Thermoelectrode cables TERK (extension and compensation)

Thermoelectrode cables TERK (extension and compensation)

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Thermoelectrode cables TERK (TU 3567-015-76960731-2009)

comply with the international standard IEC 584-3, national standards GOST 1791-2014, and others.
suitable for use, including in explosive zones of all classes

  • Termoelectrode cables TERK are designed for connecting thermocouples to secondary converters (temperature measuring instruments).

    To significantly eliminate the influence of the operating conditions of the measured object (e.g., a heating furnace) on the temperature of the thermocouple’s free ends,

  • they must be moved a considerable distance away from the heat source. It is not necessary to use long thermocouples for this purpose; it is more practical to extend them with flexible cables. These cables must be thermoelectrically identical to the thermocouple electrodes, which is why they are called thermoelectrode cables.


Thermoelectrode cables TERK are divided into extension and compensation types

  • Extension cables (eXtension cables) — the cable conductors are made of the same alloys as the thermocouples. Unlike thermocouple cables, extension cables operate within a narrower temperature range.

    In cable designation, after indicating the thermocouple type (according to GOST R 50342-92 or IEC 584-1), the symbol “X” is added. For example, “NX” denotes an extension cable for an N-type thermocouple (Nicrosil-Nisil). The symbol “X” comes from the English term “eXtension cable.”

    Within the specified temperature range, the electrodes (conductors) of these cables, in combination with a third electrode (e.g., copper or platinum), generate the same thermoelectric EMF as the corresponding thermocouple electrodes. Therefore, extension cables are also referred to as cables with electrode compensation.

  • Compensating cables (Compensating cables) — compared to extension cables, the conductors of compensating cables are made of less expensive or non-precious metals. For example, for a K-type thermocouple (Chromel-Alumel), a compensating cable with copper (positive) and constantan (negative) conductors is used. The use of compensating cables may also be necessary to achieve minimal electrical circuit resistance. These cables generate a thermoelectric EMF equal to that of the thermocouple for which they are intended, which is why they are referred to as total compensation cables. In compensating cable designations, after specifying the thermocouple type (according to GOST R 50342-92 or IEC 584-1), the symbol “C” is added. If two variants of the cable are provided for a thermocouple, they are marked as “CA” or “CB.” For example, “KCA” is a compensating cable according to IEC 584-3 for a K-type thermocouple (Chromel-Alumel). The symbol “C” originates from the English term “Compensating cable.” Compared to extension cables, compensating cables have narrower operating temperature ranges and higher allowable error values.


Two standards for the manufacturing of TERK cable

TERK cables can be manufactured in one of two variants and comply with standards

  • Cables designated as KX, KCA, KCB, NX, EX, JX, TX, SCA, SCB, RCA, and RCB are manufactured according to the international standard IEC 584-3 “Thermocouples. Part 3: Extension and compensating cables — Tolerances and identification system” (see Table 2).

    This standard defines the allowable deviation of the thermoelectric EMF of the thermoelectrode pair, as well as the color coding of the conductor insulation and the outer cable sheath. Using TERK cables compliant with IEC 584-3 is recommended in conjunction with thermocouples manufactured according to the international standard IEC 584-1 “Thermocouples — Part 1: Reference tables.”

  • The conductors of cables designated as HA(KX), HA(KC), HKn(EX), ZhK(JX), HK(LX), MKn(TX), PP(SCA), PP(SCB), PP(RC), PR(BC), and MK(MX) are made from metals or alloys in accordance with Russian national and interstate standards: GOST 1791-2014, GOST 492-2006, GOST 859-2014, and others. GOST 1791-2014 defines tolerance classes for the maximum deviation of thermoelectric EMF for the wire used in cable conductors, including alloys such as Chromel K, Copel, Constantan, and TP. The color of the conductor insulation and the outer sheath of thermoelectrode cables is not specified in any national standards, but TERK cables follow the commonly accepted Russian color coding for conductor insulation (see Table 3). The cable sheath can be of any color (black by default).


Scope of application

  • Cables are designed for stationary and flexible installation both indoors and outdoors, provided they are protected from direct solar radiation. They can be laid on shelves, in trays, ducts, channels, tunnels, and in the ground (trenches), including areas exposed to stray currents.

    Cables with the “UF” designation can be installed outdoors without protection from solar radiation. Cables with the “M” designation have a sheath resistant to motor oil, gasoline, and diesel fuel. Cables with the “V” designation prevent the longitudinal spread of water under the sheath.

    Fire-resistant “FR” cables have the highest fire resistance rating PO1 according to GOST 31565-2012 and maintain functionality in fire conditions for at least 180 minutes.

  • Cables with extruded filling (“Z”) have a round cross-section and prevent the spread of explosive gases under the sheath. These cables fully comply with the technical regulations of the Customs Union TR CU 012/2011 “On the safety of equipment for use in explosive atmospheres” and GOST IEC 60079-14-2011 “Explosive atmospheres. Part 14. Design, selection, and installation of electrical installations” and can be used in explosive zones of all classes.

    The operating temperature of the cables is specified in Table 6 and depends on the insulation and sheath material. The preferred application areas of TERK cables, considering their design type and fire hazard class according to GOST 31565-2012, are provided in Table 7.


TERK cable design

  • The cable conductors are made of metal and alloy or a combination of alloys, according to Table 2 (based on IEC 584-3 standard) or Table 3 (based on national standards).

    The conductors are manufactured as multi-wire (by default) or single-wire (with the “ozh” index).

    Cables marked with “G” are made with increased flexibility conductors.

    The conductor of fire-resistant cables “FR” is wrapped with mica-containing tapes before insulation is applied, ensuring maximum resistance to mechanical impacts during a fire.

    The conductors in the cable can be twisted into a thermoelectric pair; in this case, the order code includes the symbol “x2” next to the number of pairs.

    Cables can be produced with a combined cross-section of current-carrying conductors (for example, “2×1.5 + 4×1.0” or “1x2x1.5 + 2x2x1.0”).

    Digital marking is applied to all insulated conductors of the same color in the cable.

    Cables may have shielding: either individual for each pair and/or common for all pairs. Shields can be made in the form of:

    • aluminum foil film (alumoflex) with a tinned copper drain wire “E”,
    • braid of bare copper wire “Em”,
    • braid of tinned copper wire “El”,
    • braid of nickel wire “En”.
  • Individual shields of conductor pairs can be electrically isolated from each other by a polymer extrusion layer. They can also be combined as “EEl” — where a braid of tinned copper wires is applied over the aluminum foil shield (alumoflex).

    Cables may have armor:

    • made of galvanized steel wires “K”, with an outer sheath applied over the armor;
    • made of galvanized steel tapes “B”, with an outer sheath applied over the armor;
    • made of stainless steel wires “Kn”, with an outer sheath applied over the armor;
    • made of stainless steel tapes “Bn”, with an outer sheath applied over the armor;
    • corrugated armor made of galvanized wire “Kp” over the inner sheath, with no outer sheath applied;
    • corrugated armor made of stainless steel wire “Knp” over the inner sheath, with no outer sheath applied.

    Cables with a single thermoelectric pair can be manufactured in a flat design “P”.

    Table 6 provides information on insulation and sheath materials, as well as their corresponding fire safety characteristics.


Table 1. Nominal conductor cross-section and number of conductors or pairs

Nominal conductor cross-section, mm²Number of pairsNumber of conductors
0,201, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 24, 27, 30, 32, 36, 37, 402, 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40
0,35
0,50
0,75
1,0
1,5
2,5
4,0

Conductor alloy material, insulation color of conductors, and outer sheath of TERK cables according to IEC 584-3 standard

with designations KX, KCA, KCB, NX, EX, JX, TX, SCA, SCB, RCA, RCB

  • The insulation color of the negative conductor of TERK cables according to the IEC 584-3 standard must be white.

    The insulation color of the positive conductor must correspond to Table 2. The color of the outer sheath matches the color of the positive conductor. Cables intended for intrinsically safe circuits may be manufactured with a blue (light blue) sheath.


Table 2. Material and insulation color of TERK cable conductors according to IEC 584-3

Thermocouple type according to IEC 584-1General industrial thermocouple designationTERK cable designation according to IEC 584-3Positive conductor (+)Negative conductor (-)
MaterialColorMaterialColor
JTZhKJX100% Feblack44% Ni – rest Cuwhite
TTMKnTX100% Cubrown44% Ni – rest Cu
ETHKnEX90% Ni – 10% Crviolet44% Ni – rest Cu
KTHAKX90% Ni – 10% Crgreen95% Ni + Al-Mn-Si
KCA100% Fe43% Ni – 2% Mn – 2% Fe – rest Cu
KCB100% Cu44% Ni – rest Cu
NTNNNX84% Ni – 14.2% Cr-Sipink95% Ni – 4.3% Si
RTPPRCA100% Cuorange3% Ni – Mn – rest Cu
RCB100% Cu3% Ni – Mn – rest Cu
STPPSCA100% Cuorange3% Ni – Mn – rest Cu
SCB100% Cu3% Ni – Mn – rest Cu

Conductor alloy material, insulation color of conductors, and outer sheath of TERK cables according to national standards

with designations HA(KX), HA(KC), HKn(EX), ZhK(JX), HK(LX), MKn(TX), PP(SCA), PP(SCB), PP(RC), PR(BC), MK(MX)

  • The insulation color of the conductive core of TERK cables, according to established tradition in Russia, is used to indicate the metal or alloy (see Table 3). Other insulation colors may be used upon agreement.

    In Russia, there are no specific requirements for the color of the outer sheath of the cable, so TERK cables are typically manufactured with a black sheath by default. If a different sheath color is required, it should be specified in the order code.


Table 3. Manufacturing material and insulation color of TERK cable conductors according to national standards

Thermocouple type according to GOST R 50342-92 (GOST R 8.585-2001)Thermocouple designationTERK cable designationPositive conductor (+)Negative conductor (-)
MaterialColorMaterialColor
TTMKnMKn(TX)Copper (Cu)Red or pinkConstantan alloy (CuNi)Brown
ETHKnHKn(EX)Chromel K alloy (NiCr)Purple or blackConstantan alloy (CuNi)Brown
JTZhKZhK(JX)Iron (Fe)Blue or light blueConstantan alloy (CuNi)Brown
KTHAHA(KX)Chromel K alloy (NiCr)Purple or blackAlumel alloy (Ni)White or natural
HA(KC)Copper (Cu)Red or pinkConstantan alloy (CuNi)Brown
RTPPPP(RC)Copper (Cu)Red or pinkTP alloy (CuNi)Green
STPPPP(SCA)Copper (Cu)Red or pinkTP alloy (CuNi)Green
PP(SCB)KPR alloy (Cu+3.2Si)White or naturalKP alloy (Cu+5Ni+3.7Mn)Black
L*THKHK(LX)Chromel K alloy (NiCr)Purple or blackCopel alloy (CuNi)Orange or yellow
A-1, A-2, A-3TVRVR(AS)Copper (Cu)Red or pinkMN 2.4 alloy (Cu+(2.2-2.6)Ni)Blue or light blue
MTMKMK(MX)Copper (Cu)Red or pinkCopel alloy (CuNi)Orange or yellow
BTPRPR(BC)Copper (Cu)Red or pinkCopper (Cu)Black
* Thermocouple type L according to GOST R 50342-92, not to be confused with thermocouple L according to DIN 43710 (Fe-CuNi)

Tolerance classes and permissible deviations of thermoelectric voltage (TEV)

The tolerance class defines the limits of permissible TEV deviations. In the IEC 584-3 standard, tolerance classes are specified for the thermoelectric pair of cable conductors, while in GOST 1791-2014, they are defined for the wire from which the conductor is made, in combination with a copper reference sample. For some cables, the tolerance class is determined for the wire paired with a platinum reference sample. If there is no additional specification for the tolerance class, the tolerance class of TERK thermoelectric cables is determined at the manufacturer’s discretion—usually, this corresponds to an alloy of the 2nd tolerance class.

1. TERK cable tolerance classes according to IEC 584-3 standard:

designated as KX, KCA, KCB, NX, EX, JX, TX, SCA, SCB, RCA, RCB

In the international standard IEC 584-3, the cable’s tolerance class defines the maximum allowable TEV deviation in microvolts and degrees Celsius within a specific operating temperature range of the cable (see Table 4). Since TEV depends non-linearly on temperature, the tolerance value in degrees Celsius is given for a specific working junction temperature of the thermocouple.

Two tolerance classes are provided for cables. Extension cables (with the symbol “X”) can be manufactured in both 1st and 2nd classes, while compensation cables (with symbols “C”, “CA”, “CB”) are produced only in the 2nd tolerance class.


Table 4. Limit deviations of TEV for TERK cable according to IEC 584-3 standard

TERK cable type according to IEC 584-3Limit deviation of TEV for tolerance class (values in parentheses indicate deviation in degrees Celsius for the operating junction temperature from the last column)Operating temperature range of the cable for which the limit deviation in µV is determinedOperating junction temperature for which the limit deviation in degrees Celsius is specified
1st2nd
JX± 85µV (±1.5°C)± 140µV (±2.5°C)-25 … +200°C500°C
TX± 30µV (±0.5°C)± 60µV (±1.0°C)-25 … +100°C300°C
EX± 120µV (±1.5°C)± 200µV (±2.5°C)-25 … +200°C500°C
KX± 60µV (±1.5°C)± 100µV (±2.5°C)-25 … +200°C900°C
NX± 60µV (±1.5°C)± 100µV (±2.5°C)-25 … +200°C900°C
KCA± 100µV (±2.5°C)0 … +150°C900°C
KCB± 100µV (±2.5°C)0 … +100°C900°C
NC± 100µV (±2.5°C)0 … +150°C900°C
RCA± 30µV (±2.5°C)0 … +100°C1000°C
RCB± 60µV (±5.0°C)0 … +200°C1000°C
SCA± 30µV (±2.5°C)0 … +100°C1000°C
SCB± 60µV (±5.0°C)0 … +200°C1000°C

2. Tolerance classes of TERK cable according to GOST 1791-2004 standard:

Cables with the designation HA (KX), HKn (EX), ZhK (JX), HK (LX), MKn (TX), MK (MX), HA (KC), PP (SCA), PP (RC)

The GOST 1791-2014 standard provides for two tolerance classes for the wire from which the thermoelectric cable conductor is made, using alloys: Chromel K, Copel, Constantan, TP (see Table 5). The tolerance class is determined for the wire in combination with a copper reference sample at a temperature of 100°C (with the free end at 0°C). Each class corresponds to a limit deviation of TEV in millivolts.


Table 5. Limit deviations of TEV for the wire used in TERK cable manufacturing according to the Russian (interstate) standard GOST 1791-2014

Wire alloy nameTERK cable designation in which the wire is usedTEV in pair with a copper sample at 100°C (free end at 0°C), mVLimit deviation, mV, for tolerance class
1st2nd
Chromel KHA(KX), HKn(EX), HK(LX), HA(KC)+2.090.050.08
CopelHK(LX), MK(MX)-4.770.060.1
ConstantanHKn(EX), ZnK(JX), MKn(TX)-4.100.060.1
TPPP(SCA), PP(RC)-0.64

Table 6. Fire safety rating and operating temperature depending on sheath and insulation material

Insulation and sheath materialFire safety ratingDescription of insulation and sheath materialOperating temperature of the cable, °C
V(no index)Insulation and sheath made of PVC plastic compounds-50°…+70°C *
ng(A)Insulation made of PVC plastic compounds, sheath made of low-flammability PVC plastic compounds-50°…+70°C *
ng(A)-LSInsulation and sheath made of PVC plastic compounds with reduced smoke and gas emission-50°…+70°C *
ng(A)-FRLSInsulation and sheath made of PVC plastic compounds with reduced smoke and gas emission, fire-resistant cable-50°…+70°C *
Vt(no index)With insulation and sheath made of heat-resistant PVC plastic compounds-50°…+105°C
Png(A)-HFInsulation and sheath made of halogen-free polymer compositions-50°…+70°C *
ng(A)-FRHFInsulation and sheath made of halogen-free polymer compositions, fire-resistant cable-50°…+70°C
Tng(A)Insulation and sheath made of low-flammability thermoplastic elastomers-60°…+125°C
ng(A)-FRInsulation and sheath made of low-flammability thermoplastic elastomers, fire-resistant cable-60°…+125°C
Sng(A)Insulation and sheath made of low-flammability silicone rubber-60°…+180°C
F(no index)Insulation and sheath made of extruded fluoroplastic-60°…+200°C
N(no index)Insulation and sheath made of heat-resistant glass fibers-60°…+400°C
* Cables can be manufactured in a frost-resistant version “HL” with an operating temperature of up to -60°C

Table 7. Preferred application areas of TERK cables considering their design type and fire hazard class according to GOST 31565-2012

Design typeFire hazard classPreferred application area
no designationO1.8.2.5.4For single installation in cable facilities and industrial premises. Group installation is allowed only in outdoor electrical installations and industrial premises where only periodic presence of maintenance personnel is possible, and passive fire protection must be used
ng(A)P1b.8.2.5.4For installation in open cable facilities (overpasses, galleries) of outdoor electrical installations
ng(A)-LSP1b.8.2.2.2For installation in indoor electrical installations, as well as in buildings, structures, and enclosed cable facilities
ng(A)-HFP1b.8.1.2.1For installation in indoor electrical installations, as well as in buildings and structures with high occupancy, including multifunctional high-rise buildings and building complexes
ng(A)-FRLSP1b.7.2.2.2For installation in fire protection systems, as well as other systems that must remain operational under fire conditions
ng(A)-FRHFP1b.7.1.2.1

Table 8. Permissible bending radius of TERK cables

Cable typeBending radius (D — outer cable diameter)
Standard design (with multi-wire conductors)without armor and in wire armor3 D
in tape armor5 D
“TERK-G” design (with increased flexibility conductors)without armor and in wire armor2.5 D
in tape armor5 D
“ozh” design (with single-wire conductors)without armor and in wire armor5 D
in tape armor7.5 D

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