Designation: E 780 – 92 (Reapproved 1998)
AMERICAN SOCIETY FOR TESTING AND MATERIALS
100 Barr Harbor Dr., West Conshohocken, PA 19428
Reprinted from the Annual Book of ASTM Standards. Copyright ASTM
Standard Test Method for
Measuring the Insulation Resistance of Sheathed
Thermocouple Material at Room Temperature1
This standard is issued under the fixed designation E 780; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
1. Scope E 585 Specification for Sheathed Base-Metal Thermo-
1.1 This test method covers the techniques and requirements couple Materials2
for measuring the electrical insulation resistance at room E 608 Specification for Metal-Sheathed Base-Metal Ther-
temperature between the thermoelements and between each of mocouples2
the thermoelements and the metal sheath of compacted 3. Terminology
ceramic-insulated, sheathed thermocouple material. It may be
used to measure the insulation resistance of bulk lengths of 3.1 Definitions—The definitions given in Terminology
sheathed thermocouple material environmentally sealed at the E 344 shall apply to the terms used in this test method.
time of manufacture. It may also be used for testing sheathed 3.2 Definitions of Terms Specific to This Standard:
thermocouples with a Type U junction. This test method cannot 3.2.1 bulk material length (BML), n—a single length of
be used for sheathed thermocouples with a Type G junction thermocouple material (produced from the same raw material
unless the junction is removed, prior to testing. lot) after completion of fabrication resulting in sheathed
1.2 This test method applies to the testing of sheathed thermocouple material.
thermocouple materials that are suitable for use in air. It is also 3.2.2 dry, adj—a condition which does not exceed the
applicable for sheathed thermocouple materials whose sheath equivalent of 50 % relative humidity at 22°C.
or thermoelements are composed of refractory metals and are 3.2.3 nonreactive, adj—a condition which will not produce
tested in a dry and nonreactive environment. a chemical transformation or change.
1.3 This test method may be used for sheathed thermo- 3.2.4 test specimen, n—a short length, at least 300 mm long,
couple material having an outside diameter of 1.0 mm or larger. cut from the bulk material length.
1.4 Since the insulation resistance at room temperature of 4. Summary of Test Method
sheathed thermocouple materials may change during shipment,
storage and use, the results obtained by this test method may 4.1 This test method involves measuring the d-c electrical
not be the same as insulation resistance values determined at resistance at normal room temperatures (22 6 5°C) between
some later time. the thermoelements and between each of the thermoelements
1.5 This standard does not purport to address all of the and the metal sheath of a length of sheathed thermocouple
safety concerns, if any, associated with its use. It is the material. The resistance measurements are made with an
responsibility of the user of this standard to establish appro- instrument such as a megohm bridge or megohmeter. The
priate safety and health practices and determine the applica- instrument must be capable of determining values of resistance
bility of regulatory limitations prior to use. from 5 3 104V to 1 3 1012V with an uncertainty of not more
than 610 %. The applied voltage for the resistance measure-
2. Referenced Documents ment is 500 V d-c for sheathed thermocouple material having
2.1 ASTM Standards: an outside diameter larger than 1.5 mm, and an applied voltage
E 235 Specification for Thermocouples, Sheathed, Type K, of 50 V d-c is recommended for smaller diameter sheathed
for Nuclear or for Other High-Reliability Applications2 thermocouple materials.
E 344 Terminology Relating to Thermometry and Hydrom- 4.2 Special precautions must be exercised when preparing
etry2 the sheathed thermocouple material for the resistance measure-
ments to prevent the intrusion of moisture and other contami-
nants that might alter the insulation resistance. The repeatabil-
1
ity of the test method depends primarily upon how well this is
This test method is under the jurisdiction of ASTM Committee E-20 on
Temperature Measurement and is the direct responsibility of Subcommittee E20.04
achieved. Preparation of the sheathed thermocouple material
on Thermocouples. involves removing 5 to 30 mm of the metal sheath from the
Current edition approved Oct. 15, 1992. Published December 1992. ends of the sheathed thermocouple material, heating the sheath
2
Annual Book of ASTM Standards, Vol 14.03.
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E 780
adjacent to the open ends, and sealing the ends with epoxy 7. Test Specimen
resin. 7.1 Conduct the test by using an entire bulk length of
sheathed thermocouple material or a test specimen removed
5. Significance and Use
from it. Determine the test specimen length by the distance
5.1 Thermocouples fabricated from sheathed thermocouple from one end of the compacted ceramic insulation to the other.
material that has been contaminated by moisture, or by certain 7.2 In cases where a test specimen is removed for testing,
other impurities, may undergo large calibration changes or may take the test specimen from any location along the bulk
fail catastrophically when they are heated to high temperatures. material length, provided the ends of the bulk material length
Since such contamination usually substantially lowers the were sealed at the time of manufacture. If the ends were
electrical resistance between the thermoelements and the unsealed and exposed to ambient surroundings for more than 1
sheath, a measurement of the insulation resistance can provide min at any time since manufacture, take the test specimen from
a valuable check on insulation quality and cleanliness, and it a location that is at least 300 mm from the ends. This also
can serve as a basis for rejection of unsuitable material. applies when the integrity of the end seals is in doubt or when
5.2 This test method is primarily intended for use by the the history of the bulk material length is not known.
manufacturers and users of sheathed thermocouple materials to
verify that the measured values of insulation resistance meet or 8. Procedure
exceed specified values, such as those listed in Specifications 8.1 Preparation of Sheathed Thermocouple Material for
E 235, E 585, and E 608. Both manufacturers and users should Test:
be aware, however, that when the insulation resistance is high, 8.1.1 Bulk Material Length—Complete the procedures de-
above 1 3 106V, disagreement by an order of magnitude in scribed in [Link], [Link], and [Link] within 1 min and
results obtained by using this method is not unusual. In perform in a location where the moisture content of the
addition, users should be aware that the insulation resistance at ambient atmosphere (air) does not exceed the equivalent of
room temperature of sheathed thermocouple materials and of 50 % relative humidity at 22°C.
finished sheathed thermocouples may change during shipment, [Link] Remove the seal and a 5 to 30 mm length of the
storage, and use, particularly if the end seals are damaged or metal sheath from one end of the bulk material length. Use of
defective. Consequently, values of insulation resistance deter- a metal-sheathed cable stripper (commercially available) is
mined by this test method may not necessarily apply at a later recommended for removing the sheath.
time.
NOTE 2—Other sheath removal methods will be permitted provided a
clean sheath removal is made, one that does not contaminate the insulation
6. Apparatus
nor reduce the effective cross-sectional insulation spacing dimensions.
6.1 Megohmeter or Megohm Bridge, with ranges from
[Link] Remove the exposed compacted ceramic insulation
5 3 104V to 1 3 1012V with an accuracy of better than 610 %
surrounding the thermoelements.
of the measured resistance and test voltage of 50 or 500 V d-c,
[Link] Separate (or spread apart) the thermoelements so
depending upon the outside diameter of the sheathed thermo-
that they are not in contact with each other or with the sheath.
couple material.
[Link] Immediately after completing the procedure de-
6.1.1 Other resistance-measuring instruments or circuits
scribed in [Link], heat the open end of the sheathed thermo-
that satisfy the electrical requirements given in 6.1 are equally
couple material with a heat source to remove moisture intro-
acceptable.
duced while performing the procedures in [Link]-[Link].
6.2 Insulated Copper Connecting Wires, with suitable
Starting approximately 75 mm from the open end and proceed-
mechanical-type connectors.
ing towards it, move the heat source slowly along the sheath.
6.3 Heat Source, (for example, a small propane-type torch
Repeat this process until the entire 75 mm end portion attains
or an electric heat gun).
a temperature of approximately 200 to 300°C.
6.4 Epoxy Resin, 3 suitable as an environmental seal for the
ends of the bulk material length or of the test specimen at NOTE 3—Magnesium oxide insulation is extremely hygroscopic. Mois-
temperatures up to 200°C. ture absorption from the ambient atmosphere may degrade the insulation
6.5 Metal-Sheathed Cable Stripper—Any commercially resistance by several orders of magnitude, or more, with exposure for only
a few minutes.
available cable stripper that will satisfactorily remove the
sheath without damage to the thermoelements is acceptable. [Link] Seal the open end of the bulk material length
6.6 Optical Magnifier, with a magnification of 53 to 103 immediately, before it cools appreciably, by applying a sealant
(for example, a watchmaker’s loupe). of epoxy resin. Make sure the epoxy resin sealant completely
6.7 Cutting Tools, such as diagonal cutters or a suitable covers the end of the sheathed thermocouple material and
metal saw may be required, if a test specimen is to be removed extends at least 3 mm along the outside of the sheath from the
for test purposes. end but keep the tips of the bare thermoelements free of epoxy
resin.
NOTE 1—Caution: All tools that are used must be clean and must not
introduce oil or other contaminants into the insulation.
[Link] Heat the applied epoxy resin with hot air (at approxi-
mately 200°C) to accelerate its curing process. Then, allow the
end seal to cool slowly to room temperature. Do not handle the
3
Devcon “5-Minute” Epoxy, (Devcon Corp., Endicott St. Danvers, MA 01923), end seal with bare hands. Keep the seal clean and dry.
or an equivalent nonconducting epoxy, has been found suitable for this purpose. [Link] Remove the environmental seal at the other end of
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E 780
the bulk material length and immediately prepare the end by 8.2.5 Select the lowest range of the measuring instrument
following the procedures described in 8.1.1-[Link]. that gives an on-scale reading.
[Link] Allow the seals at both ends of the bulk material 8.2.6 After 1 min from the time recorded in 8.2.4, record the
length to cure completely. Inspect the seals for defects using an reading indicated by the measuring instrument.
optical magnifier that has a magnification of 53 to 103. If any 8.2.7 Reverse the polarity of the applied voltage and repeat
cracks, air pockets, or voids are observed, consider the seal 8.2.4-8.2.6.
defective. Remove the defective seal and a 100 to 125 mm [Link] Interchange the positions of the connecting wires at
length of metal sheath adjacent to it, and prepare a new seal by either the measuring instrument or the thermoelements to
repeating the procedures in 8.1.1-[Link]. accomplish the polarity reversal.
8.1.2 Test Specimen—Cut the test specimen from the bulk 8.2.8 Make electrical connections to one of the thermoele-
material length by using diagonal cutters, a tube cutter, or a ments and to the sheath from the input terminals of the
metal saw, and seal the cut end of the bulk material length resistance measuring instrument.
following the procedures described in 8.1.1-[Link]. 8.2.9 Follow procedures given in 8.2.3-8.2.7 for the resis-
[Link] Prepare both ends of the test specimen following the tance measurements.
procedures described in 8.1.1-[Link]. 8.2.10 Make electrical connections to the other thermoele-
[Link] Perform the procedures in [Link] in accordance ment and the sheath as in 8.2.8 and follow procedures given in
with the requirements given in 8.1.1. 8.2.3-8.2.7 for the resistance measurements.
[Link] Heat both ends of the test specimen with a heat 8.2.11 Repeat the procedures described in 8.2.2-8.2.9 for
source to remove moisture introduced while performing the each thermoelement contained in the bulk material length or
above procedures. Follow the procedure described in [Link] test specimen.
for heating the ends of the test specimen.
[Link] Seal both ends of the test specimen as described in 9. Report
[Link] and [Link]. 9.1 Report the following information:
[Link] Inspect seals for defects as described in [Link]. If 9.1.1 Date and time of the test,
any defect is observed in the seals, discard the test specimen 9.1.2 Identification of the bulk material length and test
and prepare a new one by repeating the procedures in [Link]- specimen (if taken) including its nominal dimensions (length
[Link]. and outside diameter), the type of sheath, insulation, and the
8.2 Resistance Measurement: number and type of thermoelements,
8.2.1 Make the resistance measurements of the bulk mate- 9.1.3 Brief description of the resistance measuring instru-
rial length or test specimen after the epoxy resin sealant has ment used, including its accuracy,
cured but not later than 72 h after sealing. Make the resistance 9.1.4 The applied voltage used for the resistance measure-
measurements in a dry location and where the temperature is ments,
between 17 and 27°C. 9.1.5 Values of the resistances measured between each
NOTE 4—Surface adsorption of atmospheric moisture on the end seals thermoelement and between each thermoelement and the
will be a problem in conducting the test, and care must be taken to ensure sheath, for both normal and reversed polarity, and
that the end seals of the test specimen are clean and dry when tests are 9.1.6 Ambient temperature and relative humidity during test
made. period.
8.2.2 Make electrical connections to any two thermoele-
ments from the input terminals of the resistance measuring 10. Precision and Bias
instrument. 10.1 Insulation resistance is primarily used as an in-process
[Link] When insulated copper connecting wires are used check on insulation quality and cleanliness. Measurements of
for this purpose, make sure the open-circuit resistance between resistance are not usually repeated or reproduced. Conse-
them is greater than 1 3 1013V. quently, statements of precision and bias are not relevant.
NOTE 5—Large errors can arise in the measurement of high resistances When an insulation resistance test at room temperature is
due to electrical current leakage effects. Electrical resistance measurement prescribed as a purchasing stipulation, both parties should
techniques for high resistance should be used to minimize current leakage. concur as to the details of the test, and should be aware that
8.2.3 Adjust the resistance measuring instrument for an disagreement by an order of magnitude is not unusual.
applied voltage of either 50 6 2 V d-c or 500 6 20 V d-c. Use
a test voltage of 500 V d-c when the outside diameter of the 11. Keywords
sheathed thermocouple material is greater than 1.5 mm. Use of 11.1 insulation resistance; sheathed thermocouple insulation
50 V d-c is recommended for smaller diameter materials. resistance; sheathed thermocouple material insulation resis-
8.2.4 Record the time and energize the measuring circuit. tance
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E 780
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