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02-18-2008, 07:50 AM
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Join Date: Mar 2007
Location: UK
Posts: 65
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Canabalising old thermocouples
Our aircraft has EGT thermocouples which are compressed onto the outside of the exhaust pipes. They cables are a thin brown wire (possibly standard vans issue?) I have decided to replace these with drilled and clamped EGT probes.
The ones I have purchased are not long enough, by about 18in for cyl2. cyl3 might just reach. If I am binning the old thermocouples, can I use some of the old wire as extensions ( assuming that when I strip them, they are red and yellow.)
If so, can they be soldered and heat sleaved, or just twisted and heatsleved. Also does each need exteding by the same amount?
Thanks
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02-18-2008, 05:50 PM
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Join Date: Jul 2006
Location: Houston, TX
Posts: 208
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Check this out
You can extend thermocouple wires by making a secure mechanical connection (twisting tight and solder) but you have to use the same type of thermocouple wire (yours sound like type K) and always match the wire types e.g. Ni-Cr to Ni-Cr and Ni-Al to Ni-Al to avoid making 'new' thermocouples... (I assume they will solder... hmm type K, been awhile..)
Standard thermocouple wire colors and descriptions may be found here:
http://www.omega.com/toc_asp/framese...=tc_colorcodes
Minor differences in length won't matter.
Have fun.
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John Oldenkamp
RV-7A project for sale 
VAF Paid 2018
Last edited by lucky333 : 02-18-2008 at 05:57 PM.
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02-18-2008, 06:20 PM
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Join Date: Jan 2005
Location: albuquerque, nm
Posts: 1,167
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Lucky has it right, I just want to emphasize that you MUST twist the wires together. They need to be in intimate contact with no solder in between or you'll form miniature thermocouples in series with the real ones.
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02-18-2008, 08:27 PM
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Join Date: Jul 2006
Location: Houston, TX
Posts: 208
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What Guy said..
Quote:
Originally Posted by Guy Prevost
Lucky has it right, I just want to emphasize that you MUST twist the wires together. They need to be in intimate contact with no solder in between or you'll form miniature thermocouples in series with the real ones.
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Yeah, I didn't really point that out so well.. the connection must be mechanical. In this case, the solder is just glue. If you twist the wires tight enough (and you MUST), you don't need solder but under conditions of vibration, thermal cycling etc. the solder helps keep things together.
'Real' thermocouple guys spot-weld the wires together.. I still twist..
BTW.. I guess I should add that in all properly soldered electrical connections, the solder is just glue. The connection must be mechanically secure before soldering... ... Ha! Sometimes, I make myself laugh... Seriously, you should do it that way.. I was just thinking of all of the stuff I've glued together with solder... bad me 
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John Oldenkamp
RV-7A project for sale 
VAF Paid 2018
Last edited by lucky333 : 02-18-2008 at 08:31 PM.
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02-18-2008, 09:44 PM
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Join Date: Jun 2006
Location: 8I3
Posts: 3,564
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Ordinary crimped fast-on terminals may be used to join thermocouple wire to extension wire provided that both sides of the terminal splices are at the same temperature and of the same resistance. I have a pretty expensive thermocouple calibrator sitting on my desk right now that I've used to test this exact thing.
Ordinary thermocouple wire is fine to use for extension wire provided it is the same type of wire used in the thermocouple. Extension wire is just cheaper wire. EGT probes are K-type, which is red and yellow. J-type are red and white. I'd love to smack whoever came up with the color scheme, because red is the negative side of the thermocouple.
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Bob Japundza CFI A&PIA
N9187P PA-24-260B Comanche, flying
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Not a thing I own is stock.
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02-18-2008, 10:23 PM
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Join Date: Jul 2006
Location: Houston, TX
Posts: 208
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Hadn't thought of that..
Quote:
Originally Posted by rocketbob
Ordinary crimped fast-on terminals may be used to join thermocouple wire to extension wire provided that both sides of the terminal splices are at the same temperature and of the same resistance.
Ordinary thermocouple wire is fine to use for extension wire provided it is the same type of wire used in the thermocouple. Extension wire is just cheaper wire. EGT probes are K-type, which is red and yellow. J-type are red and white. I'd love to smack whoever came up with the color scheme, because red is the negative side of the thermocouple.
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For the accuracy in question, that would work as well as long as the temps of the connectors were roughly the same.
I agree on the smacking.. who and when do we start?
__________________
John Oldenkamp
RV-7A project for sale 
VAF Paid 2018
Last edited by lucky333 : 02-18-2008 at 10:26 PM.
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02-19-2008, 07:00 AM
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Join Date: Feb 2005
Location: Blacksburg, VA
Posts: 149
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Aeroelectric Bob recommends these thermocouple splices
http://www.omega.com/pptst/SMPW_SMP_HMP_HMPW.html
I just bought some, but have not tested them. On my plane, I used fast on terminals. the EGT never seemed to work at all and the CHT is now starting to 'bounce'. I am sure it was something I screwed up.
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