The 200 °c to 400 °c band is a material boundary, not a convention. Beyond every polymer insulation. Thick film on stainless or ceramic, mica-insulated elements, or a high Curie point PTC — the construction changes completely at this boundary. This page covers what that means for pt100 and pt1000 rtd sensors, which is rated to 400 °C continuous.
What the 200 °C to 400 °C Band Requires
Beyond every polymer insulation. Thick film on stainless or ceramic, mica-insulated elements, or a high Curie point PTC — the construction changes completely at this boundary.
| Band | 200 °C to 400 °C |
|---|---|
| This construction, continuous | 400 °C |
This band reaches the ceiling of the construction. At 400 °C there is no headroom left, so the control has to hold the set point rather than approach it from above, and the limit device has to be set where it can act before the insulation does. A duty that spends its time at the top of the band is a duty that should be quoted against the next construction up.
Why the Boundary Is Where It Is
Above 200 °C no polymer insulation survives, so the candidates are inorganic: fired glass dielectric on stainless or alumina, mica-insulated ribbon, or a high Curie point PTC. Each is rigid and each has to be clamped rather than bonded.
Expansion becomes a design item in this band. A stainless plate 300 mm long grows about 1.5 mm between 20 °C and 400 °C, and a mounting that does not allow for that puts the growth into the joint or into the substrate.
What a PT100 and PT1000 RTD Sensors Is
Platinum resistance sensors for anything that has to be accurate, repeatable and calibratable — process plates, medical warming, and any loop that gets validated.
A sensing component, specified by its tolerance class, its usable range and its response time. It has no watt density and no outline; it is fitted to a heater or to the surface the heater is warming, and where it is fitted decides what the control loop is actually controlling.
The heat leaves through whatever the component is clamped or bonded to; a sensing component adds no heat of its own and simply has to be in thermal contact with the thing it is reporting on.
| Total thickness | Component |
|---|---|
| Maximum size, one piece | Component |
| Continuous working temperature | 400 °C |
The continuous limit of 400 °C is set by the insulation system. The element alloy would run far hotter; it is never the element that decides.
Which Temperature Is Being Held
Three temperatures matter and they are not the same number: the element temperature, the temperature of the surface being heated, and the ambient. A heater rated for a continuous working temperature is rated at the element — the hottest point in the assembly, and the one nothing on the outside is measuring.
The gap between element and surface is the thermal path. Bonded to metal it may be a few degrees; across an air gap, a void in the adhesive or a dry clamped joint it can be tens of degrees, and every one of them appears at the element rather than at the load.
Attachment and Thermal Contact
A sensing component is fitted where it will read the temperature that matters: against the element for a limit device, against the load for a control device. The two positions give different numbers, and choosing the wrong one is the commonest reason a correctly built loop holds the wrong temperature.
A sensor reads its own junction, not the surface it is near. Bed it in thermal compound, clamp it, or pot it into the assembly: an air gap of a tenth of a millimetre between a thermistor and the plate it is supposed to be measuring is worth several degrees of error, and it is an error the controller cannot see.
Control and Protection
This heater has no way of limiting its own temperature. Resistance heating draws roughly the same power whatever the temperature, so with the load removed, the fluid gone, the fan stopped or the sensor open circuit, the element keeps producing watts until something stops it.
The design must therefore contain a control device and, separately, a protective one: a controller with a sensor to hold the set point, and a bimetal thermostat or a one-shot thermal cutoff wired in series with the element to open the circuit if the loop ever fails. The two are not interchangeable — a controller that has lost its sensor cannot protect anything, which is exactly the fault the cutoff exists for.
How This Construction Fails
- Loss of the control loop. An open-circuit sensor, a welded relay contact or a controller in manual leaves the element at full power with nothing watching it — the case the series thermal cutoff exists for, and the reason it must not be omitted to save a part.
- Measuring the wrong thing. A sensor in the air near a heated plate reports the air, and the loop holds the air where the specification wanted the plate. Nothing in the instrument can detect this.
Other Constructions That Hold 200 °C to 400 °C
Constructions in this catalogue that will hold 200 °c to 400 °c continuously:
How to Specify One
This is a made-to-drawing part, so there is no catalogue number to quote. A quotation is built from the following, and the more of it that arrives with the enquiry the fewer rounds it takes:
- The temperature to be sensed or switched, and the tolerance the application actually needs.
- Where the component sits — against the element, in the potting, on the load, or in the airflow.
- The electrical duty: for a switching device, the voltage, the current and whether the load is AC or DC.
- Lead length, insulation and termination, and whether the component is fitted by us into a heater assembly or supplied loose.
- The standard the end product is certified to, so the component chosen is one that fits inside that approval.
Lead time: Samples 7-10 days from approved drawing; production 15-20 days.
PT100 and PT1000 RTD Sensors — Capability Table
These are process limits for the construction, not the specification of one stocked item. Every line is what the factory can hold; what your part holds is fixed on your drawing.
| Parameter | Specification | Limit / note |
|---|---|---|
| Type | Thin film platinum resistance temperature detector | Nearly linear, and its characteristic is defined by standard |
| Standard | IEC 60751, class AA / A / B | Class A is u00b10.15 u00b0C at 0 u00b0C; class B is u00b10.3 u00b0C |
| Nominal resistance | 100 u03a9 (PT100) or 1000 u03a9 (PT1000) at 0 u00b0C | PT1000 is preferred on long low-voltage runs: lead resistance matters ten times less |
| Temperature range | -50 u00b0C to +400 u00b0C | The element itself; the leads and potting are usually the limit |
| Wiring | 2, 3 or 4 wire | 2-wire adds the lead resistance to the reading u2014 use 3-wire beyond a metre |
| Self heating | Keep the measuring current at or below 1 mA | A sensor heated by its own excitation current reads high, consistently |
| Encapsulation | Laminated into the heater, in a stainless probe, or surface bonded | |
| Calibration | Certificate traceable to national standards on request | Required for validated processes |
Figures are the published tolerance and rating bands of the standard sensor and control components fitted to these heaters. Sensor tolerance classes follow IEC 60751 for RTDs and IEC 60584 for thermocouples; thermostat and thermal cutoff ratings are the component manufacturers' own.
