Introduction
Industrial machinery depends on measurement systems to monitor operating conditions. Temperature is particularly important because excessive or unexpected temperature can indicate changes in process conditions, equipment loading or component behavior. PT100 sensors are commonly incorporated into industrial measurement systems because they provide temperature information through the predictable resistance characteristics of platinum.
Raystek Process Instruments provides PT100 RTD sensors for industrial applications and supports customized designs for machinery, OEM equipment and process installations. Its published information identifies applications including motors, generators, chemical processes, pharmaceutical equipment, food processing, plastic machinery and power-related equipment.
A customized PT100 sensor can be useful when a standard temperature probe does not match the physical or electrical requirements of a machine.
Why Industrial Equipment May Need Custom Sensors
Standard catalog dimensions do not always fit specialized machinery.
A machine may have limited installation space, a particular mounting thread, a specific cable length or a defined sensing depth.
Common Customization Requirements
Industrial buyers may need:
Specific probe diameter
Fixed insertion length
Special sheath material
Defined cable length
Particular connector
2-wire, 3-wire or 4-wire wiring
Class A or Class B accuracy
Single or dual sensing elements
Threaded connection
Compression fitting
Flange
Thermowell compatibility
Raystek states that it can manufacture customized PT100 sensors according to customer drawings, samples and technical specifications.
PT100 Sensors for Motors and Generators
Motors and generators can require specialized temperature monitoring because conventional cylindrical probes may not fit all measurement locations.
Raystek provides bearing temperature detectors using RTD or thermocouple elements. It also manufactures stator winding RTDs in PT100 configurations for large motors and generators.
Bearing Temperature Measurement
Bearing temperature detectors are designed for measurement locations such as bearings, thrust bearing plates and shafts. Raystek describes these detectors as compact and suitable where space is limited.
The appropriate sensor design depends on the machine construction and measurement location.
Stator Winding RTDs
Stator winding RTDs are constructed differently from conventional probe-style sensors. Raystek describes them as flat, laminated assemblies positioned between motor or generator windings.
This illustrates why industrial temperature sensors often need to be designed around the equipment rather than selected only from a generic catalog.
PT100 Sensors for Process Equipment
Chemical and pharmaceutical equipment can require temperature measurement at specific points.
The sensor must be compatible with the process conditions and installation method.
Material and Connection
Raystek's RTD specifications include SS316 as a standard sheath material, with other options available according to requirements. Process connections include threaded, compression, flange and Tri-Clamp arrangements.
The selected material and connection should be determined by the actual process.
PT100 Sensors for Plastic Machinery
Temperature control is important in plastic processing, including injection molding and extrusion.
Raystek states that its temperature sensor solutions can be customized for plastic and packaging applications, including probe dimensions and mounting arrangements.
Why Dimensions Matter
A sensor installed on plastic processing machinery must fit the machine's mounting location and provide the desired measurement point.
The correct probe diameter, insertion length and connection can therefore be just as important as the RTD element itself.
Choosing the Wiring Arrangement
Customized machinery can require a particular electrical configuration.
Raystek provides 2-wire, 3-wire and 4-wire PT100 arrangements.
Matching the Instrument
Before specifying a sensor, confirm which RTD configuration the receiving controller, transmitter or measurement system supports.
A technically suitable PT100 element may still be unsuitable if the wiring arrangement does not match the instrumentation.
Accuracy and Measurement Requirements
The required accuracy should be defined by the process.
Raystek offers DIN Class A and Class B configurations.
Do Not Specify Accuracy in Isolation
The actual measurement chain includes:
Sensor
Cable
Connection
Transmitter or controller
Installation
Calibration
Process conditions
Therefore, selecting a tighter sensor tolerance is only one part of achieving an appropriate measurement system.
Protection and Thermowells
Some industrial processes expose sensors to mechanical PT100 Sensor Manufacturer forces or process conditions that make additional protection desirable.
Raystek lists thermowells as optional RTD accessories.
When a Thermowell May Be Considered
A thermowell can provide a barrier between the sensing element and process environment and may simplify sensor replacement in some installations.
The thermowell dimensions should be coordinated with the PT100 probe to maintain compatibility.
Enclosure and Cable Options
A custom PT100 assembly may also require a particular termination.
Raystek provides enclosure options including die-cast aluminium, SS304 and SS316. Its specifications include different cable insulation arrangements and connector options.
Environmental Considerations
For outdoor or exposed installations, weatherproof protection may be required. Raystek lists IP65 and IP67 configurations. Specialized flameproof arrangements are also available for applicable requirements.
Hazardous-area applications should be evaluated against the relevant certification and installation requirements.
Preparing an OEM Sensor Requirement
OEM manufacturers can simplify the quotation process by providing complete technical information.
Useful Data to Send
A technical request can include:
Existing sensor drawing
Existing sensor sample
Temperature range
PT100 element configuration
Accuracy class
Number of elements
Probe dimensions
Sheath material
Mounting arrangement
Cable length
Connector type
Quantity
Application description
Raystek states that OEM customers can share drawings, samples or technical specifications for evaluation and customized manufacturing.
Supporting Maintenance and Replacement
Customized PT100 sensors can also be relevant for maintenance teams replacing sensors in existing equipment.
A replacement should match the original measurement system where required. Important dimensions and electrical characteristics should be verified before ordering.
Replacement Checklist
Maintenance teams can record:
Existing element type
Number of wires
Probe diameter
Insertion length
Thread or mounting type
Cable length
Connector
Temperature range
Accuracy requirement
This reduces the chance of receiving a sensor that cannot be PT100 Sensor Manufacturer installed or integrated correctly.
Conclusion
Custom PT100 sensors provide a way to adapt RTD temperature measurement to specific machinery and process requirements. This can be particularly useful for motors, generators, chemical equipment, pharmaceutical systems, plastic processing machinery and OEM applications.
Raystek Process Instruments offers standard and customized PT100 sensors and supports application-specific configurations involving dimensions, wiring, sheath material, connections, cables and terminations.
For a successful custom sensor order, the most important step is to provide accurate technical information about the measurement point and existing equipment. A well-defined requirement allows the manufacturer to develop a PT100 assembly that fits the mechanical installation and integrates with the intended measurement system.