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Process heaters, which include immersion heaters, employ various types of sensors to precisely gauge and modify the temperature inside a production process. One of these three sorts of sensors is usually used by tubular heater supplier if you’re a design engineer working with the newest heating products: A thermocouple, also known as an RTD, a thermostat, and a thermistor.

Heating Products

Thermocouple 

A thermocouple measures voltage by using the metal junction of two distinct kinds of wire. The electron density of every metal wire varies in tandem with variations in temperature at the measurement location. The voltage, which is determined at the connecting point, is this fluctuating electron density. The process controller detects these voltage variations and computes the connection using a mathematical formula.

RTD

RTDs measure temperature using resistance and work on a similar premise. These sensors by RTD sensor supplier are perfect for a more accurate and consistent evaluation of your processing system.

Thermistor

Thermistors are the best choice for precise measurement and quick testing. Examine each of these sensor alternatives to see whether you should replace your current one or think about using a different approach to assess your industrial heating operation. 

Indications of a Broken Sensor

In industrial processes, more precise heating is needed when using an immersion or circulation heater. To attain industry-leading performance, these intricate heating systems need more stringent regulations to maintain the required temperatures. Your sophisticated thermal system may suffer if a thermocouple or other sensor is damaged.

Make that your sensor is detecting the right temperature using a second device if your processing output seems inconsistent or of low quality. If not, try these troubleshooting techniques before swapping out the sensor:

• Adjust the setpoint
• Install higher output cabling
• Relocate the sensor
• Replace the sensor insulation.

Thermocouples and RTDs can break and cause them to interpret your heating goods’ current and temperature inaccurately. A new or fixed sensor can get your heating process back to working at its best if you have anomalous temperature swings or temperature variations across different heater bundles.

Eliminating a Sensor

To ensure the uninterrupted operation of your industrial process, find out how to remove a broken thermocouple or RTD. Before removing or replacing your heater bundle, try to follow these steps to remove and replace your sensor.

Hose clamps and compression fittings are frequently used with sheath thermocouples, also known as RTDs, to hold the sensor in the ideal sensing position. Remove the element leg clamp and pull apart the fitting within the terminal enclosure to free the sensor assembly from your heating system.

Sensor Replacement

Get a replacement sensor that satisfies the needs of your industrial process and heating goods. You must repair the clamps and compression fittings in addition to making sure the wire is still operational to replace your sensor. This allows you to create the perfect sensor while giving you visible feedback as you work.

Your new sheath thermocouple or RTD will be secure to the exact measuring point with new compression fittings. Before you attach your new sensor, install a new compression fitting at the bottom of the enclosure.