terminal block. Be careful to observe color coding polarity.

6.7. Tighten terminal block retaining screws in the terminal block. Spring should be compressed about
3/16". Spring may be repositioned as required.

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 Instruction
TEMP-PRO Inc.An ISO 9001 CERTIFIED Company Manual
Figure 2: Removal and Assembly Instructions into Thermowell

Retaining
Screws
Option 1
Option 2
Option 3

Terminal Block

7. Thermocouple Spring-Loaded:
Removal and Assembly Instructions into Thermowell
(Refer to Figure 2 above)

7.1. To remove the thermocouple inset, open the cover of the thermocouple connection head and
loosen the two terminal block retaining screws, until they are disengaged from the connection head.

7.2. Carefully remove the terminal block and thermocouple inset. Avoid bending or straining the
thermocouple bare wires. Close cover.

7.3. Screw the thermocouple head and extension with the extension into the existing thermowell.

7.4. Replace the thermocouple inset.

7.5. Insert the thermocouple block into the head allowing the bare thermocouple wires to pass
through the 5/16" diameter hole in the terminal block. The negative leg of the thermocouple wire is
color coded red and is to match with the brass post next to the stamped negative sign in the terminal
block.

7.6. Connect extension wires through the head conduit connection port and into the brass post.
Close cover.

Figure 3: Thermocouple Inset

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 Instruction
TEMP-PRO Inc. An ISO 9001 CERTIFIED Company Manual
8. Screw-In Thermowell Installation
8.1. If necessary, remove sensor assembly from thermowell by unscrewing nipple from well or by
breaking the extension at the union. (Refer to §6 and §7). Use care whenever removing or replacing
the sensor element.

8.2. Insert thermowell into process connection and screw in until snug. Apply additional torque until
the threads are well engaged. The following chart (see Table 4) indicates the approximate length of
thread engagement of various pipe sizes:

TABLE 4
PROCESS ENGAGEMENT
"L”
1/2" NPT 1/2"

3/4" NPT 1/2"

"U"
1" NPT 5/8"

1-1/4" NPT 5/8" SENSOR

CONNECTION

1-1/2" NPT 5/8"

MAX. DIA.
2" NPT 5/8"
MIN. DIA.
2-1/2" NPT 3/4"
PROCESS
3" NPT 3/4" CONNECTION

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 Instruction
TEMP-PRO An ISO 9001 CERTIFIED Company
Inc. Manual
PRODUCTS
•Thermocouple's •Thermowells
•Sub-Zero up to 5,000 °F. •Industrial Glass Thermometers
•Gas Turbine T/C •Limited Space Threaded
•Multipoint •Raised Face Flanged
•Specials •Sanitary Thermowells
•Plastics Industry •Socket-Weld
•Platinum •Steam Sampling Nozzles
•Threaded
•RTD's •Van Stone
•Copper •Weld-In
•Platinum
•Nickel •Electrical Accessories
•Ni-Iron •Junction Boxes
•Flat Strip (Stator) •Turning Gear Boxes
•Immersion •Wiring Harnesses
•Custom •Cable Assemblies
•Gauge Panels
•Thermistors •Control Panels
•All Applications, •Circuit Boards
Including Compressor •Liquid Level Detectors

•Remote Terminal Units (RTU's)

•Thermocouple & RTD Wire •Remote Sensing
•Compensated Terminal Blocks
•Plugs, Jacks, and Fittings •Swamping (Averaging) T/C Boards
•Selector Switches
•Reference Junctions •Logistics Management
•Transmitters/Controllers/Scanners •Purchasing
•Warehousing
•Thermometers •Assembling/Kitting
•Bimetal Thermometers •Shipping Services
•Filled System Thermometers
•Research & Development in
•Hydrogen Activity Probes Temperature Sensing Products

Reg. No. 950 98 0142

Form 990309

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