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Classification and Technical Specifications of Thermocouple Compensation Cables
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1. Types of Compensation Cables
1.1 Tolerance Levels and Application Conditions
Compensation cables are categorized based on the tolerance of their thermoelectric properties into two main types: standard and high-precision. These classifications determine their suitability for different environments and applications.
1.2 Structural Types
1.2.1 Core Construction
The core of compensation cables can be either single-strand or multi-strand. The number of strands is specified in Table 2, ensuring flexibility and durability depending on usage requirements.
1.2.2 Insulation, Sheath, and Shielding Layers
Typically, the insulation and sheath of standard compensation cables are made from polyvinyl chloride (PVC). For heat-resistant cables, the insulation layer is usually made from polytetrafluoroethylene (PTFE), while the sheath may consist of PTFE or alkali-free glass fiber. The surface should be coated with silicone or a PTFE dispersion paint to enhance performance.
The shielding layer is often woven with tinned copper wire or wrapped with composite aluminum tape. This ensures electromagnetic interference (EMI) protection and structural integrity.
2 , Technical Specifications
2.1 Insulation, Sheath, and Shielding Layer Requirements
2.1.1 Dimensions and Tolerances
The thickness of the core insulation, sheath, and maximum outer diameter of the cable must comply with Table 4. These specifications ensure proper mechanical strength and electrical performance.
2.1.2 Insulation Layer
The insulation layer should be smooth, uniform in color, and free from mechanical damage. Its thickness tolerance is -10% of the nominal value, with the thinnest part not less than 90% of the nominal thickness minus 0.1 mm. It must withstand an AC voltage of 4000 V at 50 Hz without breakdown, with each point under voltage for at least 0.1 seconds.
For heat-resistant cables, the insulation thickness tolerance is -20%, with the thinnest point not less than 90% of the nominal thickness minus 0.1 mm. The outer diameter of the insulated core may have localized increases, but it must not exceed the maximum allowable diameter.
2.1.3 Sheath
The sheath must be tightly wrapped around the insulation layer without adhesion, with a smooth surface and uniform color. The thickness tolerance is -20% of the nominal value, with the thinnest part not less than 80% of the nominal thickness. For glass wool sheaths, the weaving density must be at least 90%.
2.1.4 Shielding Layer
The shielding layer must have a weaving density of at least 80%. Broken ends should be trimmed after connection. Composite aluminum (copper) tape must be closely attached to the insulation layer and not easily loose. The thickness of the shielding layer must not exceed 0.8 mm.
2.2 Insulation Resistance
At ambient temperatures of 15–35°C and relative humidity no more than 80%, the insulation resistance between cores and between the core and shield must be at least 5 MΩ per 10 meters.
2.3 Physical and Mechanical Properties
The physical and aging properties of the insulation and sheath generally follow the standards outlined in Table 5.
2.4 Heat Resistance
Heat-resistant compensation cables must undergo a 24-hour heat resistance test at 220±5°C. After bending the specimen 180° around a cylinder with a diameter five times that of the cable, there should be no surface cracks, and the insulation resistance between the core and shield must be at least 25 MΩ per meter.
2.5 Moisture Resistance
Heat-resistant cables must withstand 40±2°C and 95±3% relative humidity for 24 hours. After this test, the insulation resistance between the core and shield must remain above 25 MΩ.
2.6 Low Temperature Winding Performance
Standard compensation cables should be tested at -20°C. When wound around a test bar, the insulation layer must show no visible cracks, ensuring reliability in cold environments.