CHAPTER 2: INSTALLATION
THERMOCOUPLE WELDER
990-070
2-3
Section II. Thermocouple Wire Preparation
Insulation Stripping
The jacket insulation and the insulation covering both thermocouple wires must be stripped back a
MINIMUM distance from the end of the wire where the weld is to take place. Proper removal of the
insulation allows the bare thermocouple wires to protrude a minimum distance from the end of the
Handpiece Wire Clamping Jaws. Mechanical strippers with oval shaped cutters work best. Do not use
Thermal Strippers with Teflon Coated Wires. Thermal stripping Teflon leaves a thin Teflon coating on the
wires, preventing weld current from flowing. When properly stripped, the bare thermocouple wires will be
of equal length, parallel, and free of insulation residue. The table below gives the minimum wire stripping
length for each wire size.
Wire Size
AWG
Stock No.
Model No.
ID No.
Strip Length
Inches
Strip Length
MM
38 – 32
10-293-01
TCWCS38
1
.200
5.08
31 – 27
10-294-01
TCWCS31
2
.200
5.08
26 – 23
10-295-01
TCWCS26
3
.200 - .220
5.08 – 5.59
22 – 20
10-296-01
TCWCS22
4
.200 - .220
5.08 – 5.59
The recommended tolerance on Strip Length is –0, +.010 inches (-0, +0.25 mm). Any strip length greater
than those shown above is acceptable.
The TCW Handpiece can be used with non-insulated thermocouple wire. Non-insulated wire must protrude
a MINIMUM of .135 inches (3.43 mm) from the closed Wire Clamp Jaws.
Summary of Contents for TCW
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