Thermocouple compensation wire Manufacturers

Precision Thermocouple Compensation Wire for Industrial Temperature Loops

Jiangsu Zhaolong Electrics Co., Ltd. is a Thermocouple compensation wire manufacturer based in Jiangsu, China. Our wires extend the thermocouple measuring junction to indicators, recorders, temperature transmitters and controllers while keeping the millivolt signal stable over the full cable run.

We manufacture both extension wire and compensation wire types for S, R, K, E, J and T thermocouples, with fiberglass, PVC and PTFE insulation and optional stainless steel braid. Because our production line is integrated with our assembled thermocouple and temperature transmitter business, the wire specification, connector and calibration are matched to the instruments we ship.

Product Range and Application Fit

Both constructions are included in our Thermocouple compensation wire range and are produced with color-coded conductors for fast identification during installation and maintenance. We also accept special specifications and custom production based on drawings or samples.

Extension Wire vs Compensation Wire

Extension wire uses alloys that match the two thermocouple wires of the same graduation mark. Compensation wire uses copper and cupronickel materials in different proportions to replicate the thermoelectric characteristics of the sensor. Both types extend the cold junction to the measuring instrument and are designed to resist acid, alkali, abrasion and fire.

The common working temperature range for our standard extension and compensation wires is -25°C to +200°C. These wires can be immersed in oil for long-term operation, making them suitable for machinery and process equipment where oil contamination is unavoidable.

Our wires are manufactured according to the GB/T 4989 standard for thermocouple extension and compensation wires, covering the graduation symbols S, R, K, E, J and T.

Standard Wire Types by Thermocouple Graduation

The standard product list covers SC, KC, KX, EX, JX and TX types according to the thermocouple graduation mark and installation condition.

Construction and Specification Options

• Conductor: solid NiCr-NiSi for K-type extension wire; copper-cupronickel for compensation wire.
• Insulation: fiberglass, PVC or PTFE, selected according to temperature, chemical exposure and moisture levels.
• Shielding and armor: glass fiber, stainless steel braid in 304, 201 or 316 grade, copper, PTFE, PVC or unshielded.
• Core count: 2, 3, 4, 5, 6 or 8 wires for multi-channel and multi-sensor runs.
• Gauge: 18 AWG, 22 AWG and 24 AWG are available in our standard program.
• Color coding: white, black, red, blue, yellow, purple, green and metallic finishes for clear circuit identification.
• Length: 100 meters, 300 meters or 500 meters per roll; minimum order quantity is 10 meters.

For a complete proposal, match the wire gauge and core count to the distance between the thermocouple and the receiving instrument, and confirm the mechanical load on the cable tray or conduit.

Quality Control and Testing

Our factory applies quality supervision through the entire production process, from conductor drawing and insulating to shielding, cutting and final inspection. We operate a modern temperature sensor and wire production line with a dedicated R&D and laboratory team.

We have obtained GB/T 19001-2016/ISO9001:2015 quality system certification and CE certification, and we hold national explosion-proof production qualification certificates for explosion-proof thermocouples and resistance temperature detectors. Our laboratory is equipped with noble metal high-temperature test furnaces, low-temperature test tanks and oil tank test furnaces to support verification across a wide temperature range.

We provide professional calibration services for thermocouples and related instruments, with calibration resolution up to 0.01°C and a temperature capability from -200°C to +2000°C. Every product carries a 12-month warranty against non-human damage, and we keep spare wire stock to minimize downtime when replacements are needed.

Integration and Project Support

Because we also manufacture temperature sensors, transmitters and controllers, we can match the compensation wire to the complete measurement loop rather than treating it as an isolated cable purchase. This reduces the risk of signal error caused by mismatched alloys, incorrect polarity or incompatible connectors.

Our engineering team can produce standard and special specifications, manufacture according to drawings or samples, and design automatic temperature control boxes, temperature control rooms and remote monitoring temperature control systems. We export to more than 30 countries and regularly support OEM projects where the wire must integrate with existing instrumentation cabinets or junction boxes.

Information We Use to Configure Your Solution

Every quotation is prepared around the sensor type and the installation route. Please provide as much of the following as possible:

• Thermocouple type / graduation mark: S, R, K, E, J or T.
• Wire type: extension or compensation, and whether the cold junction will be kept at a controlled temperature.
• Distance between the thermocouple head and the receiving instrument.
• Ambient conditions along the route: oil, chemicals, moisture, vibration, heat or mechanical abrasion.
• Number of cores and required AWG.
• Shield, armor and outer sheath preference.
• Termination style: bare leads, thermocouple connector, terminal block or custom marking.
• Roll length, total quantity and packaging requirement.

Frequently Asked Questions

What is the difference between extension wire and compensation wire?

Extension wire uses alloys that match the thermocouple wire itself, while compensation wire uses copper and cupronickel in different proportions to produce a similar thermoelectric output. Both extend the thermocouple cold junction to the measuring instrument. We select the type according to the thermocouple graduation and required accuracy.

Which thermocouple types can your compensation wire support?

Our standard range supports S, R, K, E, J and T thermocouples. The wire types are SC, KC, KX, EX, JX and TX according to the graduation mark and application requirement.

Can you supply multi-core or armored thermocouple wire?

Yes. We supply 2, 3, 4, 5, 6 and 8-wire constructions with PVC, PTFE or fiberglass insulation, and optional copper or stainless steel braid in 304, 201 or 316 grade.

What temperature range is typical for your thermocouple compensation wire?

The common working range for standard extension and compensation wire is -25°C to +200°C. For areas exposed to higher ambient heat, our glass fiber high temperature stainless steel braided construction provides additional insulation and mechanical protection.

What information do you need for a quotation?

Please provide the thermocouple type, wire type, core count, AWG, insulation and shield requirements, total length and quantity. We also need the installation environment so we can recommend the correct outer sheath and armor.

What after-sales support do you offer?

We provide a 12-month warranty against non-human damage, professional calibration service for thermocouples and related instruments, and spare parts availability to support long-term operation.