What Are Thermocouple Connectors & 5 Most Important Things You Should Know Before Selecting One?

5 Most Important Things To Consider Before Choosing The Best Thermocouple Connector For Your Industrial Process!


Thermocouple connectors are devices that are responsible to transmit accurate thermocouple sensor signals in millivolts to the final display or control device. Different thermocouple sensors require compatible thermocouple connectors based on the type of alloy used in the sensor, specific color coding for identifying and matching the thermocouple wires, and finally the functional temperature range at which the specific thermocouple works. Before you go on to select the correct type of thermocouple connector for your thermocouple device, you should be aware of the following:

  • Thermocouple Alloys – For most accurate measurements, the thermocouple pins inside the connector should match with the lead wires or thermocouple sensor wires. You must note here that 9 different types of calibrations of thermocouple alloys are available in the primary connectors. The base metal thermocouples generally have J, K, T, E, and N types of calibrations that are widely used designs.  
  • Color Codes – There are specific color codes for specific types of thermocouple connectors to easily identify and exactly match the thermocouple connector to the sensor and the thermocouple wire. You must refer to the manual provided by the manufacturer to understand this concept in totality as it might be sometimes very confusing due to different international color coding systems such as USA ANSI color coding & International Electrotechnical Commission color coding system.
  • Functional Temperatures – The alloy pins and the thermocouple connector body material plays an important role while selecting the correct thermocouple connector depending on the range of functional temperature they are required to operate. 
    • The metal alloy pins of the thermocouple connector are capable of operating optimally between the temperature ranges of below Zero to up to 2000° F.
    • The thermocouple connector body material is the main factor that helps in determining the functional temperature range where it can efficiently and accurately operate. 
    • Typically the thermocouple connector body materials and the pins are made from either ceramics, thermosets, or thermoplastics all of which operate at a specific functional temperature range, i.e., from -40° F to 1200° F. 

5 Most Important Things To Consider Before Choosing The Best Thermocouple Connector For Your Industrial Process!

  1. Mechanical Durability: The thermocouple connectors made from thermoplastics are most widely used in all types of industries where highly accurate temperature measurements are needed because of their high mechanical durability. They are best suited to operate between -40° F to 400° F and above.
  2. Continuous Exposure To High Temperatures: When you need a connector to work efficiently on a continuous high temperature range of 500° F to 800° F, a thermocouple connector made from a Thermoset would be an excellent choice. 
  3. Heatcon Sensors: These sensors are meant to withstand continuous exposure to high temperatures and operate best between 600° F to up to 1000° F. 
  4. Highest Operating Range: The thermocouple connectors that work the best for highest temperature operating ranges are the ones which are made from high-quality ceramics. They can efficiently work between the temperature range of -20°F to up to 1200° F. Such connectors also work efficiently in vacuum based applications. 
  5. Shape & Size:  Depending on your process requirement and design, you have the option to select either the circular or rectangular shaped connector available both in miniature design and also in standard body design. 

Heatcon Sensors – A Globally Recognized Manufacturer of High Quality Thermocouple Connectors!

If you are looking to procure a high-quality thermocouple connector for your industrial process or if you are confused about your options to select the best thermocouple connector that will accommodate all your process requirements, you can contact the highly expert team of engineers at Heatcon Sensors who will answer all your queries in this regard and help you make the best informed decision in procuring the one.