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Thermocouple Design Guide

Custom Thermocouple Design Guide. ThermX is a manufacturer of custom thermocouple probes used for applications in analytical test equipment, heating & cooling systems, aerospace, automotive, transportation, medical, pharmaceutical, chemical processing, food processing, semiconductor processing, power generation, and fabrication machinery.

Use our custom thermocouple design guide as a starting point for your probe. Available thermocouple types J, K, T, E, R, S, B and C. Temperature ranges from -200 °C to 2315 °C (-328 °F to 4200 °F) depending on probe type and configuration. Available in diameters ranging from 0.020" to 0.500" with grounded or ungrounded junctions, a wide selection mineral insulated sheath material, and wire insulation materials ranging in temperature from -200 °C to 1200 °C (-328 °F to 2200 °F).

We offer custom designs for monitoring surface temp, air temp and direct immersion liquid temp with a variety of probe types and housings. Housing options include closed end tubes, flanged tubes, ring lug/terminal, flag terminal, hex fitting, threaded hex screw, aluminum block, air flow birdcage and transition probes. Special limits of error thermocouple material available.

For higher temperature industrial applications, we offer mineral insulated probes which are more robust and can be shaped and formed to suit an application. These sensors are available in longer lengths than the traditional tube and wire thermocouple design.  Available sizes include 1/16", 1/8", 3/16" and 1/4", 5/16", 3/8" and 1/2" diameter sheath material. Available mineral insulated sheath materials are 316 SS, 310 SS, Inconel® 600, Hastelloy® C, Hastelloy® X, Haynes® HR-160 and Pyrosil® D.

Call for Technical Design Support | Built to Your Specification | OEM Thermistor Probes
Contact Us With Your Design Requirements 1-800-284-3769

Style "WB" Beaded Wire Thermocouple

Bead Wire ThermocoupleTeflon Encapsulated Bead Wire Thermocouple
  • Ideal for UL testing, oven mapping, & thermal profiling
  • Teflon® cap and cover available for acid & plating tanks monitoring
  • 40 AWG, 36 AWG, 30 AWG, 24 AWG, 20 AWG wires
  • Special Limits Accuracy wire available

Style "WT" Washer Thermocouple

Washer Thermocouple
  • Ideal to measure surface temperatures up to 900°F
  • #6 & #8 washers use 24 AWG wire
  • #10 & 1/4" washers use 20 AWG wire

Style "HW" Heavy Duty Ring Lug Thermocouple

Heavy Duty Ring Lug Thermocouple
  • Ideal to measure surface temperatures up to 900°F

Style "HB" Hex Bolt Thermocouple

Hex Bolt Thermocouple
  • Ideal to measure surface temperatures up to 900°F
  • Available with 8-32, 10-32, 1/4 -20 hex screw
  • Customs available upon request

Style "CI" Ceramic Insulator Wire Thermocouple

Ceramic Insulator Wire Thermocouple_
  • Low-Cost Rigid Ceramic Insulator
  • Available with Teflon® & fiberglass leads with stainless steel overbraid

Style "TU" Tube & Wire Thermocouple

Tube and Wire Thermocouples
  • Ideal for general applications for air and liquid 
  • Teflon® probe cover available for protection in corrosive environments
  • Angle probes available

Style "HFT" Tube and Wire Hex Fitting Thermocouple

Tube and Wire Hex Fitting Thermocouple
  • Low Cost Ridget SS Tube with Brazed or Welded Hex Fitting
  • Available with Teflon® & fiberglass leads with stainless steel overbraid

PCR Well Plate Thermocouple

PCR Well Plate Thermocouples
  • Ideal for PCR Maping and Verification
  • 30 AWG & 36 AWG PFA Teflon, type "T" or "K" Thermocouple Wire

Style "VT" Validation Thermocouple

FEP Teflon Validation ThermocoupleKapton Validation Thermocouple
  • Ideal for deep freezers, incubators, steam sterilizer,depyrogenation tunnels, & dry ovens
  • 22 AWG & 28 AWG stranded type "T"
  • FEP Teflon® (200°C) ±0.3°C at 121°C
  • Kapton® (300°C) (±0.5°C or ±0.4% of reading)

Style "VP" Tube and Wire Validation Thermocouple

Validation Tube and Teflon Wire ThermocoupleValidation Tube and Kapton Wire Thermocouple
  • Ideal for -80 °C Deep freezers, incubators, steam sterilizer, depyrogenation tunnels, & dry ovens
  • 22 AWG & 28 AWG stranded type "T"
  • FEP Teflon® (200°C) ±0.3°C at 121°C
  • Kapton (300 °C) (°0.5 °C or 0.4% of Reading

Style "AP" Validation Air Probe Thermocouple

Validation Air Probe Thermocouple
  • Ideal cold storage rooms ovens to 200 °C
  • 22 AWG stranded type "T"
  • FEP Teflon® (200°C) ±0.3°C at 121°C

Style "ABT" Aluminum Block Wire Thermocouple

Aluminum Block Thermocouple
  • Ideal for measuring surface temperatures
  • PFA Teflon Lead wire rated to 500 °F

Style "OP" Oven Profiling Thermocouple

Oven Profiling Thermocouple_1Oven Profiling Thermocouple_2Oven Profiling Thermocouple_3
  • Ideal for profiling high temperature belt & push ovens to 2200°F
  • High temperature ceramic fiber with Inconel 600 overbraid on a 20 AWG solid
  • Type "K" thermocouple wire

Style "AC" Autoclave Thermocouple

Autoclave Thermocouple
  • Ready to use
  • Ideal for composite repair & fabrication
  • Special limits of error type "J" wire with a molded connector
  • Certification to BAC 5621

Style "FT" Flanged Tube and Wire Thermocouple

Flanged Wire Thermocouple
  • Low Cost Ridget SS Tube with Flange
  • Ideal fo duct mount air temperatures

Style "AL" Alligator Clip Thermocouple

Alligator Clip Thermocouple
  • Ideal for residential or commercial oven temperature measurement

Style "PO" Pointed Tip Plug and Jack Thermocouple

Pointed Tip Thermocouple
  • Ideal for measuring food temperature
  • Reduced pointed tip for quick response, rated to 500°F
  • Quick Disconnect Extensions
  • Available with Teflon® & fiberglass leads with stainless steel overbraid

Style "TS" Spring Bayonet Thermocouple

Bayonet Spring Thermocouple
  • Ideal for injection molding & composite industries

Style "TB" Fixed Bayonet Thermocouple

Fixed Bayonet Thermocouple
  • Ideal for injection molding & composite industries

Style "TF" Adjustable Flex Armor Bayonet Thermocouple

Flex Armor Adjustable Bayonet Thermocouple
  • Ideal for use in plastics & composite industry

Style "TW" Custom Thermowells

Tapered Thermowell_Flanged Thermowell_1
  • Custom built straight wells, tapered wells, step down, flanged, & weld-in thermowells
  • Mmaterials available: 316 SS, 310 SS, Hastelloy C, Monel, etc...
  • Standard bore is 0.260" & 0.385" (others available upon request)

Multipoint Thermocouple

MultiPoint Thermocouple Probe
  • Ideal for chemical reactors, fractionation towers, & fluidized bed catalyst
  • Specify up to 19 individual points depending on OD cable
  • Temperature ranges to 2100°F
  • Lengths up to 100 feet long

Style "MW" Cut & Strip Minerial Insulated Thermocouple

Cut & Strip Thermocouples
  • Cold end stripped & epoxy sealed to inhibit moisture absorption
  • Available from 0.020" to 0.375" OD sheath
  • 0.020" - 0.062" available with Ungrounded Junction up to 500 ft. long
  • Available in 316 SS, 310 SS and Inconel 600

Style "MP" Plug and Jack Mineral Insulated Thermocouple

Plug and Jack Thermocouples
  • Cold end stripped & epoxy sealed to inhibit moisture absorption
  • Available from 0.020" to 0.375" OD sheath
  • 0.020" - 0.062" available with Ungrounded Junction up to 1000 ft. long
  • Available in 316 SS, 310 SS and Inconel 600

Style "MP" Half-Shield Plug & Jack Mineral Insulated Thermocouple

Half Shield Plug & Jack Thermocouple
  • Cold end stripped & epoxy sealed to inhibit moisture absorption
  • Available from 0.020" to 0.375" OD sheath
  • 0.020" - 0.062" available with Ungrounded Junction up to 1000 ft. long
  • Available in 316 SS, 310 SS and Inconel 600

Style "MTT" Miniature Transition Mineral Insulated Thermocouple

Miniature Transition Thermocouples
  • Smalll space thermocouple
  • 0.020" to 0.062" OD sheath
  • Small 1/8" diameter Transition

Style "MT" Mineral Insulated Transition Thermocouple

Mineral Insulated Transition Thermocouple
  • 0.020" to 0.375" OD sheath
  • Single or Duplex
  • Spring strain relief
  • Available in 316 SS, 310 SS and, Inconel 600 ( other options available)

Style "MT" Mineral Insulated Half-Shield Transition Thermocouple

Half Shield Transition Thermocouple
  • Quick response in hot exhaust streams in aerospace & dyno testing
  • Transition epoxies rated to 500°F standard (600°F upon request)
  • Also available with Hi-Temp cement (1200°F)
  • 0.063" to 0.375" OD sheath

Style "MI" Industrial Mineral Insulated Thermocouple

Fixed Fitting Industrial Thermocouple
  • Rated to 2200°F
  • Fixed and Spring-loaded stainless steel hex fittings
  • Several head styles to choose from with in-head transmitters available

Style "MR" Replacement Industrial Mineral Insulated Thermocouple

Replacement Industrial Thermocouple
  • Fixed & spring-loaded stainless steel hex fittings
  • 0.062" to 0.500" OD sheath
  • Single or duplex with metal sheaths

Style "IT" Metal Protection Tube Pipewell Thermocouple

Metal Protection Tube Pipewell Thermocouple
  • Available in 1/2" NPT & 3/4" NPT pipewells
  • Multiple head styles available
  • Pipe schedule 40 or 80
  • Wide selection of metal protection tube available

Style "RT" Replacement Mineral Insulated  Thermocouple

Replacement ThermocoupleSpring Loaded Replacement Thermocouple
  • Self-gripping spring
  • Ceramic terminal block style
  • Available in 3/16", 1/4", & 3/'8" diameter sheath material

Style "SS" Size on Size Mineral Insulated Transition Thermocouple

Size on Size Transition Thermocouple
  • Size on size transition for easy installation of compression fitting from cold end
  • Transition epoxies rated to 500°F standard (600°F upon request)
  • Available in lengths up to 200 feet with grounded junction in 24" coils

Style "WP" Weld Pad (Tube Skin)  Mineral Insulated Thermocouple

Weld Pad Thermocouple
  • Size on size transition for easy installation of compression fitting from cold end
  • Transition epoxies rated to 500°F standard (600°F upon request)
  • Available in lengths up to 200 feet with grounded junction in 24" coils

Style "NR" Platinum Replacement Thermocouple

Platinum Beaded Replacement Thermocouple
  • High temperature to 3000°F
  • Available in R, S & B
  • Available with high purity alumina ceramic insulators
  • NIST Calibration Available

Style "NM" Platinum Metal Protection Tube Thermocouple

Platinum Metal Protection Tube Thermocouple
  • Ideal for high temperature ovens up to 3000°F
  • Thermocouple type R, S, & B
  • Available with: Inconel 600, Molybdenum, or Platinum-Rhodium protection tubes
  • NIST traceable calibration available

Style "TM" Tungsten-Rhenium Metal Protection Tube Thermocouple

Type C Tungsten Rhenium Thermocouple
  • Ideal for high temperature ovens up to 4000°F
  • For use in vacuum only
  • Thermocouple type C
  • Available with Molybdenum protection tubes
  • NIST traceable calibration available

Style "NE" Platinum Exposed Junction Thermocouple

Platinum Exposed Junction Thermocouple
  • Ideal for high temperature ovens to 3000°F
  • Available In: R & S
  • 'B' Available in ±1.0% Only

Style "NC" Platinum Ceramic Protection Thermocouple

Platinum Ceramic Protection Tube ThermocouplePlatinum Ceramic Protection Thermocouple
  • Ideal for high temperature ovens to 3000°F
  • Available In: R, S & B
  • Available with high purity alumina ceramic insulators
Ceramic Isolated Wire Thermocouple
  • Available in 8 & 14 AWG
  • Oval or round ceramic insulators
  • TIG welded junctions
  • Temperature rated to 2200°F

Style "CT" Ceramic Protection Tube Thermocouple

Ceramic Protection Tube Thermocouple
  • Available in: K, R, S & B
  • High temperatures to 3200°F
  • Alumina (3000°F - 3200°F)
  • Mulite (2700°F - 2800°F)
  • Silicon Carbide (2800°F - 3000°F)
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