industrynet · 2019-10-04 · a • flameless electric air heaters . 1. flameless electric air...

Heaters • Sensors • Controls

www.convectronics.comemail: [email protected]

111 Neck Road • Haverhill, MA 01835(978) 374-7714 • Fax# (978) 374-7794 • (800) 633-0166

CONVECTRON

ICS

HEATERS

SENSORS

CONTROLS

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Flameless Electric Air Heaters:Heater Style Application & Selection Guide

High Temperature Air Heater

When you need a heat source, Convectronics’ products are designed to meet and exceed all expectations. Convectronics Air Heaters use state of the art materials and can be found throughout the world in countless industries.

• Temperature up to 1500°F• Clean electric heat without the flame• Compact size with rapid heat-up and cool-down• Controllable by varying voltage, flow rate or temperature controls• Excellent repeatability• Directable heat• Easy installation

Air heaters work by continuously passing air/fluid over a heated element. This air/fluid is heated and then discharged from the heater, giving a consistent supply of reliable heat. The material being heated can either be inert gas, compressed air or air from a regenerative blower. Unfiltered gas that may contain dirt, grease, oil, oil vapors, corrosive or reactive gases along with volatile or combustible gases should never be used. It should be noted that material should always be flowing over the element before and even after power is supplied to the heater or the result may be overheating of the element and reduced life.

Optimum heater life is achieved by operating theelement within its specified performance characteristics and monitoring the element temperature. Elements operating outside their recommended limits will glow beyond the midsection of the heated length.

Best operating results will be obtained by using a thermocouple feedback temperature control and phase angle power control. When using only a voltage control extra caution should be taken. Apply voltage to the heater until the desired air temperature is obtained.

Air Heater Selection:When selecting a heater you must first determine the power required to heat air. This can be done by using the following formula:

This will give you an approximate power requirement which can aid you in selecting a heater.

When selecting heaters it is important that a good control system is also selected. A good control system is critical for long heater life. Convectronics offers open-loop (manual) controls, closed-loop (feedback) controls and all the components necessary to run our heaters.

Power (Kilowatts) = [(SCFM x Delta T) / 3000] x 1.2

SCFM = Standard cubic feet per minuteDelta T = Temperature (exit) - Temperature (inlet) In Degrees Fahrenheit

• Repeatable • Adaptable • Stable • Reliable• Precise • Accurate • Controllable

• Clean • Sturdy • Responsive• Economical • Dependable

• Compact • Efficient• Powerful

A • Flameless Electric Air Heaters

2

• Smallest As small as 0.410” OD x 5-1/4” long• Lowest Cost Contact your Distributor or Factory• Nozzle Available 0.065” diameter outlet opening for soldering and other small target applications • Lowest Flow 25 to 400 SCFH air flow range• Lowest Wattage 465 watts @ 120 volts and can be adjusted lower

Flameless Electric Air Heaters:Heater Style Application & Selection Guide

• Most Efficient Triple pass heat exchanger pre-heats air before passing through element• Choice of Wattages 2000 to 6000 watts @ 240 volts• Replaceable Element Plug-in socket connection allows quick replacement• Physical Strength Sturdy stainless steel housing with protective outlet screen• Cool Outer Shell User friendly because heat exchanger feature keeps outer shell cool to the touch• Medium to High Air Flow 150 SCFH to 1500 SCFH

• Modular Construction Select size and wattage combinations to suit application• No Back Pressure Elements are mounted 90 degrees to air flow resulting in minimal back pressure so that a fan can be used for the air source• Highest Air Flow Limited only by combination of heater duct sizes

Accessories for Style 003 HeatersPressure Switch, Relay, Thermocouple Attachments

Accessories for Style 001 HeatersShields, Thermocouples,Replacement Quartz

Power/Temperature Controls - manual and automatic

Style 001

Style 002

Style 003

Style 004

Style 005

Style 006

Style 007• In-Line Applications NPT pipe threads at inlet and outlet• Highest Pressure Feed-thru style rated to 150 PSI Construction

Application Guide

Packaging:Poly-coated paperboard sealing (cups, composite cans, etc.)

Styles 001 or 003

Adhesive curing (tri-seal cartons, etc.) Styles 001 or 003

Heat shrinking (bulk packaging, etc.) Styles 001, 003 or 005

Automotive:Bonding of components (side trim molding, etc.)

Style 003

Exhaust testing Styles 003, 005 or 007

Plastics and Rubber:Salt removal from rubber extrusions Style 003

Deflashing molded parts Styles 001 or 003

Staking, forming and bending of plastics Styles 001 or 003

Plastic welding Styles 001 or 003

Textiles:Cutting and welding Styles 001 or 003

Texturizing Style 007

Soldering:Soldering and desoldering operations Styles 001, 003 or 005

Semiconductor and Electronics:Soldering and desoldering (boards, lead frame and components)

Styles 001 or 003

Solder repair stations Styles 001 or 003

Epoxy curing (conductive and non-conductive)

Styles 001 or 003

Heat shrink tubing Styles 001 or 003

Wafer drying Style 001

Process gas heating Styles 003 or 007

Printing and Paper:Ink drying Styles 001 or 003

Adhsive activation Styles 001, 003 or 005

Coated paper drying Styles 003 or 005

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* Standard Tubing Adaptors on ALL Series 001 Air Heaters have a 1/4” NPT Female Thread for use with a compression tube fitting (not supplied).

* To order an 001 Series Air Heater with a PLAIN Tubing Adaptor (NO Threads) use the suffix “T” at the end of the Part Number. This adaptor accepts a 3/8” OD Tube.

Flameless Electric Air Heaters:Single Pass Quartz Tube Heaters

Recommended Element TemperatureAbove Recommended Element TemperatureMaximum Recommended Flow

015050 100 200 250

200

100

1200°F

1000

6

1000

8

1000

4

1000

2

1000°F 1300°F

1001

0

300

1100°F

1300°F

VOLTS

AC

TU

AL

FLO

W S

CFH

Nozzled Air Heaters

050 100 200150 250

1000

3

1100°F

100

200

1000

9

1000

510

007

300 1200°F

1400°F

1000

1

1300°F

1500°F

VOLTS

AC

TU

AL

FLO

W S

CFH

Open Air Heaters

1"

D ±.010"I.D.

A ±1/16"

C

O.D.±1/32"

B ± 1/16"

1/4"-18 NPT

13/16"

MTG HOLE FOR #3-48 SCREW

Quartz TubeHeaters

Dimensions Wattage at Standard Voltages

Part Number Type A B C D 60V 120V 240V

001-10001 OPEN 6.875” 8.25” .410” - 115 465 1850

001-10002 NOZZLE 7.875” 9.25” .410” .065” 115 465 *

001-10003 OPEN 7.75” 9.125” .410” - 210 850 *

001-10004 NOZZLE 8.75” 10.125” .410” .065” 210 850 *

001-10005 OPEN 3.875” 5.25” .410” - 240 * *

001-10006 NOZZLE 4.875” 6.25” .410” .065” 240 * *

001-10007 OPEN 3.875” 5.25” .410” - 480 * *

001-10008 NOZZLE 4.875” 6.25” .410” .065” 480 * *

001-10009 OPEN 6.875” 8.25” .594” - 290 1150 4650

001-10010 NOZZLE 7.875” 9.25” .594” .115” 290 1150 *

Performance Characteristics:

Select the heater thatmatches your application

(See detailed curves in technical section (T) of catalog)

*not recommendedStandard Wattage Tolerances +5% / -10%Standard outer casing: quartz


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Flameless Electric Air Heaters:Air Heater Accessories

All shields made with 300 series stainless steel.

Outer Shield OpenProvides better heating efficiency and protection against accidental breakage.

Outer Shield Open with Thermocouple Port

Outer Shield FlareProvides a wider heat distribution area. For use with open heaters only.

Outer Shield Flare with Thermocouple Port

Thermoplastic Male Connectors¼-18NPT

PolyethyleneTubing

ThermocouplesExposed Junction3 Ft. standard length with steel braid.

Used with Model #

Part Number A B

001-10001 002-10012 1/2” 6-3/4”

001-10003 002-10011 1/2” 7-5/8”

001-10005 002-10013 1/2” 3-3/4”

001-10007 002-10013 1/2” 3-3/4”

001-10009 002-10014 11/16” 6-3/4”

Used with Model #

Part Number C D

001-10001 002-10082 7-3/8” 1/2”

001-10003 002-10083 8-1/4” 1/2”

001-10005 002-10084 4-3/8” 1/2”

001-10007 002-10084 4-3/8” 1/2”

001-10009 002-10085 7-3/8” 11/16”

Used with Model #

Part Number A B Flare

Opening

001-10001 002-10015 1/2” 8-3/8” 2” x .062”

001-10003 002-10016 1/2” 9-1/4” 2” x .062”

001-10005 002-10017 1/2” 5-3/8” 2” x .062”

001-10007 002-10017 1/2” 5-3/8” 2” x .062”

001-10009 002-10018 11/16” 8-3/8” 2 1/2” x .062”

Used with Model #

Part Number C D Flare

Opening

001-10001 002-10077 9” 1/2” 2” x .062”

001-10003 002-10078 9-7/8” 1/2” 2” x .062”

001-10005 002-10079 6” 1/2” 2” x .062”

001-10007 002-10079 6” 1/2” 2” x .062”

001-10009 002-10080 9” 11/16” 2 1/2” x .062”

Part Number Use with

002-10022 1/4” tubing

002-10024 3/8” tubing

Part Number Use with

002-10021 1/4” tubing

002-10023 3/8” tubing

Part Number O.D.

002-10019 3/8”

002-10020 1/4”

Type Part Number

“J” 002-10087

“K” 002-10088

StraightElbow

1 3/16"

2 3/8"

2"

.203" DIA. A

B

1 3/16"

2 3/8"

2"

.203" DIA.

CD

#10-321/4"

1 3/16"2 3/8"

2"

.203" DIA. A

FLARE SLOTTED 1/16"

B

C

1/4"

2 3/8"

1 3/16"

2"

.203" DIA.

D

FLARE SLOTTED 1/16"

#10-32

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Flameless Electric Air Heaters:Metal Shell Air Heaters

These fast responding heaters deliver up to 1400°F air temperatures through a protective metal shell. The element design insures faster response, higher temperature, and longer life than any other heater of this type on the market today.

A

EPOXY SEAL

2 FT. LEADS

3/8" NPT

1/2"

1/2"DIA.

5/8"

5/16"

7/8"

1-3/8" 7/8"

Part Number Watts Volts A Min Flow @

120V

001-10209 450 120 7-3/8” 50 SCFH

001-10210 600 120 7-3/8” 75 SCFH

001-10211 800 120 8-3/8” 110 SCFH

001-10212 1000 120 8-3/8” 130 SCFH

001-10213 1250 120 8-3/8” 180 SCFH

Features: • Air temperatures up to 1400°F • Flow rates up to 400 SCFH • Long life • Fast response • Choice of five wattages up to 1250 watts

Construction: • 1/2” diameter 304 stainless steel body • Copper tee with 3/8” NPT air connection • Epoxy sealed 2 Ft. leads • High temperature ferrous alloy element


6

001-10209450W/120V50 SCFH MIN @ 120V

175

150

125

75

100

50

25

00 100 200 300 400 500

WATTS57 80 98 114

VOLTS

FLO

W (S

CFH

)

1200°F

1000°F

800°F

600°F

120

FLO

W (S

CFH

)

600°F

800°F

1000°F

1200°F

250

300

200

150

100

50

00 100 200 300 400 500

WATTS

600W/120V001-10210

75 SCFH MIN @ 120V

VOLTS50 70 86 99 111 120

600

FLO

W (S

CFH

)

300

200

100

150

250

50

00 200 400 600 800 1000

110 SCFH MIN @ 120V

001-10211800W/120V

1400°F

1200°F

1000°F

800°F600°F

60 86 105 120WATTS

VOLTS

WATTS

VOLTS

300

250

200

150

100

50

0

001-102121000W/120V130 SCFH MIN @ 120V

0 200 400 600 800 1000 1200 1400

54 76 93 108 120

800°F

1200°F

1000°F

600°F

1400°F

FLO

W (S

CFH

)

001-102131250W/120V180 SCFH MIN @ 120V

400

300

200

100

FLO

W (S

CFH

)

00 200 600 800 1000 1200 1400400

48 68 83 96 107 120

WATTS

VOLTS

1400°F

1200°F

1000°F800°F600°F

Flameless Electric Air Heaters:Performance Characteristics of Metal Shell Air Heaters

Part # 001-10213

Part # 001-10211

Part # 001-10209

Part # 001-10212

Part # 001-10210

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Exchanger HousingsTriple pass air flow forimproved efficiency anda cool outer shell

Part Number Type A B C D E

003-10026 10” HOUSING 1-1/2” 9” 10” 11/16” 3/8” NPT

003-10027 13” HOUSING 2-1/8” 11-7/8” 12-7/8” 1-3/8” 3/4” NPT

Flameless Electric Air Heaters:Triple Pass Housings/Elements

A

BC

D (O.D.)

SCREEN

A (O.D.)

E

Heater Elements for Exchanger Housings

Dimensions Wattage at Standard Voltages

Part Number Type A B 60V 120V 240V

10” HOUSING

003-10028 2000W 8-3/16” 5/8” 125 500 2000

003-10029 2800W 8-3/16” 5/8” 175 700 2800

003-10030 3600W 8-3/16” 5/8” 225 900 3600

003-10141 3600W 8-3/16” 5/8” 225 900 3600

003-10193 4600W 8-3/16” 5/8” 290 1150 4600

13” HOUSING

003-10031 5000W 10-3/4” 1-1/4” 312 1250 5000

003-10032 6000W 10-3/4” 1-1/4” 375 1500 6000

003-10072 8000W 10-3/4” 1-1/4” 500 2000 8000

003-10140 6500W 10-3/4” 1-1/4” 405 1625 6500

A

B (O.D.)

Standard WattageTolerances +5%/ -10%

* Heater Elements sold separately


8

Flameless Electric Air Heaters:Performance Characteristics of Triple Pass Heater Elements

Performance Characteristics: Select the heater that matches your application (See detailed curves in technical section (T) of catalog)

0

5

10050 150 200 250 300

30

10

15

20

25

1150°F

1003

2

1003

1

1150°F

0 50

200

100

400

300

600

500

1002

8

100 150 200 250 300

1450°F

1003

0

1002

9

1400°F

1450°F

Recommended Element TemperatureAbove Recommended Element TemperatureMaximum Recommended Flow

VOLTS

VOLTS

VOLTS

VOLTS

VOLTS

VOLTS

FLO

W (S

CFH

)FL

OW

(SC

FH)

FLO

W (S

CFH

)

FLO

W (S

CFH

)FL

OW

(SC

FH)

FLO

W (S

CFH

)

0 50 100 150 200 2503

6

9

12

15

VOLTS

FLO

W (

SCFM

)

003-10072 (240v-8kW)

800°

F

1 PSI

5.5 PSI

2 PSI

3 PSI

1000

°F12

00°F

1300

°F

50 100 150 200 2503

6

9

12

15

VOLTS

FLO

W (

SCFM

)

003-10140 (240v-6.5kW)

800°

F

1 PSI

6 PSI

2 PSI

3 PSI

1000

°F12

00°F

1300

°F

0 50 100 150 200 250100

200

300

400

500

VOLTS

FLO

W (

SCFH

)

003-10193 (240v-4.6kW)

800°

F

1000

°F12

00°F

1300

°F

1 PSI

3 PSI

5 PSI

10 PSI

50 100 150 200 250 300

100

200

300

400

500

VOLTS

FLO

W (

SCFH

)

003-10141 (240v-3.6kW)80

0°F

1000

°F12

00°F

1300

°F

1 PSI

3 PSI

8 PSI

13 PSI

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Flameless Electric Air Heaters:High Volume Metal Shell Air Heaters

Performance Characteristics:

Part # 003-10107This fast responding heater delivers up to 1300°F air through a protective metal shell. The larger geometry allows for a greater volume of air to be heated than in previous designs. This stand alone design can be run without a housing making it an economical choice andperfect for smaller scale applications.

11 1/4"

1.0" REF. Ø1.375"

1/2 NPT THREADON HEATER INLET

2 1/4"

CONVECTRONICS 003-10107 240V-6000W

Ø1.250" SHELL O.D.

24" REF. LONG, 10 GAFIBERGLASS LEADS

Features: • Air Temperatures up to 1300°F • Stand Alone Design • Fast Response • Economical

A • Flameless Electric Air Heaters 10

Flameless Electric Air Heaters:Triple Pass Accessories

Pressure Switch FOR 10” EXCHANGER (NOT SHOWN) -ORDER SWITCH #004-10033Adjustable: 0-30 psi Proof: 45 psi

FOR 13” EXCHANGER (SHOWN) -ORDER SWITCH #004-10034Adjustable: 0-2.9 psi Proof: 5 psi

RELAY #004-10035Required for loads 15-25 amps

Thermocouple AssemblyStraight Opening

Exchanger A B Part Number including ‘K’ Thermocouple

10” 3/4” 1-1/2” 004-10036

13” 1-1/2” 1-1/2” 004-10038

‘K’ THERMOCOUPLE PROBE ONLY - #004-10037

FlareExchanger A B C D Part

Number

10” Flare Only 3/4” 3” 2-1/2” 3/32” 004-10044

10” Flare & TC Port 3/4” 3” 2-1/2” 3/32” 004-10045

13” Flare Only 1-1/2” 4-3/16” 4” 1/4” 004-10046

13” Flare & TC Port 1-1/2” 4-3/16” 4” 1/4” 004-10047

‘K’ THERMOCOUPLE PROBE ONLY - #004-10037

Exchanger Junction Box Assembly

Exchanger A B C D E F Part Number

10” 1-7/32” 4-3/8” 2-1/2” 3/8” 2-3/8” 4-3/8” 004-10042

13” 2-3/16” 4-11/16” 4-1/2” 3/4” 3-11/16” 4-11/16” 004-10043

C

A

B

D

A

B

SHIELDED LEAD2 FT. LG.

E

F

C

A

B

CORDCLAMP

D

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Flameless Electric Air Heaters:Triple Pass Flanged Housings/Elements

Features: • Gasket flanged inlet for strong air-tight seal • Pipe thread connections at both inlet and outlet ends for in-line applications

H

G

E

DBC

A

F

HOUSING

ELEMENT

Housing Part Number A B C D E F G H Element Part

Number Watts Volts

003-10181 11-3/16” 8-11/16” 1/2” 1/4” 1-1/2” 1/2” NPT 3/8” NPT 2-1/2” 003-10028 2000 240

003-10029 2800 240

003-10030 3600 240

003-10182 14-3/16” 11-7/16” 3/4” 1/4” 2-1/8” 1-1/4” NPT 3/4” NPT 4” 003-10031 5000 240

003-10032 6000 240

003-10072 8000 240

Plus the Standard Features of Style 003: • Triple pass heat exchanger housing which maximizes heat transfer efficiency while maintaining cool outer shell • Replaceable elements with choice of wattages See performance curves on page A12

* See page A7 for element dimensions



HEA

TER

LIF

E (H

OU

RS)

ELEMENT TEMPERATURE (°F)1900 2000 2100 2200

1000

2000

3000

4000

5000

Flameless Electric Air Heaters:Performance Characteristics of Triple Pass Heaters

150

300

450

600

750

AIR

FLO

W (S

CFH

)

ABOVE 1950°FELEMENT TEMP.

PT #003-10028(2000W/240V)BROKEN LINE =

300°F 600°F 900°F

1200°F

1400°F

0

0

500 1000 1500 2000 2500 3000

120 170 208 240 268 294POWER (WATTS)

VOLTS

0 1000 2000 3000 4000

150

300

450

600

750 300°F 600°F 900°F

1200°F

AIR

FLO

W (S

CFH

)

0 140

POWER (WATTS)

200VOLTS

245 283

1500°F


BROKEN LINE = (2800W/240V)PT #003-10029

150

300

450

600

750 300°F 600°F 900°F

1200°F

1500°F

1000 2000 3000 4000POWER (WATTS)

126 179 219 2530

0

VOLTS

AIR

FLO

W (S

CFH

)

PT #003-10030(3600W/240V)BROKEN LINE = ABOVE 1950°FELEMENT TEMP.

600°F400°F 800°F 1000°F

1200°F

PT #003-10031

BROKEN LINE = (5000W/240V)

ELEMENT TEMP.ABOVE 1950°F

0 1000 2000 3000 4000 5000 6000POWER (WATTS)

1521070VOLTS

215186 263240 284

7000

AIR

FLO

W (S

CFM

)

5

10

15

20

25

30

400°F 600°F 800°F 1000°F 1200°F


(6000W/240V)PT #003-10032

BROKEN LINE =

0 1000 2000

13898

60003000 50004000POWER (WATTS)

195VOLTS

169 218

7000

240 2580

25

5

10

15

20

30

AIR

FLO

W (S

CFM

)

Part # 003-10028

Part # 003-10029

Part # 003-10030

Part # 003-10031

Part # 003-10032

Part # 003-10072

0 50 100 150 200 2503

6

9

12

15

VOLTS

FLO

W (

SCFM

)

003-10072 (240v-8kW)

800°

F

1 PSI

5.5 PSI

2 PSI

3 PSI

1000

°F12

00°F

1300

°F

Heater Life vs. Element Temperature

(for all Heater Styles)

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Flameless Electric Air Heaters:Triple Pass Heaters: Three Element Housing

Part # 003-10268

Features: • Triple Pass Stainless Steel Housing • Replaceable Elements • Choice of Wattage • Can Be Wired Single or Three-Phase • Built-In Thermocouple Port • Flow Rates Up To 50 SCFM

12 1/2" 1 1/2"

1 3/4"

5/8"

3 1/4"

2 3/

4" D

IA

2 1/

2" D

IA

3/4" NPT AIR INLET

2 FT. FLEXIBLESILICONE CABLE

COMPRESSION FITTING FOR 3/16" OD THERMOCOUPLE

The triple pass housing causes the air to be preheated prior to flowing through the elements resulting in a more efficient heater. The outer shell remains cool to the touch, making this product user friendly.

The elements can be replaced by removing the Rear Adaptor (2 screws), sliding the electrical leads off the Element Terminal Pins, removing the Element Retaining Screw, and sliding the three elements out of the housing. New elements are then installed by reversing the above sequence.

There are three different wattage elements that fit this housing:

Part # 003-10028 (3) 2,000 Watts/Element 240V 6,000 Watts TotalPart # 003-10029 (3) 2,800 Watts/Element 240V 8,400 Watts TotalPart # 003-10030 (3) 3,600 Watts/Element 240V 10,800 Watts Total

The element connections are brought out of the housing through a six conductor (Plus Ground) flexible cable. Each conductor is numbered and color coded so that they can easily be connected single or three-phase externally. The silicone jacketed cable is rated at 500 volts and 180°C.

The housing comes complete with a thermocouple port (3/16” Dia. compression fitting) and a plug if a thermocouple is not used. When using a thermocouple be sure to insert it to a depth that will center the junction over one of the elements. Use thermocouple #004-10037 (“K” type with 2 Ft. armor)

Refer to pages A22-A24 of our catalog for power control of these heaters.



Flameless Electric Air Heaters:Air Flow Characteristics of Triple Pass Heaters

1200°F

900°F

600°F

300°F

AIR

FLO

W (S

CFM

)

POWER (KW)

VOLTS

50

40

30

20

10

01 2 3 4 5 6

98 139 170 196 219 240

1200°F

300°F 500°F

900°F

1300°F

54321 6 7 8 90

10

20

30

40

50

POWER (KW)

18583VOLTS

117 143 165 202

AIR

FLO

W (S

CFM

)

219 234

600°F 900°F

1200°F

1300°F

300°F

0

10

20

30

40

50

AIR

FLO

W (S

CFM

)

1 2 3 4 5 6 7 8 9 10 11

16373 127103 146 179 193 207 231219 240

POWER (KW)

VOLTS

0

Air flow rates up to 50 SCFM can be used with this housing, however, a regenerative blower should not be used as the back pressure is too high. The compressed air used should be filtered and regulated. Refer to the included performance curves for each wattage.

Part Number#003-10028(3 ea.) - 2KW Elements

Part Number #003-10029(3 ea.) - 2.8KW Elements

Part # 003-10030 (3 ea.) - 3.6KW Elements

NOTE:Broken line sections of curves indicate Reduced Heater Life Area. The filament temperature is above 1950°F. Refer to the Heater Life Curve in the technical information section (T) of our catalog.

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Single ElementBoth Connections Same End

Part Number

Wattage at Standard Voltages

A B C 120V 230V

005-10048 1-1/2” 5-1/2” 2” 400 1450

005-10049 1-1/2” 5-1/2” 2” 750 2700*

005-10050 1-1/2” 8-1/4” 2” 600 2150

005-10051 1-1/2” 8-1/4” 2” 1150 4250*

Single ElementConnections at Opposite Ends

Part Number


A B C 120V 230V

005-10052 1-1/2” 5-1/2” 2” 400 1450

005-10053 1-1/2” 5-1/2” 2” 750 2700*

005-10054 1-1/2” 8-1/4” 2” 600 2150

005-10055 1-1/2” 8-1/4” 2” 1150 4250*

Dual ElementBoth ConnectionsSame EndSingle Wattage

Part Number


A B C 120V 230V

005-10056 1-1/2” 5-1/2” 3-3/4” 350 1350

005-10057 1-1/2” 8-1/4” 3-3/4” 600 2150

Dual ElementThreeConnectionsOne EndMultiple Wattages

(Both in Series or Both in Parallel)

Part Number


A B C 120V 230V

005-10058 1-1/2” 5-1/2” 3-3/4”Series

400 1350

005-10059 1-1/2” 5-1/2” 3-3/4”Parallel

1450 5350*

005-10060 1-1/2” 8-1/4” 3-3/4”Series

600 2150

005-10061 1-1/2” 8-1/4” 3-3/4”Parallel

2300 8550*

Flameless Electric Air Heaters:Open Coil Convection Heaters

CONVECTRONICS offers the same coil figuration used in the Styles 001 and 003 Air Heaters as a design concept for convection heating applications in ducts and plenium chambers. This construction is stronger, more efficient and has a longer life than other types of convection heating elements.

These elements are available mounted on frames as shown or as elements alone for those who use their own frames. Other designs and wattages are available upon request. Please let us know what your requirements are if the designs shown do not fit your needs.

A B

C

A B

C

*All elements may be run in still air except for those marked with (*), which require moving air for 230V operation.


Flameless Electric Air Heaters:Open Coil Convection Heaters

A B

C

A B

C

0"

1 1/2"

7 /32"DIA

TYP.4 1/4"3 3/4" 5 1/2"

0"

1 1/4" 1 3/4"

3/8"

1 1/8"

3/8"

1 1/8"

1 1/2"

0"

8 1/4"6 5/8" 5 5/8"2 5/8"1 5/8"0"7 /32"DIA

TYP.

Base Mount Layouts for Convection Heaters

Part Numbers

Single Element: 005-10048 Dual Element: 005-10056

005-10049 005-10058

005-10052 005-10059

005-10053

Part Numbers

Single Element: 005-10050 Dual Element: 005-10057

005-10051 005-10060

005-10054 005-10061

005-10055

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Flameless Electric Air Heaters:In-Line Pipe Heaters

The Style 007 Fluid Heater uses the same element configuration as the Styles 001 and 003 but in a stainless steel pipe. This construction is suited to in-line applications where pipe threads are required at both inlet and outlet ends. Electrical terminations are offered in the form of lead wires and as feedthrus rated up to 150 psi. These heaters can be used to heat substances other than air as long as the fluid is non-conductive and does not chemically react with 300 series stainless steel, silver solder, nickel, aluminum oxide or the epoxy potting material used on the leaded model. This product must be properly grounded and fused.

PerformanceCharacteristics: Heating AirSelect the heater that matches your application

0

100

200

300

400

40 80 120 160 200 240VOLTS

FLO

W (S

CFH

)

007-10133/007-10134

600°F800°F

1000°F

1200°F

1400°F

007-10135/007-10136

040 80

FLO

W (S

CFH

)

200

400

600

800

160VOLTS

120 200 240

007-10137/007-10138

040 80

FLO

W (S

CFH

)

400

800

1200

1600

160VOLTS

120 200 240

600°F800°F

1200°F

1000°F

600°F

800°F1000°F

10 5/8" REF.1"

3/8" NPT(2) PLACES

#10-32 THD(2) PLACES

4 1/2"

7/8"DIA

3/8" NPT

2" REF8 3/4"

3/8" NPTMALE

3/8"NPTFEMALE

3/8"NPTMALE

#16 AWG 12" LG.

1 5/16" REF.

15/16"

REF.

3/8” Pipe

Part # 007-10133 Terminations - FeedthrusRating - 800W 120V

Part # 007-10134Terminations - LeadsRating - 800W 120V


Flameless Electric Air Heaters:In-Line Pipe Heaters

½” Pipe

Part # 007-10135Terminations - FeedthrusRating - 4000W 220V



9" REF.1"

1/2"NPT(2) PLACES


4 1/2"

3 1/8" REF.

2 1/4" REF7 3/8"

1/2"NPTMALE

1/2"NPTFEMALE

1/2"NPTMALE

#14 AWG 12" LG.

1 1/4"11" REF.

1 1/4"NPT MALE(2) PLACES


5"

1/2"

1 1/4"NPT FEMALE

1 1/4"NPT MALE(2) PLACES

1/2"NPT MALE

#10 AWG 12"LG.

2"DIA9 5/16"12 5/16" REF.

1 ¼” Pipe

Part # 007-10137Terminations - FeedthrusRating - 6000W 220V

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Flameless Electric Air Heaters:High Volume In-Line Pipe Heaters

This heater is intended for heating air at high flow rates (up to 60 SCFM) to 1000°F maximum and features threaded inlet and outlet connections.

Part # 007-10197

Features: • High volume flow – 60 SCFM (Pressure drop across heater is approximately 1.5 psi) • Temperature – 1000°F maximum at outlet • Power required – 18 KW at 240 volts 3 phase

Performance Characteristics:A high volume air source (such as a regenerative blower) is connected to the 2-1/2” NPT inlet and a variable voltage source is connected to the elements via the junction box.

600°F 800°F

1000°F

0 5 10 15 200

POWER (KILOWATTS)

10

20

30

40

50

60

70

AIR

FLO

W (S

CFM

)

0 125 178 218 252VOLTS

2-1/2" NPT

3/4" NPT

3-7/8"

1"

12"

2-7/8"

3-1/8"

Construction: • Heater element – High temperature ferrous alloy • Heater shell – 2-1/2” NPT type 304 stainless steel • Junction box – Cast aluminum box – ¾” hub


Flameless Electric Air Heaters:High Volume In-Line Pipe Heater Accessories

Part # 007-10202 Thermocouple Assembly including a 2-1/2” NPT coupling, compression fitting and armored 2 Ft. ‘K’ T/C.

3/16" TUBECOMPRESSION

FITTING

2-1/2" NPT FEMALE NIPPLE

SPLIT LEADSSPADE LUGS

2-1/8"

2"

2" REF. 24" 4"

1 THERMAL ELEMENTS ANSI TYPE "K"

THERMOCOUPLE JUNCTIONEXPOSED BEAD

3/16"DIA

FLEXIBLE 1/4" ARMOR

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Flameless Electric Air Heaters:Regenerative Blower

3.4858.12059.0229

.38

1.538.9

6.0152

3.889

11.1282

12.9327

6.1156

11.0280

11.5291

8.383

3.999

ROTATIONDIRECTION

1 1/4-11 1/2 NPSCBOTH PORTS

(4) MTG HOLES

IN OU

T

.410

DIA

AIR

PR

ESSU

RE-

PSIG

AIR FLOW (SCFM)15 30 45 60 75 90

0.5

1.0

1.5

2.0

Part Number # 009-10252(For use with 003-10027 Housing Only)

CONVECTRONICS’ REGENERATIVE BLOWER can be used as the air source for the 003-10027 Housing (13”), as the maximum pressure is 1.5 psi under normal conditions. All the other heater types operate at higher pressures and can not be used with this blower.

The amount of air flow to the heater should be adjusted by venting some of the blower output into the room by means of a gate valve connected off a tee at the blower outlet.

Never throttle unwanted blower air. Dumping and bleeding air is recommended so that the blower is not over-pressured and overheated.

Use the shortest length and largest diameter piping practical to minimize friction losses and pressure drop. Excessive losses will cause motor overheating and reduced air flow.

Specifications: • ¾ Horsepower • 115/230 Volt Single Phase • Max. Flow - 84 SCFM • Max. Pressure - 1.8 psi • Weight – 52 Lbs.

Accessories: • 009-10253 Pressure Gauge (0 - 2 psi) • 009-10254 Input Filter (Recommended in dusty areas)


Flameless Electric Air Heaters:Power Control Module

Part # 006-10062 The Power Control Module offers infinitely variable phase control when used with resistive loads up to 25 amps. The solid state circuitry provides modified transient suppression, exceptional stability and life. An external potentiometer/switch (dial plate and knob included) is used to control output voltage. A trimming potentiometer is mounted on top of the module to adjust turn on voltage level. This device should be installed in a circuit fused at 120% rated load or 30 amps maximum.

Part Number # 006-10139Heat Sink

Recommended for load currents exceeding 15 amps(see ambient temperaturevs. current curves shown above)

Input voltage: 110-277 volts, single phase, 60 Hz.Output voltage: Adjustable from 17% to 99% of applied voltageCurrent rating: 25 amps maximum (see ambient temperature vs. current curve)Power consumption: (maximum): 50 watts Maximum temp: 75°C Measured at center of base plate

MA

XIM

UM

AM

BIE

NT

TEM

P (°

C)

2520151050CURRENT (AMPS)

0

10

20

30

40

50

60

70

80WITH EXTRAHEAT SINK SHOWN BELOW

WITHOUT EXTRAHEAT SINK

3 1/2"

1 5/

8"2 1/

8"

7/16"

1 1/

4"

2 1/

2"

WHITE

ORANGERED

.201 DIA. HOLES(2 PLACES)

2 5/8"

6 3/4"

9 1/

4"

2 3/4"

3/4" 1/2"

3 1/2"

0.41 DIA - 4 HOLES EQUALLYSPACED ON 8 1/2" DIA B.C.

8-32 UNC x 1/2DEEP(2 PLACES)

3.58

"

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Flameless Electric Air Heaters:S.C.R. Power Controls

The single-phase, 60 amp and the three-phase 30 amp S.C.R.’s could be used with heater style 003-10268. The three-phase 60 amp S.C.R. could be used with the heater style 007-10197.

For closed loop control we offer a precision PID temperature controller with self-tuning. This unit is in a 1/16th DIN size set up with a 4-20mA output, ‘K’ thermocouple input and an alarm. The part number is 006-10273 (See page A24).

These controls provide phase angle proportional control of our fast responding heaters. They are available in single and three-phase 240-volt configurations. Each unit comes complete with I2T Rectifier Fuses and a Voltage Limiting Adjustment.

The controls can be operated manually with the addition of the optional Manual Voltage Control, which allows one to vary voltage from zero to full voltage.

The S.C.R power control can be used with a 4-20mA temperature controller for closed loop operation.

The S.C.R power controls are also available in NEMA 1 Enclosures upon request.

RATING PART NUMBER DIMENSIONS MOUNTING

Single-Phase 60 amp, 240V 006-10269 10” x 9.3” x 5” 8” x 8”

Three-Phase 30 amp, 240V 006-10270 10” x 10” x 3.5” 8” x 8”

Three-Phase60 amp, 240V 006-10271 12” x 12” x 5.7” 10” x 10.8”

Manual VoltageControl 006-10272 3-1/8” x 1-1/2”

with 2 Ft. leads


Flameless Electric Air Heaters:Contactors and Controllers

Convectronics now offers a temperature controller and solid state contactor combination suited for control of its fast responding (low thermal mass) air heaters

CONTACTOR # 006-10290

• Input - 4-20mA DC

• Output - 25 amps Phase Angle Fired

• Supply Voltage - 120/240

• Voltage Limiting - Adjustable

35 - 95% of line input voltage

• Dimensions - 3.6” L x 3.5” W x 3” H

TEMPERATURE CONTROLLER #006-10273 (PID Autotuned)

• Supply Voltage - 120/240 Volts• Output - Configured to 4-20mA DC• Thermocouple - Configured for “K” type• Temperature Range - Configured for 32oF - 1500oF• Dimensions - 1/16 DIN (Requires 1.77” x 1.77” cut out)• Response - Very fast time proportioning

This combination of controller & contactor is recommended for use with all types of Convectronics Air Heaters

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Convectronics’ Tubular Electric Heaters, with their unique and durable construction, are extremely versatile as they can be formed into nearly any configuration. With the broad selection of materials and terminations, combined with a wide range of ratings and sizes, Convectronics’ Tubular Electric Heaters are extremely adaptable to a wide range of industrial, scientific, and commercial applications.

Our heater design consists of a helical coil of nickel-chromium resistance wire that is precisely centered in a metal sheath. Vibration loaded magnesium oxide powder is added into the sheath, insuring even density distribution throughout its length. The entire assembly is then reduced to its finished diameter, therefore compacting the MgO, ensuring that the coil maintains its precise centering in the heater. Lastly, the sheath can be fully annealed for factory or field bending.

HEATED LENGTH

SHEATH LENGTH

CERAMICINSULATOR

STANDARDTERMINAL

TERMINAL PIN MgO INSULATION METALSHEATH

"A" GRADE RESISTANCE ALLOY

Sheath MaterialSheath material selection should be made based on the chemical composition of the solution being heated, the classification of the materials entering the solution, the application and the process controls used. Common sheath materials used are:

Incoloy®800: Resistant to high temperature oxidation and carburizationCommon Uses: Air Heating, Radiant Heating, Cleaning & Degreasing Solutions, Plating Solutions & Corrosive LiquidsStainless Steel: Types 304, 316 and 321Common Uses: Food Processing Equipment & Corrosive Liquids Steel: Low carbon, mid-range temperature applicationsCommon Uses: Oil Immersion, Alkaline Cleaning Solutions, Asphalt & TarCopper: Inexpensive alternative for low temperature applicationsCommon Uses: Water Heating & Freeze Protection

Sheath Material Maximum Sheath Temp.

Maximum Watts per sq. inch

Incoloy®800 1600°F/870°C 40

Stainless Steel 1200°F/650°C 30

Steel 750°F/400°C 22

Copper 350°F/175°C 55

Electrical Limits

Sheath Diameter .250” .312” .375” .430”

Minimum Ohms/inch .100 .060 .040 .040

Maximum Ohms/inch 17 21 21 21

Maximum Voltage 250 250 480 600

Maximum Amperes 15 30 30 40

Wattage Tolerance +5% -10% @ Rated Voltage

Resistance Tolerance +10% -5%

Sheath Diameters.250” .312” .375” .430”

Max. Sheath Length @ given Diameter 128” 118” 118” 110”

Sheath Length Tolerance +/- 1/8”

Tubular Heater Products:Tubular Electric Heaters

B • Tubular Heater Products 2

EW

L

A

B

DIA

C

D

Sheath Diameter

Bushing Thread Size

Hex Dimension A

.250” 1/2-20 3/4 1”

.312” 1/2-20 3/4 1”

.375” 5/8-1/8 1 1”

.430” 3/4-16 1 1”

A threaded bushing is brazed or welded to the sheath to provide quick, rigid, liquid or air-tight mounting through tank walls, oven walls, etc.

• Available in Brass or Stainless Steel• All bushings furnished with plated washer, compressed non-asbestos gasket and jam nut• Hex head bushings are standard• Specify location from end of sheath

Locator rings are permanently attached to the heater sheath and are used to limit the movement of the heater while allowing for expansion and contraction of the heater sheath. When ordering, please specify the location from the end of the sheath.

The 16 gauge stainless steel mounting bracket is an economical way to mount the heater in non-pressurized, non-liquid applications. Unless otherwise specified the brackets will be located 1/2” (13 mm) from the edge of the heater sheath.

Bushings

Locator Rings

Mounting Brackets

*All letter designated dimensions must be supplied by the customer.

Tubular Heater Products:Mounting Methods - Tubular Electric Heaters

A

GASKET WASHER

3/16"

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Figure B1

Figure B2

Figure B3

Figure B4

Figure B5

Figure B6

15/16"

1/4"

1/4"

11/16"

9/16"

FIBERGLASS SLEEVING

Standard Thread.250 Dia #6-32

.312 Dia #6-32

.375 Dia #8-32

.430 Dia #10-32

Stainless Steel threaded stud terminal with ceramic insulator. Standard terminal configuration*

Flag terminal - projection weldedAvailable in both #8-32 and #10-32.

Flag terminal - side projection weldedAvailable in both #8-32 and #10-32.

Quick-connect - projection welded

Quick-connect - projection welded

Lead wire. Please specify length.(12” standard w/ 2” standard sleeve)

*Stainless Steel terminalsOther thread sizes and thread lengths are available to accomodate your requirements.

*Hermetic Seals available upon request.

Tubular Heater Products:Terminations - Tubular Electric Heaters

1"

9/16"

9/16"

BINDING HEAD SCREW#8-32 OR #10-32

1 3/16"

#8-32 or #10-32 BINDING HEAD SCREW


BF2

BF4

BF6

BF1

BF3

BF5

E

Ø

R

B

SL=2B+1.14R-.43ØE=2R+Ø

Tubular Electric Heaters can be formed into a multitude of different shapes. Figures BF1 through BF28 are typical of some common designs. For orders or custom design requirements, please specify the dimensions for the figures shown or provide a drawing or sample of the desired shape.

• SL = Sheath Length• Bends are repressed as required• Minimum bend radius is equal to the element diameter

Tubular Heater Products:Forming - Tubular Electric Heaters

R

ER

SL=.0175 (2R +Ø)+1.14R-.43ØE=2R+Ø

1

1

Ø

C

B

R

R

Ø

E

SL=2C-.86R -2.86Ø+2B+1.14RE=2R+Ø

1

1

B

R

R E

SL=2B+2.28R2 -1.29Ø+2F+1.14R1

E=2R +Ø

F

1

2

1

Ø

R

B

C

E

R

R

RG

F

SL=2C-.86R -3.72Ø+2B+2F+2.28R+1.14RG=E+Ø

1

2

2 1

Ø

B

F

G R

R

R

E

SL=2B+2.28R-1.29Ø+2F+1.14RG=E+Ø

1

1

Ø

SL=2B+1.14R-.43ØE=2R+Ø

SL=2B+2.28R2 -1.29Ø+2F+1.14R1

E=2R1+ØSL=.0175 (2R1+Ø)+1.14R-.43Ø

E=2R+Ø

SL=2C-.86R1-2.86Ø+2B+1.14RE=2R+Ø

SL=2C-.86R2-3.72Ø+2B+2F+2.28R+1.14R1

G=E+ØSL=2B+2.28R-1.29Ø+2F+1.14R1

G=E+Ø

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BF7 BF8

BF10

BF12

BF14

BF9

BF11

BF13


E

J

C

BF

H

R

R

R

R

R

SL=2C+2B+2F-6.717Ø-1.717R-E-.858R -.858R

1

2

2

1

Ø

2

E

R

R

RF

G

CA

B

R

R

G=4R+2R +4ØSL=2C-1.72R -6.15Ø+2A+2B+2F+2.28R+1.14R

Ø 2

2

1

2

1

1

C

A

G

B

F

E

R

R

R R

R

SL=2C+2B+2F+6.28R+3.14R -1.15Ø-1.72R -EG=4R+2R +4Ø

Ø

1

2

2

1

1

2

X

R

R

R

R

R

F

G

B

E

Ø

G=2RX+2R(X1-1)+2ØXSL=2B+.43Ø(1-2X)+2F(X-1)+1.14R (X-1)

X=NUMBER OF OUTSIDE BENDS

1

1

1

RRR

G

B

J A

E

R RR

RR

C

X

F

X=NUMBER OF OUTSIDE BENDSSL=2J+2B+2C+2A-.86R -6.86Ø-1.72R +2F(X-1)+1.14R (X-1)+1.14XR-.86XØ

G=2RX+2R (X-1)+2ØX

Ø

2

2

3

1 1

1

3 2 1

E

EØ

F

B

R

SL=2B+3.42R-1.29Ø+2F

C

A

G

E

R

R

RØ

SL=2G+2C-E+2.28R-.86R -3.29Ø

1

1

E

B

G

HF

A

C

R

R

RR

R

R

X

SL=2B-1.72R +3.14RX+3.14R (X-1)+2F(X-1)-E+1.14ØX-1.42ØX=NUMBER OF OUTSIDE BENDS

G=2RX+2R (X-1)+2ØX

RØ

22

1

1

1

2 1

SL=2G+2C-E+2.28R-.86R1-3.29Ø

X=NUMBER OF OUTSIDE BENDSSL=2J+2B+2C+2A-.86R3-6.86Ø-1.72R2+2F(X-1)+1.14R1(X-1)+1.14XR-.86XØ

G=2RX+2R1(X-1)+2ØX

X=NUMBER OF OUTSIDE BENDSSL=2B-1.72R2+3.14RX+3.14R1 (X-1)+2F(X-1)-E+1.14ØX-1.42Ø

G=2RX+2R1 (X-1)+2ØX

SL=2B+3.42R-1.29Ø+2F

SL=2C-1.72R2-6.15Ø+2A+2B+2F+2.28R+1.14R1

G=4R+2R1+4Ø

SL=2C+2B+2F+6.28R+3.14R1-1.15Ø-1.72R2-EG=4R+2R1+4Ø

X=NUMBER OF OUTSIDE BENDSSL=2B+.43Ø(1-2X)+2F(X-1)+1.14R1 (X-1)

G=2RX+2R(X1-1)+2ØX

SL=2C+2B+2F-6.717Ø-1.717R-E-.858R1-.858R2


BF16 BF15

BF18

BF20

BF22

BF17

BF19

BF21

SL=.0175 (R+.5Ø)

RØ


R

ØD E

R

B

C

SL=3.14D+1.14R+2C-3.71Ø-E

SL=3.14D+1.14R+2A+1.14R +2C+3.28Ø-E

1

1

Ø

D

AR

E

RC

B

D

Ø

C

E

R

SL=3.14D+1.14R+2C+3.28Ø-E

Ø

R

E

B

SL=2B-.86R-1.43Ø+E

ER

C

B

ARR

Ø

SL=2A+2B+2C+E-6.29Ø-.86R-.86R -.86R

1 2

1 2

B

ER

Ø

R

C

SL=2C-.86R -3.86Ø+2B-.86R+E

1

1

C

L

FB

MG

M

Ø

E

R

R

R

G=2M+L-2ØSL=2C+4M+2L+2B+2F-E-2.58R-.86R -12.15Ø

1

2

1

SL=.0175 (R+.5Ø) SL=3.14D+1.14R+2C-3.71Ø-E

SL=3.14D+1.14R+2A+1.14R1+2C+3.28Ø-E SL=3.14D+1.14R+2C+3.28Ø-E

SL=2B-.86R-1.43Ø+E SL=2C-.86R1-3.86Ø+2B-.86R+E

SL=2A+2B+2C+E-6.29Ø-.86R-.86R1-.86R2

SL=2C+4M+2L+2B+2F-E-2.58R-.86R1-12.15ØG=2M+L-2Ø

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BF23 BF24

BF26

BF28

BF25

BF27

SL=2C+2G+2B-E-1.72R-.86R -6.29Ø

A=

G

R

R

A

B

E

Ø

C

Ø

(G-(E-Ø))2

1

1

Ø

R

NC K

D

SL=((D+Ø)(3.14)(NUMBER OF 360° TURNS))+C+C1

1C

All Convectronics’ Tubular Heating Elements have the MgO insulation compacted by reducing the element diameter. The elements are then annealed in a furnace to relieve the metal stressing (work hardening) that takes place during the roll reduction of the sheath. Annealing brings the metal back to a soft state, allowing the element to be bent into virtually any configuration. However, forming also work hardens the metal so some precautions must be observed in order to prevent the sheath from breaking during bending or developing stress crack marks.Note: Elements with tight bends and some applications require the bends to be recompacted in special dies to re-store the insulation density and maintain dielectric strength.


SL=2C+2G+2B+2A-E-1.72R-.86R -.86R -8.72Ø

1

2

1 2

B

R

G

Ø

R

A E

R

C

J

G

R

B

Ø R

E

C

A

SL=2C+2G+2B-E-1.72R-.86R -6.29Ø1

1

SL=((D+Ø)(3.14)(NUMBER OF 360° TURNS))+2C

E

KC

Ø

D

SL=((D+Ø)(3.14)(NUMBER OF 360° TURNS))+(D/2)+B+C

C

BK

E

R

Ø

D

END OF HEATED SECTIONCANNOT BE LOCATEDIN BEND SECTIONS.

LEAVE 1" MINIMUM STRAIGHTSECTION AT TERMINAL END.

BEND SECTION

SL=((D+Ø)(3.14)(NUMBER OF 360° TURNS))+C+C1

SL=((D+Ø)(3.14)(NUMBER OF 360° TURNS))+2CSL=2C+2G+2B-E-1.72R-.86R1-6.29Ø

SL=2C+2G+2B+2A-E-1.72R-.86R1-.86R2-8.72Ø

SL=((D+Ø)(3.14)(NUMBER OF 360° TURNS))+(D/2)+B+C

SL=2C+2G+2B-E-1.72R-.86R1-6.29ØA= (G-(E-Ø))

2


Let our experienced and knowledgeable staff assist you with Custom Engineering,

Design and Implementation of your toughest applications!

Call Toll Free1-800-633-0166

Contact CONVECTRONICS for your custom design projects.

Tubular Heater Products:Custom Design - Tubular Electric Heaters

Custom Formed Tubular Heater Designs

Radiant Process Heaters

Tubular Heaters for Hot Runner Manifolds

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APPLICATIONS

Ideal for applications where high velocity air is not practical, such as:• Resin Curing• Plastics Processing• Food Processing• Ink Drying• Paper Products Manufacture• Ceramic Drying• Fabric Manufacture

CONSTRUCTION

• Rigid extruded aluminum housing

• Incoloy®800 sheathed tubular element (maximum sheath temp - 1500°F)

• Polished aluminum reflector

• Adjustable mounting bolts (3/8” Dia)

• 1/2” NPT tapped wiring holes

• Snap-on protective grill available

STANDARD RANGES

• Voltage: 120, 240 and 480 Volts

• Wattage: 800 to 7200 Watts

• Length: 24 to 86 Inches

• Contact CONVECTRONICS for custom wattages and lengths!!

Tubular Heater Products:Radiant Process Heater Assemblies

Series RH Radiant Heater Assemblies are metal sheathed Tubular Heaters mounted in an aluminum housing with a polished reflector. This package delivers infrared heat (2.5 - 3 micron range) to the surface being heated over a typical range of 500°F. The practical maximum temperature is 900°F.

Series RH Radiant Heater Assemblies

L"±1/4"

3 5/8"±1/16

2 1/4"± 1/16


Total Length* “L” (Inches) Volts Watts Housing/Element

Assembly #Replacement

Element #Replacement Reflector #

Single Element (RHS)

24 120 800 RHS 801 RE8120 RR24

24 240 800 RHS 802 RE8240 RR24

30 120 1100 RHS 1101 RE11120 RR30

30 240 1100 RHS 1102 RE11240 RR30

46 240 1800 RHS 1802 RE18240 RR46

46 480 1800 RHS 1804 RE18480 RR46

60 240 2500 RHS 2502 RE25240 RR60

60 480 2500 RHS 2504 RE25480 RR60

72 240 3000 RHS 3002 RE30240 RR72

72 480 3000 RHS 3004 RE30480 RR72

86 240 3600 RHS 3602 RE36240 RR86

86 480 3600 RHS 3604 RE36480 RR86

Double Element (RHD)

24 120 1600 RHD 1601 RE8120 RR24

24 240 1600 RHD 1602 RE8240 RR24

30 120 2200 RHD 2201 RE11120 RR30

30 240 2200 RHD 2202 RE11240 RR30

46 240 3600 RHD 3602 RE18240 RR46

46 480 3600 RHD 3604 RE18240 RR46

60 240 5000 RHD 5002 RE25240 RR60

60 480 5000 RHD 5004 RE25240 RR60

72 240 6000 RHD 6002 RE30240 RR72

72 480 6000 RHD 6004 RE30240 RR72

86 240 7200 RHD 7202 RE36240 RR86

86 480 7200 RHD 7204 RE36240 RR86*Heated length is 8” less than total length

Tubular Heater Products:Radiant Process Heater Assemblies

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• Translucent Quartz Tube for Fast Response

• Three Diameters Available (3/8”, 1/2”, 5/8”)

• Heated Lengths to 48 Inches

• Designed for Horizontal Use

• Two Mounting Methods Available

• Custom Designed

Quartz Infrared Radiant Heater EmissionWavelength vs Temperature 300° - 850°C (Useful Range)

Tubular Heater Products:Quartz Radiant Infrared Heaters

M4 THREADOTHER TERMINATIONS

3/8", 1/2", 5/8"

AVAILABLE

CERAMIC CAP

QUARTZ TUBING

COLD LENGTH1/4">

HEATED LENGTH48"

>

2 3 4 50

500

1000

WAVELENGTH

TEM

PER

ATU

RE

(°C

)

(MICRONS)

Features

B • Tubular Heater Products 12 Ceramic Cap:

with a #8 or M4 threaded terminal for electrical connection.

• 3/8” Heaters can run up to 45 watts/linear in.• 1/2” Heaters can run up to 60 watts/linear in.• 5/8” Heaters can run up to 90 watts/linear in.

Tubular Heater Products:Mounting Methods - Quartz Radiant Infrared Heaters

Aluminum Cap: .540 Dia by 5/8” long Aluminum cap is used on each end

Mounting Style 1

M4 OR #8 STUD

CERAMIC CAP

WITH NUTS

QUARTZ TUBING

MOUNT STYLE # 2

Mounting Style 2

Maximum Recommended Wattages

CERAMIC CAPALUMINUM CAP TO FITSPRING LOADED CLIPS

QUARTZ TUBING

MOUNT STYLE # 1

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We are confident that our products’ quality, performance and competitive prices will, indeed, meet the most stringent requirements of your temperature application.

CONVECTRONICS, Inc. has many years of temperature sensing, control knowledge and experience to offer. We invite inquiries on any temperature sensing or control problem whether in design or application. Our technical staff will be glad to assist you on a totally engineered system of controls, sensors, heaters and enclosures to your specifications.

If your needs are technical assistance or price and delivery, please do not hesitate to give

us a call toll free at:

1-800-633-0166

Temperature Sensors:Wide Range Thermometry

• Range: -450° F to 4200° F (Oxidizing, Reducing, Neutral Atmosphere)• Noble/Refractory Metal Sheaths

• Noble/ Refractory Metal Elements• RTD/Thermistor Assemblies• Base Metal T/C Assemblies

Spanning the Total Temperature Spectrum

CONVECTRONICS, Inc. manufacturingcapabilities cover the broad spectrumof temperature sensing and control. Wemanufacture custom and all standard designsensors in all thermocouple types and RTD’sincluding refractory and noble metals for “Just In Time Delivery.”

C • Temperature Sensors

2

Helpful Hints

Temperature Sensors:Constructing the Perfect Temperature Sensor

• Ceramic, Silicon Carbide, LT-1 metal ceramic, Cerite-II and Cerite-III protection tubes are all

somewhat subject to thermal shock, and all should be preheated prior to inserting into a high temperature process.

• Incinerator applications, because of the high temperatures and harmful high velocity gases normally experienced, require high temperature rated and gas tight protection tubes.

• Do not use Molybdenum or Tantalum sheathed thermocouples in oxidizing atmospheres. They will evaporate within minutes!

• Welded on NPT bushings must be a larger NPT size than the NPT size of the protection tube onto which the bushing is being welded.

• Recommended minimum sensor immersion length

is equal to 10 times the diameter of the sensor sheath or protection tube.

Constructing the perfect Temperature Sensor is a difficult task, but with some rational thinking, the assistance of material specification tables, process application guides, and a little luck, most applications can be matched with a temperature sensor that will provide good temperature measurement and a useful life.

Information contained here and in the Technical Information Section of this catalog

• Select your element wire gauge as follows: as large as possible for the longest element life or as small as possible for the fastest time response.

• Thermocouple elements used at temperatures higher than what is recommended for their wire gauge will have a drastically reduced useful life.

• Do not use unprotected type K elements around the presence of sulfur or with protection tubes that have not been degreased. Cutting oils contain sulfur and will cause the element to “green-rot” when exposed to elevated temperatures.

• Do not use platinum thermocouple elements in a metal protection tube without using an inner ceramic protection tube, as the metal will contaminate the platinum.

• Do not use open ended protection tubes with the

thermocouple exposed where the element would be exposed to a harmful process environment. For example, type J thermocouples exposed to moisture will allow the iron to rust and deteriorate very rapidly.

will provide you with basic operating principles, thermocouple material specifications, material tolerances, and recommended temperature limits. Also found in the these sections are protection tube material specifications, temperature limits and process application guides that are critical to your selection process. Materials are selected based on the process temperature range and the process environment in which the sensor will be used.

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Temperature Sensors:Thermocouple Junction Types

Grounded Junction

Exposed Junction

Ungrounded Junction

Junction Types:

Thermocouple wires are welded and insulation is sealed against liquid or gas penetration. This junction style provides the fastest possible response time but leaves the thermocouple wires unprotected against corrosive or mechanical damage.

The sheath and conductors are welded together forming a completely sealed integral junction. Recommended in the presence of liquids, moisture, gas or high pressure. The wire is protected from corrosive or erosive conditions. Response time with this style approaches that of the exposed junction.

On this type, the thermocouple junction is fully insulated from the welded sheath end. The ungrounded junction is excellent for applications where stray EMF’s would affect the reading and for frequent or rapid temperature cycling. Response time is longer than for the grounded junction.

In general the Grounded Junction offers the best compromise of performance and reliability. It is usually the best choice for general purpose measurements. If your leadwire will be shielded and attached to the sheath, select an Ungrounded Junction.

How do I select a Thermocouple Junction Type?

The Ungrounded Junction is also used to avoid ground loops between instruments, power supplies and the sensor. If you are unsure of the Junction Type you require, contact our staff of engineers who will be happy to assist you.


4

Temperature Sensors:General Operating Principles

Thermocouples

Resistance Temperature Detectors (RTDs)

Thermistors

Additional Requirements

Thermocouples are the most common, convenient and versatile devices used to measure temperature. They convert units of heat into useable engineering units that serve as input signals into process controllers and recorders.

A Thermocouple consists of a welded “hot” junction between two dissimilar metals - usually wires - and a reference junction at the opposite ends of the parent

The Resistance Temperature Detector (RTD) accurately senses heat with an excellent degree of repeatability and interchangeability of elements. The RTD is composed of certain metallic elements whose change in resistance is a function of temperature. In operation, a small excitation current is passed across the element and the voltage,

A Thermistor is an economical means of precisely sensing heat over a limited range of temperatures. A thermistor is a metal oxide whose change in resistance is an inverse function of the change in temperature. An excitation current is passed across the sensor and the voltage, which is proportional to the resistance, is measured and converted to units of heat calibration.

Other components usually essential in integrating the principles of Thermocouples, RTD’s, and Thermistor sensor into a functioning system may include: (1) A protection tube or sheath of a material suitable to protect the sensing element from the environment surrounding the point of measurement, (2) A connecting head and terminal block, or possibly a temperature transmitter,

All CONVECTRONICS’ temperature sensor products are designed and manufactured to applicable ISA standards with accuracy traceable to the National Institue of Standards and Technology (NIST).

American National Standard Institute (ANSI) nomenclature is used by CONVECTRONICS. Standard or Special Limits of Error contained in ANSI Circular MC 96.1 – 1982 can be specified by the customer when ordering CONVECTRONICS’ Thermocouple products.

(3) Leadwire of the correct material and insulation to connect the temperature sensor and the process instrumentation, and (4) Recording or controlling instrumentation and control devices to provide a continuous temperature history of the system and to provide constant or programmed temperature regulation.

Since thermistors usually have a large base resistance and a large change in resistance per unit of temperature change, lead wire length does not generally need to be compensated for. Thermistors can operate across a temperature range of -40° F (-40° C) to 300° F (150° C) by selecting the proper sensor and protective materials.

which is proportional to resistance, is then measured and converted to units of heat calibration. The RTD element is manufactured by winding a wire (wire wound elements) or plating a film (thin film elements) on a ceramic or glass core and hermetically sealing the element within a ceramic or glass capsule.

materials. Heating the “hot” junction in the working environment produces a temperature gradient which generates an EMF. The EMF appears across the free ends of the thermocouple wires, where it is measured and converted into units of heat calibration. Through selection of appropriate thermocouple wires and sheath components, thermocouples are suitable to be used in temperature ranges from -450° F (-184° C) to 4200° F (2315° C).

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5Plastics Thermocouples/RTD’s (Fixed and Adjustable)

See Pages: C13-16

Bayonet Fixed and Adjustable T/C’s and RTD’s are widely used in the plastics molding and die casting industries. These units come in the standard base metals (J, K, T and E) with the RTD styles in standard platinum element with a 3.85 a DIN standard (others available). Range of temperatures are up to 1800oF.

Bare Wire ThermocouplesSee Page: C11

The Bare Wire Thermocouples are used in a wide variety of applications such as moving air and surface contact. The size, and variable insulations give an excellent range of temperatures. Standard units come in base thermocouple metals (J, K, T and E). Noble and Refractory metals are available. (Consult Factory)

Temperature Sensors:Thermocouple Types and Applications


6

Nozzle ThermocouplesSee Page: C17

The Nozzle Thermocouple has been designed to be used in the plastics/die casting industries where mounting of the sensor in the nozzle is required. These units come in standard thermocouple base metals (J & K).


Bolt StyleThermocouples See Page: C18

The Fixed Length Bolt Style Thermocouple and RTD are used in applications where the melt temperature of the materials is required. These units are immersed into the melt (Molten) for actual temperature measurements. Available in standard thermocouple base metals (J, K, T and E) and the RTD styles in standard platinum element with a 3.85 a DIN standard.

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Metal Sheath MI (Mineral Insulated) Thermocouples and RTD’s come in a wide range of sheath materials, diameters and lengths. This style sensor is commonly used in hazardous/corrosive applications that require resistance to the harsh environment and temperatures forconsistent readings.

Metal Sheath/MI Thermocouples/RTD’s See Pages: C19 - C22 and C34 - C36

Paddle Thermocouples See Page: C23

The Paddle Thermocouple is used in harsh environments where fast response and temperature require a metal sheathed, MI style sensor to be used. Available in standard thermocouple base metals (J, K, T and E).


8

Lug & Washer Thermocouples See Page: C24

Lug and Washer Thermocouples and RTD’s are used in applications requiring temperaturereadings of surfaces, studs and bolts. These units come in all thermocouple base metals (J, K, T and E) the RTD styles in standard platinum element with a 3.85 a DIN standard.

Bearing Thermocouples See Page: C25

The Spring Loaded Bearing Thermocouple is to be used in applications of rotating and moving surfaces. This design incorporates a spring loaded sensor in an aluminum mounting block so as to be positioned on a moving or rotating surface. Available in standard thermocouple base metals(J, K, T and E). Please note: for temperatures in excess of 400oF and high speed movement please consult factory.


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9Ribbon Thermocouples See Page: C26


Ribbon Style Thermocouples are used extensively for moving air or surface temperature. Having minimal mass and maximum surface contact allow for extremely accurate and fast response temperature measurement. Available in standard thermocouple base metals (J, K, T and E).

Sabre Thermocouples See Page: C27

This type of Thermocouple was developed for the food industry to be used in taking temperatures of frozen and fresh foods. This unit can be autoclaved and is available in standard thermocouple base metals (J & T only).


10 High Temperature Thermocouples are defined as sensors used at temperatures of 2000°F and beyond. These Sensors are generally made from refractory/noble metals and refractory ceramics. Temperatures up to 5000°F can be obtained by using special design techniques and materials that have extended EMF tables. Applications can vary from extremely high-temperature furnaces to rocket engines and munitions.

For any applications regarding the above temperature sensors that are not profiled in the overall reference sections, please consult CONVECTRONICS’ Engineers for application,

design or technical information on your current or future requirements.1-800-633-0166


Refractory Metal/Ceramic & Noble Metal ThermocouplesSee Pages: C28 - C29

These Thermocouples have been designed for use in oxidizing, neutral and reducing environments. The materials used are of the highest quality, purities and manufacturing standards. Applications in all type of furnaces can be measured with these types of sensors. Temperature ranges to +4200oF are available. All standard refractory metal and noble metal thermocouple alloys are available. (C, D/F, G, R, S and B)

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Temperature Sensors:Standard Applications Thermocouples

CeramicBead DIA.

WireAWG

ANSIType

Part Number

1/8 24 JKTE

(R/S)*

TAW2-12.0E

3/16 20 TAW3-12.0E

1/4 14 TAW4-12.0E

3/8 8 TAW6-12.0E

* Standard gauge wire to be used on noble metal thermocouples (R/S): 24 AWG.* Standard ceramic insulators for noble metal thermocouples is high purity alumina oxide.* Other types of ceramic insulators are available - consult factory.* Multiple junction units available - consult factory.

1-3" LGT STD

12" 1"BARE WIRE

ROUND CERAMIC BEADSINSULATION (MULLITE)

EXPOSED BEAD WIRE JUNCTION

12"

BARE WIREEXPOSED BEADWELDED JUNCTION

WireAWG

ANSIType

PartNumber

8 JKTE

(R/S)*

TAZA-12.0E

14 TAZB-12.0E

16 TAZC-12.0E

20 TAZD-12.0E

24 TAZE-12.0E

T A Z - 1 2 . 0 EANSI TypeThermocouple StyleWire AWGLength (Inches)Junction Type

HOW TO ORDER:

EXAMPLE: To order a 20” long - 8 AWG wire - ANSI type “J” element, the part number is: T A Z - 2 0 . 0 E

ANSI TypeThermocouple StyleWire AWGLength (Inches)Junction Type

J A

T A W - 1 2 . 0 EANSI TypeThermocouple StyleDiameter Ceramic BeadLength (Inches)Junction Type

HOW TO ORDER:

EXAMPLE: To order an 18” long - 20 AWG wire - ANSI type “K” element, the part number is: T A W - 1 8 . 0 E

ANSI TypeThermocouple StyleDiameter Ceramic BeadLength (Inches)Junction Type

K 3


12


1"BARE WIRE24" STD

FIBERGLASS INSULATED FLEXIBLELEAD WIRE 20 AWG (STANDARD)

# 10 SPADE LUG (STANDARD)

T A Q 3 - 2 4 . 0ANSI Type Thermocouple StyleSpade Lug *(#10 Standard)Flexible Lead Length (Inches)

HOW TO ORDER:

EXAMPLE: To order a Spade Lug Thermocouple with standard #10 spade lug, ANSI Type “K”, the part number is:

Spade LugSize

ANSIType

PartNumber

No. 10*Spade LugStandard

JKTE

TAQ3-24.0

T A Q 3 - 2 4 . 0ANSI TypeThermocouple StyleSpade Lug *(#10 Standard)Flexible Lead Length (Inches)

K

24" STDBARE WIRE

1"

FIBERGLASS INSULATEDFLEXIBLE LEAD WIRE

EXPOSED BEAD WELDEDTHERMOCOUPLE JUNCTION

WireAWG

ANSIType

PartNumber

20 JKTE

TAS-24.0EA

24 TAS-24.0EB

30 TAS-24.0EC

36 TAS-24.0ED

T A S - 2 4 . 0 E AANSI TypeThermocouple StyleFlexible Lead Length (Inches)Gauge Wire

HOW TO ORDER:

EXAMPLE: To order anExposed Bead Welded Thermocou-ple ANSI type “K”, 24” long with 20 gauge wire, the part number is: T A S - 2 4 . 0 E A

ANSI Type Thermocouple StyleFlexible Lead Length (Inches)Gauge Wire

* When ordering, specify part number and quantity; if flexible lead length is other than 24”, specify accordingly and adjust base price.* All types of Thermocouple wire insulations and gauge sizes are available - consult factory.* All types of metal overbraid or flexible armor are available - consult factory.* Other styles of termination are available.

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Temperature Sensors:Plastic Applications Thermocouples

• Generally, plastics industry thermocouples are type J, and are enclosed in 304 Stainleess Steel sheaths that are 3/16” in diameter.

• Plastics industry sensors are not to be used in process applications above 900oF (700oF for type T), as their construction uses 900oF rated fiberglass insulated thermocouple wire inside the sheath.

• Use stranded conductor leadwire where continuous or frequent flexing of the leads occur.

• Ungrounded thermocouples are demanded in many applications due to EMF stray and instrument grounding requirements. Most plastic instrument sensors can be supplied with this option, but in some cases a MgO insulated type of thermocouple may be required.

The Plastic, Rubber and Packaging Industry sensors contained in the following pages are the most commonly used sensors in these three industries. The Thermocouple and RTD measuring elements all have insulated fiberglass leads inside the various sheath configurations. All are rated for use up to 900°F (J) maximum temperature.Some applications, because of higher temperature demands, physical abuse,

grounding problems, or other problems particular to a given process, may require the use of a MgO insulated type of sensor construction. The process may also require a special construction type of sensor to solve a particular application problem.

Our team of engineers invite your inquires to solve your sensor application problems.

• The use of sensors with short leads, used in conjunction with extensions connected to permanent instrument connected junction boxes of jack panels, may be desirable in high sensor replacement applications. The cost of replacing long leads with each sensor replacement may not be cost effective.

• Our adjustable immersion AG3 and AH3 styles will replace almost all fixed bayonet style sensors as long as the lead length and cold end terminations are compatible with the sensors currently being used.

• RTD sensors usually are the DIN Standard with a .00385α temperature coefficient.

• Hot tip immersion with RTD sensors usually require a minimum immersion of 1 1/4” because of length of the RTD measuring element inside the sheath.

Helpful Hints


14

SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

JKTE

G=Grounded(Standard)

*U=UngroundedTAD3-G

* Ungrounded junctions are available.* Multiple Junction units are available - consult factory.

A(2-5/8" STD)

1-5/8"

.188"O.D.STAINLESS STEEL

SHEATH

1"

MALE PLUGCONNECTOR

SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

J K T E


*U=UngroundedTAF3-G

SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

JKT E


*U=UngroundedTAE3-G

A (2-5/8" STD)

1-5/8"

.188"O.D. STAINLESS STEEL

SHEATH

MALE PLUGCONNECTOR

3/4"

3/4"45°

A(2-5/8" STD)

1-5/8"


SHEATH

MALE PLUGCONNECTOR

3/4"

3/4"

90°

T A E 3 - 8.00G

T A F 3 - GANSI TypeThermocouple StyleDimension “A” Length (Inches)Junction Type

HOW TO ORDER (All Styles):

EXAMPLE: To order a Bayonet Thermocouple ANSI Type “J” with an “A” dimension of 8” -45° bend the part number is: J

ANSI TypeThermocouple StyleDimension “A” Length (Inches)Junction Type


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SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

J K T E


*U=UngroundedTAG3-48.0G

SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

J K T E


*U=UngroundedTAH3-36.0G

HOW TO ORDER:


4"


SHEATH

STAINLESS STEELFLEXIBLE OVERBRAID

FIBERGLASS INSULATION

SPADE LUGS (OPTIONAL)1/2" BARE WIRE

STANDARD

1/2" 10" SPRING 48"

ADJUSTABLEBAYONET CAP

.188"O.D. STAINLESS STEEL

SHEATH

STAINLESS STEEL FLEXIBLE ARMOR

1/2"

ADJUSTABLEBAYONET CAP

FIBERGLASS INSULATION20 AWG FLEXIBLE LEADS

STANDARD

36" STD 3" 1/2"BAREWIRE

TAG3-48.0GANSI TypeThermocouple StyleLength in Inches of Leads Junction TypeU=Ungrounded*; G=Grounded (Standard)Cold End Termination Style

HOW TO ORDER: TAH3-36.0GANSI TypeThermocouple StyleLength of Armored Leads (Inches)Junction TypeU=Ungrounded*; G=Grounded (Standard)Cold End Termination Style

TAG3-72.0G

EXAMPLE: To order an adjustable Bayonet Thermocouple ANSI Type “J” Grounded Junction with 72” leads and style 3 termination the part number is:

TAH3-48.0G

EXAMPLE: To order an adjust-able Armored Bayonet Thermocouple ANSI Type “J” Grounded Junction with 48” leads and style 3 termination the part number is: J

ANSI TypeThermocouple StyleLength of Armored Leads (Inches)Junction TypeCold End Termination Style

3

J 3

ANSI TypeThermocouple StyleLength in Inches of Leads Junction TypeCold End Termination Style


4"

1/2"CONDUIT

CONNECTION

4"

Style 1 Style 2 Style 3 Style 4

PLUG CONNECTION JACK CONNECTION SPADE LUGS

Cold End Terminations:


16

SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

J K T E


*U=UngroundedTAA3-G-

SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

J K T E


*U=UngroundedTAB3-G-


HOW TO ORDER (All Styles:) TAC3-G-ANSI TypeThermocouple StyleLength of Dimension “A” (Inches)Junction TypeU=Ungrounded*; G=Grounded (Standard)Lenght of Dimension “B” (Inches)Termination Style

EXAMPLE: To order a Bayonet Ther-mocouple ANSI Type “K” with “A” Dimen-sion, - 90° Bend 3”, “B” Dimension 48” and a plug connection,the part number is:


4"

1/2"CONDUIT

CONNECTION

4"



A 1/2"

B 4"(2-5/8" STD)

1-5/8"

(36" STD)

.188" O.D.STAINLESS STEEL

SHEATH1/2" CONDUIT CONNECTOR (OPTIONAL)

STAINLESS STEELSPADE LUGS(OPTIONAL)

FLEXIBLE ARMOR

A

(2-5/

8" STD)

3/4"

B 4"

1-5/8"

(36" STD)

1/2" CONDUIT CONNECTOR (OPTIONAL)

STAINLESS STEEL FLEXIBLE ARMOR SPADE LUGS

(OPTIONAL)

3/4"45°


SHEATH

A(2-5/8" STD)

B 4"

1-5/8"

(36" STD)

1/2" CONDUIT CONNECTOR(OPTIONAL)

STAINLESS STEEL FLEXIBLE ARMOR

SPADE LUGS(OPTIONAL)

.188"O.D.STAINLESS

STEEL SHEATH

3/4"

3/4"90°

SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

J K T E


*U=UngroundedTAC3-G-

TAC3-G-ANSI TypeThermocouple StyleLength of Dimension “A” (Inches)Junction TypeU=Ungrounded*; G=Grounded (Standard)Lenght of Dimension “B” (Inches)Termination Style

K 3.00 48 2


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SheathMaterial

ANSIType

JunctionType

Part Number

304ST.

STEEL

J K T E

G=Grounded(Standard) TAU1-48.0G-

HOW TO ORDER:


TAU1-48.0G-ANSI TypeThermocouple StyleLength in Inches of Leads Junction Type: Grounded onlyCold End Termination Style

HOW TO ORDER: TAY1-12.0ANSI TypeThermocouple StyleSheath DiameterJunction TypeU=UngroundedG=Grounded (Standard)E=Exposed

EXAMPLE: To order a Nozzle Thermocouple ANSI type “K”, with 72” leads and style 3 termination the part number is:

EXAMPLE: To order a 14” long, 1/8” diameter St. Steel Sheath, ANSI type “J”, with an ungrounded junction, the part number is:

* When ordering, specify part number and quantity.* Multiple junction units available - consult factory.* For extension leads longer than 24”, specify accordingly and adjust base price.* Other styles of flexible leads are available with different types of insulations, armors and metal braids - consult factory.

BAREWIRE

1"

#20 AWG STAINLESS STEEL FLEXIBLE OVERBRAID FIBERGLASS INSULATION

1 1/4" 48"

ROTATING NOZZLE TIP

STRAIN RELIEF SPRINGHEX

1/4-28 THREAD

BAREWIRE

1"

24"12" STD

SHEATH DIA. FLEXIBLE FIBERGLASSOVERBRAID

TAU1-72.0G-ANSI TypeThermocouple StyleLength in Inches of Leads Grounded JunctionCold End Termination Style

K 3

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16304ST.

STEEL

JKTE

U=UngroundedG=GroundedE=Exposed

TAY1-12.0 12

1/8 TAY2-12.0 12

3/16 TAY3-12.0 12

1/4 TAY4-12.0 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16

INCO600

JKTE


TAY1-12.00 12

1/8 TAY2-12.00 12

3/16 TAY3-12.00 12

1/4 TAY4-12.00 12

TAY2-14.0ANSI TypeThermocouple StyleSheath DiameterSheath Length (Inches)Junction Type

J U

4"

1/2"CONDUIT

CONNECTION

4"




* Bend configurations available - consult factory.


18

SheathMaterial

ANSIType

JunctionType

Part Number

304ST. STEEL

J K

G=GroundedU=Ungrounded TAI1-03.0


* Multiple junction units available - consult factory.* Other styles of flexible leads and terminations are available - consult factory.

1/4" FLEXIBLE ARMOR.

MALE PLUGCONNECTOR

A L

3/4" HEX

1/2"-20 THREAD

4"

(AT FLATS)

MALE PLUGCONNECTOR

A L

3/4" HEX1/2"-20 N.F. THREAD

1/2"

1/4" DIA.STAINLESS

STEEL(AT FLATS)

SheathMaterial

ANSIType

JunctionType

Part Number

304ST. STEEL

J K

G=GroundedU=Ungrounded TAI2-03.0

45°

.125" DIA..312" DIA.

.421" DIA.

1/2-20 THREAD

.4375"

.250"

Recommended Drilling Dimensionsfor Proper Mounting in Extruder

Detailed Dimensions

TAI2-06.0

HOW TO ORDER (All Styles): TAI2-03.0ANSI TypeThermocouple StyleBolt Length “L” (Inches)Sheath Length “A” (Inches)Junction TypeU=UngroundedG=Grounded (Standard)

EXAMPLE: To order a Bolt Thermocouple ANSI type “K” with an “A” dimension of 1/4” and “L” dimension of 6” with an ungrounded junction, the part number is: K U

ANSI TypeThermocouple StyleBolt Length “L” Sheath Length “A” Junction Type

1/4

45°

1/2-20 N.F.

1"

45°

3/8"

1/4"

33/64"Ø 5/16"

Ø

Ø

27/64"

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Temperature Sensors:Magnesium Oxide Insulated Sensors

Helpful Hints

MgO sensors are constructed by placing an element or elements into a sheath of a suitable material and size, insulating the elements from themselves and the sheath with loose filled or crushable Magnesium Oxide powder or insulators, and then swaging or drawing the filled sheath down to its final reduced size.The swaging process produces an element with highly compacted MgO insulation and provides a high dielectric strength insulation between the elements themselves and their sheath.

Magnesium Oxide insulated thermocouples, commonly referred to as MgO thermocouples, are used in many process and laboratory applications. They are available in all thermocouple element types, a wide variety of sheath diameters and materials, they are rugged in nature and bendable, and their fairly high temperature ratings make MgO thermocouples a popular choice for a multitude of temperature measuring applications. The many desirable characteristics make them a good choice for general and special purpose applications.

• Standard purity MgO (96%) insulation is suitable for most process applications, however, where high temperatures are expected and it is desirable to use smaller sheath diameters, high purity MgO (99.6%) insulation is recommended. This is particularly true of type K and N thermocouple elements.

• Do not use exposed junctions in the presence of moisture or other process contaminants. Use only “U” ungrounded junctions with small diameter high temperature applications, and in conjunction with instrument manufacturer’s measuring circuit recommendations.

• Do not place transitions or plug and jack connectors directly into the process environment. Select fittings and connectors with sufficient temperature ratings to withstand their ambient environment.

• Select leadwire insulation and conductor style suitable for the environment. Select fiberglass insulations for high temperature applications, teflons and PVC insulations for high moisture applications, metal overbraid for physical abuse applications, and stranded conductor for moving process applications.

• Minimum insertion length should be 10 times the OD of the sheath, nominal.

• Select an element type that has a temperature rating higher than the expected process temperature, one that will resist contamination by the process environment, and one that matches the measuring instruments’ input.

• Do not use type J elements where they will be exposed to moisture, as moisture will contaminate the elements’ iron leg. A type T element, if the temperature range is suitable, is a better choice.

• Select the sheath material based on the maximum expected process temperature, and select a material resistive to any corrosiveness of the process environment.

• Element response time and process temperature are the most important considerations. The smaller the diameter, less mass will be involved and the thermal response time will be faster, however, the smaller the sheath diameter the smaller the element wire gauge size and a reduced useful life would be expected.

• Do not exceed the recommended upper temperature limits for the element wire gauge size. This wire gauge size is determined by sheath diameter. You may refer to the recommended temperature limit tables for elements of various wire sizes.


20

HOW TO ORDER:


TAJ1-12.0ANSI TypeThermocouple StyleJunction Type: U=UngroundedG=GroundedE=Exposed

EXAMPLE: To order a 12” long 1/16” Diameter Inconel Sheath, ANSI Type “E” with an exposed junction, the part number is:

* Bend configurations available - consult factory.* When ordering, specify part number and quantity.* If sheath length is other than 12”, specify accordingly and adjust base price.* Multiple junction units available - consult factory.

TAJ1-12.00ANSI TypeThermocouple StyleSheath DiameterSheath Length (Inches)Junction Type

E E

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16304ST.

STEEL

JKTE


TAK1-12.0 12

1/8 TAK2-12.0 12

3/16 TAK3-12.0 12

1/4 TAK4-12.0 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16

INCO600

JKTE


TAK1-12.00 12

1/8 TAK2-12.00 12

3/16 TAK3-12.00 12

1/4 TAK4-12.00 12

12"

SHEATH DIA

STANDARDT/C PLUG

STANDARDT/C JACK

12" 1"BARE

SHEATH DIA

WIRE

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16304ST.

STEEL

JKTE


TAJ1-12.0 12

1/8 TAJ2-12.0 12

3/16 TAJ3-12.0 12

1/4 TAJ4-12.0 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16

INCO600

JKTE


TAJ1-12.00 12

1/8 TAJ2-12.00 12

3/16 TAJ3-12.00 12

1/4 TAJ4-12.00 12

HOW TO ORDER: TAK2-12.0ANSI TypeThermocouple StyleJunction Type: U=UngroundedG=GroundedE=Exposed

EXAMPLE: To order a 12” long 1/16” Diameter Inconel Sheath, ANSI Type “E” with an exposed junction, the part number is: TAK1-12.00

ANSI TypeThermocouple StyleSheath DiameterSheath Length (Inches)Junction Type

E E

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HOW TO ORDER:


TAL1-12.0ANSI TypeThermocouple StyleJunction Type: U=UngroundedG=GroundedE=Exposed

EXAMPLE: To order a 12” long 1/8” Diameter Stainless Sheath, ANSI Type “J” with a grounded junction, the part number is:

* Bend configurations available - consult factory.* When ordering, specify part number and quantity. * If sheath length is other than 12”, specify accordingly and adjust base price.* For extension leads longer than 24”, specify accordingly and adjust base price.* Other styles of flexible leads are available with different types of insulation and armor - consult factory.* Multiple junction units are available - consult factory.

TAL2-12.0ANSI TypeThermocouple StyleSheath DiameterSheath Length (Inches)Junction Type

J G

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16304ST.

STEEL

JKTE


TAM1-12.0 12

1/8 TAM2-12.0 12

3/16 TAM3-12.0 12

1/4 TAM4-12.0 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16

INCO600

JKTE


TAM1-12.00 12

1/8 TAM2-12.00 12

3/16 TAM3-12.00 12

1/4 TAM4-12.00 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16304ST.

STEEL

JKTE


TAL1-12.0 12

1/8 TAL2-12.0 12

3/16 TAL3-12.0 12

1/4 TAL4-12.0 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16

INCO600

JKTE


TAL1-12.00 12

1/8 TAL2-12.00 12

3/16 TAL3-12.00 12

1/4 TAL4-12.00 12

HOW TO ORDER: TAM2-12.0ANSI TypeThermocouple StyleJunction Type: U=UngroundedG=GroundedE=Exposed

EXAMPLE: To order a 12” long 1/16” Diameter Inconel Sheath, ANSI Type “E” with an exposed junction, the part number is: TAM1-12.00


E E

12" STD

SHEATH DIA.

MINIATURE T/C PLUG

MINIATURE T/C JACK

12" STD

SHEATH DIA.

1"BARE WIRE


24" STD


22


* Bend configurations available - consult factory. * When ordering, specify part number and quantity. * If sheath length is other than 12”, specify accordingly and adjust base price.* For other styles of mounting threads - consult factory.* Multiple junction units are available - consult factory.

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16304ST.

STEEL

JKTE


TAO1-12.0 12

1/8 TAO2-12.0 12

3/16 TAO3-12.0 12

1/4 TAO4-12.0 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16

INCO600

JKTE


TAO1-12.00 12

1/8 TAO2-12.00 12

3/16 TAO3-12.00 12

1/4 TAO4-12.00 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16304ST.

STEEL

JKTE


TAN1-12.0 12

1/8 TAN2-12.0 12

3/16 TAN3-12.0 12

1/4 TAN4-12.0 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/16

INCO600

JKTE


TAN1-12.00 12

1/8 TAN2-12.00 12

3/16 TAN3-12.00 12

1/4 TAN4-12.00 12

HOW TO ORDER: TAO2-12.0ANSI TypeThermocouple StyleJunction Type: U=UngroundedG=GroundedE=Exposed

EXAMPLE: To order a 12” long 1/4” Diameter Inconel Sheath, ANSI Type “K” with an ungrounded junc-tion, the part number is: TAO4-12.00


K U

HOW TO ORDER: TAN1-12.0ANSI TypeThermocouple StyleJunction Type: U=UngroundedG=GroundedE=Exposed

EXAMPLE: To order a 12” long 3/16” Diameter Stainless Sheath, ANSI Type “J” with a grounded junction, the part number is: TAN3-12.0


J G

12" STD

SHEATH DIA.

1/2" NPT

1/2" NPT

CAST ALUMINUMWEATHERPROOF HEAD

12" STD

SHEATH DIA.1/4" NPT

1/4" NPT

MINI WEATHERPROOFPLASTIC HEAD

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Temperature Sensors:Surface Applications Thermocouples

EXAMPLE: To order a Paddle Thermocouple ANSI type “J”, 1/16” dia. sheath, the part number is: TPA1-06.0G

ANSI TypeThermocouple StyleSheath Dia. Sheath Length (Inches)Junction Style

J

Length (x)Inches

ANSIType

Part Number

12JK TCC--124

96

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

DIM.(A)

Inch

DIM.(B)

InchPart

Number

.040 304ST.

STEEL

JK G=Grounded

1/16 1/2 TPAD-06.0G

.062 3/32 3/4 TPA1-06.0G

AB

6"

PADDLE SHEATH DIA.MINATURE MALE

CONNECTOR

MINIATURE FEMALE CONNECTOR

1"BARE WIREX

ANSI TypeExtension typeLength x (Inches)Connection Style

HOW TO ORDER: TCC- -1

CONVECTRONICS’ Paddle Thermocouple was designed specifically to be used for surface temperature measurements. The criteria used in this design was for a practical hand held probe that has very rapid response and can be used in extremely small spaces. Applications include: Circuit boards, electrical components, solder/weld joints and surface mount applications.

In conjunction with the thermocouple a flexible retractable cable can be supplied with the above thermocouples giving the user more flexibility in both usage and connection to portable instrumentation.

1"

1.58"

Ø3/16" ST. STEELGROUNDED SHEATH

3"

1"

72" STANDARD(24 AWG STRANDED WIRE

W/ST. STL. FLEXIBLEOVERBRAID/FIBERGLASS INSULATION)

1"

1/4" EXPOSED

90° BEND

Magnet Mount Thermocouples

HOW TO ORDER: TMAG3-72.0GANSI TypeThermocouple StyleLength (Inches)Junction Type: Grounded

ProbeMaterial

ANSIType

JunctionType

Part Number

3/16” Dia.Stainless Steel

JKTE

Grounded TMAG3-72.0G

HOW TO ORDER: TPAD-06.0GANSI TypeThermocouple StyleSheath Dia. Sheath Length (Inches)Junction Style: Grounded

* 975°F Max. Temp


24

Temperature Sensors:Surface Applications Thermocouples

WasherO.D.

WasherI.D.

ANSIType

Part Number

5/16 1/8JKTE

TAP2-24.0

7/16 3/16 TAP3-24.0

5/8 1/4 TAP4-24.0

7/8 3/8 TAP6-24.0

1 1/4 1/2 TAP8-24.0

T A P 2 - 2 4 . 0ANSI TypeThermocouple StyleWasher IDFlexible Lead Length (Inches)

HOW TO ORDER:

EXAMPLE: To order a Washer Thermocouple with a 5/16” O.D. and 1/8” I.D washer, ANSI Type “J”, the part number is:

I.D.O.D.

24" STD

1"BARE


STAINLESS STEEL WASHERWIRE

(STANDARD)

T A P 2 - 2 4 . 0ANSI TypeThermocouple StyleWasher IDFlexible Lead Length (Inches)

J

WasherO.D.

ANSIType

Part Number

No. 10*Ring Tongue

TerminalStandard

JKTE

TAR3-24.0

T A R 3 - 2 4 . 0ANSI TypeThermocouple StyleRing Tongue Terminal Size*(#10 Standard)

Flexible Lead Length (Inches)

HOW TO ORDER:

EXAMPLE: To order a Ring Tongue Terminal Thermocouple with a standard #10 terminal, ANSI Type “J”, the part number is: T A R 3 - 2 4 . 0

ANSI TypeThermocouple StyleRing Tongue Terminal Size *(#10 Standard)Flexible Lead Length (Inches)

J

1"

24" STDBARE WIRE


# 10 RING TERMINAL (STANDARD)

1= #62= #83= #104= 1/4

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ProbeMaterial

ANSIType

JunctionType

Part Number

Fiberglass

JKTE

Grounded TBEP-36.0G

Temperature Sensors:Moving Applications Thermocouples

1/2"3/4"

1"

36"

Spring LoadedProbe

Fiberglass InsulatedExtension Wire

Aluminum MountingBlock

Probe 3/8" Dia.Housing

Thermal DiscMeasuring Junction

0.7"

1.7" 36"

Thermal DiscMeasuring Junction

3/8" Dia. Fiberglass InsulatedExtension Lead

Replacement Probes for use with the Spring Loaded Aluminum Mounting Block above.

ProbeMaterial

ANSIType

JunctionType

Part Number

Fiberglass

JKTE

Grounded TBE1-36.0G

CONVECTRONICS’ Spring Loaded Bearing Probe is engineered for use in applications where a Spring Loaded Sensor must give accu-rate readings on a moving or rotary surface.

HOW TO ORDER: TBE1-36.0GANSI TypeThermocouple StyleLength (Inches)Junction Type: Grounded

HOW TO ORDER: TBEP-36.0GANSI TypeThermocouple StyleLength (Inches)Junction Type: Grounded


26

Temperature Sensors:Moving/Surface Applications Thermocouples

* When ordering, specify part number and quantity. * If sheath length is other than 12”, specify accordingly and adjust base price.* All types of thermocouple wire insulations and gauge sizes available - consult factory.* Other styles of terminations are available.

SheathMaterial

ANSIType

RibbonTHK

(Approx.)

WireAWG Insulation Sheath

DIAPart

Number

FiberglassJKTE

.001 36 Fiberglass(G) - TATG-12.0E-1



304ST.

STEEL

.001 36 Ceramic (C) .040 TATC-12.0E-1

.0015 28 Ceramic (C) .062 TATC-12.0E-2

.0025 24 Ceramic (C) .125 TATC-12.0E-3

HOW TO ORDER: TATG-12.0E-1ANSI TypeThermocouple StyleInsulationFlexible Lead/MI Cable Length (Inches)Gauge Wire

EXAMPLE: To order a Ribbon Thermocouple with ANSI Type “J” elements, 24 gauge wire with fiberglass insulation and 36” of leads, the part number is:

12" STD

1"BARE WIRE

FIBERGLASS INSULATED FLEXIBLE LEAD WIRE

1”

1/4"

RIBBON T/C ELEMENT

FIBERGLASS INSULATED FLEXIBLE LEAD WIRE

12" STD

1"BARE WIRE

1/2"

1/4”

1"

RIBBON T/C ELEMENT

TATG-36.0E-3ANSI TypeThermocouple StyleInsulationFlexible Lead/MI Cable Length (Inches)Gauge Wire

J

HOW TO ORDER: TAVG-12.0E-1ANSI TypeThermocouple StyleInsulationFlexible Lead/MI Cable Length (Inches)Gauge Wire

EXAMPLE: To order a Ribbon Thermocouple with ANSI Type “K” elements, 24 gauge wire with an 1/8” Diameter 304 St. Steel sheath (MI Cable), 48” long, the part number is: TAVC-48.0E-3

ANSI TypeThermocouple StyleInsulationFlexible Lead/MI Cable Length (Inches)Gauge Wire

K

SheathMaterial

ANSIType

RibbonTHK

(Approx.)

WireAWG Insulation Sheath

DIAPart

Number

FiberglassJKTE

.001 36 Fiberglass(G) - TAVG-12.0E-1



304ST.

STEEL

.001 36 Ceramic (C) .040 TAVC-12.0E-1

.0015 28 Ceramic (C) .062 TAVC-12.0E-2

.0025 24 Ceramic (C) .125 TAVC-12.0E-3

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Hose ClampSize

ANSIType

JunctionType

Part Number

1-12”

JKTE

Grounded TBC-72.0G


CONVECTRONICS’ Sabre Thermocouple has been specifically designed for use in the food industries. The all-stainless steel construction with teflon insulated extension leads is completely autoclavable. Having a pointed tip this assembly lends itself to applications where semi-frozen, hard or raw foodstuffs must be penetrated for exact temperature readouts during preparation stages.

SheathSizeDia.

SheathMaterial

ANSIType

JunctionType

Part Number

1/8 316ST.

STEEL

JKTE

GroundedTBA2-06.0G

3/16 TBB3-06.0G

72" STD

20 AWG FIBERGLASS INSULATION WITHSTAINLESS STEEL OVER BRAID EXTENSION WIRE

STAINLESS STEEL PIPE CLAMP

1-1/8"6" 72"

Teflon InsulatedLeads

HandleSheetDiameter

Grounded ThermalJunction-Pointed Tip

CONVECTRONICS’ Pipe Probe is designed for use in applications where Heat and Water Pipes, Band Heaters or Round products require surface temperature measurements. Having an adjustable Stainless Steel Hose Clamp allows this unit to be used extensively over a large range of sizes.

HOW TO ORDER: TBC -72.0GANSI TypeThermocouple StyleHose Clamp Size (Inches)Length of Leads (Inches)Junction Type: Grounded

HOW TO ORDER: TBA2-06.0GANSI TypeThermocouple StyleSheath Dia.Sheath Length (Inches)Junction Type: Grounded


28

Temperature Sensors:High Temperature Thermocouple Probes

CONVECTRONICS offers thermocouples utilizing noble metals, refractory metals, refractory ceramics and other exotic materials for the sheath, thermocouple wires and insulation. Our thermocouples are fabricated using the highest manufacturing standards available, which ensures maximum performance and life for these sensors.

Specifications of Sheath Materials

TANTALUM (Ta):Melting point of 5430°F. The most corrosive resistant of the refractory metals. Corrosion resistant to most chemicals up to 3000°F. Good in reducing or neutral atmospheres at elevated temperatures. Poor in oxidizing atmospheres. Excellent for thermal cycling applications.

MOLYBDENUM (Mo):Excellent mechanical properties at elevated temperatures. Melting point at 4750°F. Excellent in reducing or neutral atmospheres. It has low thermal-neutron capture cross-section and excellent thermal shock resistance. Poor in oxidizing atmospheres. Excellent for thermal cycling applications.

ALUMINA (AL2O3):This high purity sintered aluminum oxide (99.5% AL2O3, dense) has a melting point of 3686°F (2030°C) and an upper working service temperature of 3452°F (1900°C). It can be used in oxidizing, reducing or high vacuum applications. (Not recommended for use in high vacuum environments in the presence of graphite at temperatures exceeding 2372°F (1300°C)). AL2O3 has high thermal conductivity and therefore good resistance to thermal shock. It has excellent resistance to chemical attack. Poor for thermal cycling applications.

ZIRCONIA (ZRO2):Zirconium oxide is fully stabilized with exceptional refractory properties, which include the highest melting point and lowest thermal conductivity of any refractory. It is not wet by most molten metals, is generally inert to oxidizing and reducing atmospheres, and resists most chemical reactions. Usable to 4400°F, it is impervious (0% water absorption). Poor for thermal cycling applications.

FUSED QUARTZ:(Fused silica) consists of 99.9% SIO2. Most acids, metals, chlorine and bromine are unreactive with fused silica at ordinary temperatures. It is slightly attacked by alkaline solutions, the reaction rate increasing with temperature and concentration of thermal expansion, 0.55 x 10-6 cm/cm/°F (0-572°F). This is 1/34th that of copper, 1/17th of platinum and 1/9th of tungsten. This low expansion produces a high thermal shock resistance, it can be heated to 2700°F, and immersed into ice water without cracking. Good for oxidizing, inert or neutral atmospheres to 3050°F. Excellent for thermal shock applications. Divitrifies rapidly at temperatures above 1800°F causing microscopic surface cracking (hazy film) upon cooling.

Thermocouple Elements

Refractory Oxide Insulators

Calibration Max. Oper. Temp.

Max. Ex-pos. Temp.

RecommendedEnvironment

Pt-10% Rh/Pt ANSI Type S

2700°F1482°C

3100°F1704°C

Oxidizing,Inert

Pt-13% Rh/Pt ANSI Type R

2700°F1482°C

1300°F1704°C

Oxidizing,Inert

Pt-30% Rh/Pt-6%Rh ANSI Type B

3100°F1704°C

3220°F1770°C

Oxidizing,Inert

W/W-26% ReW-5% Re/W-26%ReW-3% Re/W-25%Re

5000°F2760°C

5430°F3000°C

Vacuum, High Purity, Hydrogen & Inert.

Material Approx.Melt. Temp.

Max. Rec. Temp.

Hard-Fired Swaged

MagnesiaMg0

5070°F2800°C N/A 3400°F

1870°C

AluminaAL2O3

3650°F2010°C

3200°F1760°C

3000°F1650°C

Beryllia*Be0

4620°F2550°C

4200°F2315°C N/A

HafniaHfO2

5252°F2900°C

4352°F2400°C N/A

The resistivity of metal oxides decreases with increasing temperature. Above 3600°F only beryllia retains sufficient resistivity for most applications.

Pt-Platinum, Rh-Rhodium, W-Tungsten, Re-Rhenium

* Caution: Beryllia Dusts are toxic

Oxidizing, reducing and inert gas furnaces, gas burners, ovens, nuclear power generating plants, exhaust gases, wind tunnels, pollution control and high temperature process control applications.

Application

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Temperature Sensors:High Temperature Thermocouple Probes

12"

SHEATH DIA

STANDARDT/C PLUG

STANDARDT/C JACK

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8

MOLYBDENUM(MO)

B,C,R,S,F,G

Ungrounded

TAK2-12.05 12

3/16 TAK3-12.05 12

1/4 TAK4-12.05 12

3/8 TAK5-12.05 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8

TANTALUM(TA)

B,C,R,S,F,G

Ungrounded

TAK2-12.06 12

3/16 TAK3-12.06 12

1/4 TAK4-12.06 12

3/8 TAK5-12.06 12

SheathSize DIA

SheathMaterial

ANSIType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8

ALUMINIA(AL2O3)

B,C,R,S,F,G

Ungrounded

TAK2-12.08 12

3/16 TAK3-12.08 12

1/4 TAK4-12.08 12

3/8 TAK5-12.08 12

1/4 ZIRCONIA(ZRO2)

B,C,R,S,F,G

UngroundedTAK4-12.07 12

3/8 TAK5-12.07 12

1/4 QUARTZ(QR)

B,C,R,S,F,G

UngroundedTAK4-12.09 12

3/8 TAK5-12.09 12

HOW TO ORDER: TAK2-12.05ANSI TypeThermocouple StyleSheath DiameterSheath Length (Inches)Sheath Material

EXAMPLE: To order a 12” long 1/8” Diameter MOLYBDENUM Sheath, ANSI Type “C”, the part number is: TAK2-12.05

ANSI TypeThermocouple StyleSheath DiameterSheath Length (Inches)Sheath Material

* Maximum service temperatures not to exceed 1500°C.* For higher service temperatures consult factory.* The standard thermocouple is available with a thick wall metal support tube (4” long standard) attached to the connector end. The support tube is 1/8 larger in diameter than the sheath diameter. The support tube is used to eliminate any damage to the refractory sheath that may be caused by a mounting bushing.

* If a support tube is desired, insert suffix (ST) to the part number* When ordering, specify part number and quantity. If sheath length is other than 12”, specify accordingly and adjust base price.* Other style termination available.* Multiple junction units are available - consult factory.

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SheathSize DIA

(Inches)

NominalTube Wall Thickness (Inches)

Wire Gauge B&S MaxStock

Length(Feet)

SingleT/C Element

DualT/C Element

.010 .0015 44 50

.020 .003 38 100

.032 .004 34 150

.040 .006 33 200

.062 .009 28 30 500

.125 .017 22 24 375

.188 .025 20 21 175

.250 .033 16 18 100

.312 .041 16 60

.375 .052 15 45

.500 .070 10 30

Temperature Sensors:Mineral Insulated Cable (MI)

Code SheathMat’l

S4 304SS

S0 310SS

S6 316SS

S7 347SSI6 Inconel

600

CodeSheath

SizeDIA. (In.)

ABCD1234568

.010

.020

.032

.040

.062

.125

.188

.250

.312

.375

.500

Code No. ofElements

1 Single(2 wire)

2 Dual(4 wire)

OrderCode*(ANSI)Type

TJEK

InsulationType

Mg=MagnesiumAL= Aluminum

Dual ElementAvailable

.062 to .250

HOW TO ORDER: R M C - - - -Thermocouple Style

Dim. Tolerance:Up to .062 + .001; .125 to .500 + .003” Furnished in coils .010” to .312”Furnished in straight lengths 0.375” to 0.500”

WHEN ORDERING SPECIFY:1) Sheath Alloy and Size by code from table2) ANSI Calibration Type by letter code3) Length in Feet

Conopak is available for your fabrication from our stock. Ends are cut square and moisture sealed. Standard Conopak is a single element(2 wire) or dual element (4 wire) thermocouple construction withMagnesium Oxide (MgO) insulation compacted into a metal sheath.

EXAMPLE: To order 1/8” O.D., 304 St. St. Sheath Material, ANSI Type “J” elements, magnesium oxide insulation single element, - 100 ft. long, the part number is: RMC-----100FTS4 2 J Mg 1

Thermocouple StyleSheath MaterialSheath DiameterANSI Type ElementCeramic InsulationNo. of Element

* When ordering, specify part number and quantity.* Other types of sheath materials, ceramic insulation and ANSI type elements are available - consult factory.

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Temperature Sensors:General RTD Information

Resistance Temperature Detectors (RTD’s) are used in many process and laboratory appli-cations where high accuracy and repeatability are of major importance. Characteristically, RTD’s provide a stable sensor that meets the above criteria through a rather broad

temperature range. RTD elements are available in many different materials and with different temperature coefficients. The most commonly used element is a wire wound, or thin film element, conforming to the DIN standard and with a .00385α temperature coefficient.

Helpful Hints

• Sheath materials selected should be capable of resisting the process corrosiveness. Convectronics offers 304 Stainless Steel as a standard, but other materials are available upon request.

• Process temperature measurements of less than 400°F (240°C) generally require the use of the Low Temperature Range RTD construction because moisture is usually present around these lower temperatures.

• Process temperatures above 400°F (204°C) generally require the use of the High Temperature Range RTD construction. The materials used in these assemblies will withstand process temperatures of up to 1292°F (700°C), and moisture penetration is not normally a factor.

• Vibration found in many process applications can have a detrimental effect on somewhat fragile RTD elements. Sensors ordered for a suspected high vibration process should be ordered as High Temperature Range construction because the highly compacted MgO construction provides superior vibration resistance when compared to Low Temperature Range constructions.

• It is not recommended to use two lead construction RTD’s as there is no means to compensate for leadwire resistance. Uncompensated lead resistance can create large errors in the temperature measurement.

• RTD’s used in wells should be of the spring loaded type to insure good thermal contact between the well and the sensor sheath. The use of heat transfer compound in the well will also increase thermal conductivity.

• Minimum insertion of the RTD sensor assembly should be a nominal 10 times the OD of the sensor sheath to avoid heat dissipation problems.

• Connections between RTD sensor assembly and the recording of controlling instrument can be plain copper wire, and in commonly available wire gauge sizes of 16 to 22 gauge.

• The temperature sensitive portion of the RTD assembly is typically a 1” length at the hot tip, due to the length of the measuring element contained inside.


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Temperature Sensors:General RTD Specifications

CONVECTRONICS’ standard RTD assemblies are constructed using wire wound platinum elements with a reference resistance of 100 Ohms at 0°C., a temperature coefficient of .00385 Ohms/Ohm/C (European Standard) or .003916 Ohms/Ohm/C (American Standard) and are in accordance with the following standards:

1. SAMA RC21 – 4 – 19662. British Standard, 1904 and 19643. German Standard, Din 43760

Other platinum elements and elements of other materials, resistances, and temperature coefficients are available. Please consult with the factory.

Temperature Co-efficient of Resistance:The fractional change in element resistance per change of 1°C., expressed as Ohms/Ohm/C.

Accuracy:A statement of the initial element accuracy as measured at one point only, usually 0°C.

Interchangeability: An expression of the element material tolerance at various temperatures over the sensor range.

SPECIFICATIONS OF STANDARD 100 OHMPLATINUM ELEMENTS

Accuracy: ± .1 OHM (± 3°C) @ 0°C

Repeatability: ± .1°C Over Temperature Range

Interchangability:

TEMPERATURE TOLERANCE

°C ±°C ±Ohms

-200 1.2 .50

-100 .7 .30

0 .3 .10

100 .7 .25

200 1.2 .45

300 1.8 .65

400 2.5 .85

500 3.0 1.00

600 3.7 1.20

700 4.4 1.35

Element Types:Single platinum elements of 100 Ohms at 0°C and duplex platinum elements of two 100 Ohm sensors inside the same sheath are both available as standard. Consult the factory for other duplex style of elements.

Sensor Leadwire: All standard RTD sensor leadwire is stranded, silver plated copper with either Teflon or Fiberglass insulation. Teflon insulated leads are rated at 400°F maximum and Fiberglass insulated leads are rated at 900°F maximum.

Temperature Limits:Low Range (L) RTD assemblies are constructed using Teflon materials and low temperature epoxies to make them impervious to moisture penetration. These units are rated at 400°F maximum. High Range (H) RTD assemblies are constructed using pure silver element leads, ceramic insulation, and other materials suitable for maximum temperatures up to 1400°F.

Self Heating:Self heating is the rise in the measured temperature caused by the power dissipated in the element. Self heating error is affected by the thermal conductivity and velocity of the process being measured and is negligible for most applications. The self heating effect @ 25°C in water flowing at 3 ft./sec. on a 3/16” OD SS sheath diameter RTD is 50 MW/C typical.

General Construction:Elements are attached to the leads by silver soldering (Low Range) or by silver fusion (High Range) and installed in a specially cleaned and degreased stainless steel sheath. The element is completely encased and sealed in high purity, stress-free ceramic. The element is electrically insulated from the sheath. The sheath is packed with high purity aluminum powder to aid in heat transfer and provide mechanical shock protection.

Time Constant: The time required to sense 63% of a step temperature change from 25°C to 80°C in water flowing at 3 ft./sec. The time constant for a 3/16” OD SS sheath diameter is 2.0 seconds typical.

Standard Platinum RTD Assemblies

RTD Element Terminology

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Temperature Sensors:General RTD Specifications

Two-Wire:

Provides one connection to each end of the element. This construction is suitable where the resistance of the lead wire may be considered as an additive constant in the circuit, and particularly where the changes in lead resistance due to ambient temperature changes may be ignored.

Three-Wire:

Provides one connection to one end of the element and two to the other end of the element. Connected to an instrument designed to accept three wire input, sufficient compensation is usually achieved for leadwire resistance and temperature change in leadwire resistance. This is the most commonly used configuration.

Four-Wire: Provides two connections to each end of the element to completely compensate for leadwire resistance and temperature change in lead wire resistance. This configuration is used where highly accurate temperature measurement is vital.

RED

RED

BLACK

BLACK

RED

RED

WHITE

RED

RED

BLACK

BLACK

GREEN

WHITE

WHITE

WHITE

RED

RED

REDRED

BLACKBLACK

GREENGREEN

WHITE

WHITE

2 Wire Single 2 Wire Duplex



RED

RED

Element Connections:

RTD sensor assemblies are available with 2, 3, and 4 wire leads. Two wire connected elements do not provide lead resistance compensation for the measuring device. Three and four wire connected elements provide a means for compensating for lead resistance between the sensor and the measuring device.


34

Temperature Sensors:Standard RTD Applications

SheathSize DIA

SheathMaterial

RTDType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8304ST.

STEEL

100Platinum.00385ALPHASTD.

U=Ungrounded

TXAY2-12.0 12

3/16 TXAY3-12.0 12

1/4 TXAY4-12.0 12

3/8 TXAY6-12.0 12

BAREWIRE

1"

24"12" STD

SHEATH DIA. FLEXIBLE FIBERGLASSOVERBRAID

12" STD

SHEATH DIA.

1"BARE WIRE


24" STD

HOW TO ORDER: TAY2-12.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires (2-3)

EXAMPLE: To order a 22” long, 1/4”diameter, St. Steel sheath, RTD type .00385 ALPHA, 2 wire, the part number is: TAY4-22.0

RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires

X 2

HOW TO ORDER: TAM2-12.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires (2-3)

EXAMPLE: To order a 17” long, 3/16” diameter, St. Steel sheath, RTD Style Y, 3 wire, the part number is:

SheathSize DIA

SheathMaterial

RTDType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8304ST.

STEEL


U=Ungrounded

TXAM2-12.0 12

3/16 TXAM3-12.0 12

1/4 TXAM4-12.0 12

3/8 TXAM6-12.0 12

TAM3-17.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires (2-3)

Y 3

* NOTE: X = .00385; ALPHA Y=.003916 ALPHA; Standard units are 100 platinum.* When ordering, specify part number and quantity.* If sheath length is other than 12”, specify accordingly and adjust base price.* Other resistance values and alloys are available - consult factory.* Bend configurations available - consult factory.

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12" 1"BARE

SHEATH DIA

WIRE

12"

SHEATH DIA

STANDARDT/C PLUG

STANDARDT/C JACK

SheathSize DIA

SheathMaterial

RTDType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8304ST.

STEEL


U=Ungrounded

TXAJ2-12.0 12

3/16 TXAJ3-12.0 12

1/4 TXAJ4-12.0 12

3/8 TXAJ6-12.0 12

SheathSize DIA

SheathMaterial

RTDType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8304ST.

STEEL


U=Ungrounded

TXAK2-12.0 12

3/16 TXAK3-12.0 12

1/4 TXAK4-12.0 12

3/8 TXAK6-12.0 12

HOW TO ORDER: TAJ2-12.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires (2-3)

EXAMPLE: To order a 12” long, 1/8” diameter, St. Steel sheath, RTD type X, 2 wire, the part number is: TAJ2-12.0


X 2

HOW TO ORDER: TAK2-12.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires (2-3)

EXAMPLE: To order a 15” long, 3/16” diameter, St. Steel sheath, RTD type Y, 3 wire, the part number is: TAK3-15.0


Y 3

* NOTE: X = .00385; ALPHA Y=.003916 ALPHA; Standard units are 100 platinum.* When ordering, specify part number and quantity.* If sheath length is other than 12”, specify accordingly and adjust base price.* Other resistance values and alloys are available - consult factory.* Bend configurations available - consult factory.


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12" STD

SHEATH DIA.

1/2" NPT

1/2" NPT


12" STD

SHEATH DIA.1/4" NPT

1/4" NPT

MINI WEATHERPROOFPLASTIC HEAD

HOW TO ORDER: TAN2-12.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires


SheathSize DIA

SheathMaterial

RTDType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8304ST.

STEEL


U=Ungrounded

TXAN2-12.0 12

3/16 TXAN3-12.0 12

1/4 TXAN4-12.0 12

3/8 TXAN6-12.0 12

TAN2-10.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires

Y 2

* NOTE: X = .00385; ALPHA Y=.003916 ALPHA; Standard units are 100 platinum.* When ordering, specify part number and quantity.* If sheath length is other than 12”, specify accordingly and adjust base price.* Other resistance values and alloys are available - consult factory.

HOW TO ORDER: TAO2-12.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires


SheathSize DIA

SheathMaterial

RTDType

JunctionType

Part Number

STDLength (in.)

Sheath

1/8304ST.

STEEL


U=Ungrounded

TXAO2-12.0 12

3/16 TXAO3-12.0 12

1/4 TXAO4-12.0 12

3/8 TXAO6-12.0 12

TAO3-17.0RTD TypeRTD StyleSheath DiameterSheath Length (Inches)No. of Wires

Y 3

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Temperature Sensors:Terminations and Accessories

4"

1/2"CONDUIT

CONNECTION

PLUGCONNECTION

JACKCONNECTION

4"

1/2"24"

1/2"MNPT

3/4"NPT

Style 1Termination can be used on any flexible lead wires.

Style 2Termination can be used on any style thermocouple.



Style 5Termination is used on any rigid style thermocouple.Flexible leads are available in all styles of insulation and metal overbraids.

Style 6Termination is used on any rigid style thermocouple.Includes ceramic terminal block on interior of General Purpose head.

Termination Styles:

Heavy Duty Transition Junction

1/2” CONDUITCONNECTION

SPADE LUGS

HEAVY DUTY TRANSITION JUNCTION

CAST ALUMINUM WEATHERPROOF HEAD


38

HOW TO ORDER TERMINATIONS

Temperature Sensors:Terminations and Accessories

MALE PLUG FEMALE JACK

MINI MALEPLUG

MINI FEMALEJACK

GG

MALE PLUG3 PIN

FEMALE JACK3 PIN

GG

MINI FEMALEJACK 3 PIN

MINI MALEPLUG 3 PIN

1/2" NPT PORT


1/2" NPT PORT

1/4" NPT

MINIATURE PLASTICWEATHERPROOF HEAD

TUBE ADAPTOR

CABLE CLAMP

Male Plug P/N: RTMP -STDANSI Type

Female Jack P/N: RTFJ -STDANSI Type

Mini Male Plug P/N: RTMP -MINIANSI Type

Mini Female Jack P/N: RTFJ -MINIANSI Type

Male Plug 3 Pin P/N: RTMP -STD-3PANSI Type

Female Jack 3 Pin P/N: RTFJ -STD-3PANSI Type

Mini Male Plug 3 Pin P/N: RTMP -MINI-3PANSI Type

Mini Female Jack 3 Pin P/N: RTFJ -MINI-3PANSI Type

Cast Aluminum WeatherproofHead with Ceramic TerminalBlock - 1/2” NPT Ports P/N: RTGPA-STD-C

Molded Plastic Minature Weatherproof Head- 1/4” NPT Ports P/N: RTGPA-PL-STD

Tube Adaptor Standard Connector P/N: RH-TAS-

Tube Dia

Cable Clamp Standard Connectors P/N: RH-CCW-A

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39Extension Grade Wire is used to complete the thermo-couple circuit from the thermocouple element to the instrumentation. Extension grade wire should not be used to make the actual elements. The extension wire and thermocouple wire must both be of the same calibration type to maintain the accuracy of the thermo-couple. Also, the polarity of each set of wires must be maintained during installation in order for the thermo-couple circuit to function properly. Each of the calibration types has

their own insulation standard color code for easy identification. Please refer to the Thermocouple Extension Wire Color Code Table in this section.

• To assist in the installation of the wire, the Red wire is always the Negative leg of the extension wire.

• For typical, non-flexing, ambient temperature, indoor use, a 20 AWG solid conductor with PVC insulation is an excellent choice.

Temperature Sensors:Thermocouple and Thermocouple Extension Wire Information

Thermocouple and Thermocouple Extension Wire is offered with many different options and in numerous style combinations. Selecting from the various wire gauge sizes, insulating materials, conductor styles (solid vs. stranded), and limits of error enable

Thermocouple Grade Wire is generally used to make the actual thermocouple element. (Although it can be used as extension wire as well, the outer jacket insulation may have a different color and it may not be as cost effective.) Each of the calibration types has their own insulation standard color code for easy identification. Please refer to the Thermocouple Wire Color Code Table in this section.

Extension Wire

The limits of error for the calibration types listed in this section have been extracted from standards set by the American National Standard Institute, Inc. as shown in ASTM Standard E 230.

• Thermocouple and thermocouple extension wire are both available in “standard” and “special limits of error” grade conductor.

• Use a wire gauge size compatible with terminal screw size connections, and of a size that would withstand any physical abuse that may be encountered.

• Choose wire insulation that is compatible with the environment in which it will be used. For applications requiring moisture resistance use Teflon, PVC or Kapton insulations. For applications requiring high temperature insulations use Fiberglass, Ceramic Fiber or Vitreous Silica insulations.

• Use stainless steel overbraid and leads in flexible armor to provide physical abuse protection to wiring.

the user to select the correct material for virtually any industrial process application. CONVECTRONICS offers the most common constructions used by industry, however, special construction wire and cable is available upon request.

Helpful Hints

Thermocouple Wire

Extension Wire

Limits of Error for Thermocouple & Extension Wire

• To assist in the installation of the thermocouple, the Red wire is always the Negative leg of the element.

• If the thermocouple wires are installed incorrectly the instrument in the circuit will give backwards readings.

• Available in AWG sizes from 6 AWG (0.1620”) to 40 AWG (0.0031”)

• Insulation materials are available to cover temperature ranges from -190°F to 2600°F (-123°C to 1430°C)

• Use stranded conductor wire to connect thermocouples where continuous or frequent flexing of the leadwires may occur to prevent conductor fatigue and failure.

• Use leadwire with built-in aluminum mylar shields and drain wires to connect sensors to computers and to provide protection against error producing EMF stray signals. Use multi-pair cables to run large quantities of sensor leads from common point-to-point locations.

• Do not run thermocouple leads in conduits containing power wiring and do not run conduit carrying thermocouple leads parallel to electric buss bars and heavy power carrying conduits. Cross buss bars and power carrying conduits at right angles with thermocouple conduits when necessary.


40

Temperature Sensors:Thermocouple Wire Calibration Type Characteristics

Provides electrical insulation for thermocouple and thermocouple extension wire. If the insulation breaks down for any reason, the indicated temperature may be in error. When selecting insulation, moisture, abrasion, flexing, chemical attack, temperature extremes and any other adverse environmental considerations must be evaluated. Insulations are rated for a maximum continuous use temperature and also a maximum single exposure temperature because after excessive temperatures have been encountered the insulation may become conductive or conductive residues may form even though the insulation remains physically intact. Also do not assume the temperature rating as the temperature at the sensing junction of the thermocouple without evaluating the thermocouple system.

Calibration Type Characteristics

Type T (COPPER vs CONSTANTAN) is used for service in vacuum, oxidizing, inert or reducing atmospheres. It is highly resistant to corrosion from atmospheric moisture and condensation and exhibits high stability at low temperatures; it is the only type with limits of error guaranteed for cryogenic temperatures.

Type J (IRON vs CONSTANTAN) is used protected or unprotected in vacuum, oxidizing, inert or reducing atmospheres. Iron element oxidizes rapidly at temperatures exceeding 1000°F, and therefore heavier gauge wire is recommended for longer life at these temperatures.

Type E (CHROMEL VS CONSTANTAN) may be used protected, or unprotected in oxidizing, inert or dry reducing atmospheres or for short periods of time under vacuum. Must be protected from sulfurous and marginally oxidizing atmospheres. Produces the highest EMF per degree of any standardized thermocouple.

Type K (CHROMEL™ vs ALUMEL™) is used protected or exposed in oxidizing, inert or dry reducing atmospheres. Exposure to vacuum limited to short time periods. Must be protected from sulfurous atmospheres and marginally oxidizing atmospheres. Reliable and accurate at high temperatures.

Type N (NICROSIL vs NISIL) is used protected or exposed in oxidizing, inert or dry reducing atmospheres. Must be protected from sulfurous atmospheres. Very reliable and accurate at high temperatures.

Type S (PLATINUM-10%, RHODIUM vs PLATINUM)

Type R (PLATINUM-13%, RHODIUM vs PLATINUM)

Type B (PLATINUM-30%, RHODIUM vs PLATINUM- 6% RHODIUM)

Platinum alloy thermocouples are all recommended for use in inert or oxidizing atmospheres, or for short periods of time in a vacuum. Easily contaminated, these elements must be protected from the effects of reducing atmospheres and contaminating vapors. Alumina protection tubes are recommended for directly containing platinum element.

Type WR† (TUNGSTEN vs TUNGSTEN 26% RHENIUM)

Type W3† (TUNGSTEN 3% RHENIUM vs TUNGSTEN 26% RHENIUM)

Type W5† (TUNGSTEN 5% RHENIUM vs TUNGSTEN 26% RHENIUM)

Tungsten alloy thermocouples are all recommended for use in vacuum, high purity hydrogen, or high purity inert atmospheres. Very poor oxidation resistance. Pure tungsten is inherently brittle. W3 and W5 offer the advantage of ductility for ease of handling.† Not ANSI Symbols

Thermocouple Insulation

Wiring Electronic Instruments to conform to national and local codes does not address the “noise” problems of electronic instruments. Shielding of thermocouple and thermocouple extension wire may be necessary but not the only requirement of reducing noise. Ever since the introduction of electronics into instruments, noise generated by external relays, switches, motors, phase fired thyristors, etc. have caused problems that interfere with the instrument’s operation. Now that microprocessors are being increasingly incorporated into many more varied instruments, external sources that generate noise pulses that, in some cases, may render the instrument completely inoperative, have become crucial to instrumental applications. While much can be done within the instrument to reduce its sensitivity to external noise, the solution in many cases can only be resolved by suppressing the noise generation at its source.

Fibrous InsulationFibrous Insulation is either braided or carded on the conductors. In general, fibrous insulations are used for applications where extreme moisture and abrasion resistance requirements are not prevalent. Available at moderate cost for upper utilization temperatures of 900°F (482°C) for fiberglass, 1600°F (780°C) for high temperature silica fiber, and 2600°F (1430°C) for ceramic fiber.

Plastic Insulation

Plastic Insulation is used in comparatively low temperature applications and provides good moisture and abrasion resistance. Available at low to moderate cost with typical upper utilization temperature of 220°F (104°C) for PVC and 500°F (260°C) for teflon.

Wiring Electronic Instruments

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CONVECTRONICS’ insulated and bare thermocouple wire is matched to meet standard initial calibration tolerances for temperatures above 0°C as given in ANSI MC96.1. Wire conforming to special initial calibration tolerances, wire for use at sub-zero temperatures, and wire with certified

Thermocouple extension wire has approximately the same thermoelectric characteristics as the thermocouple wire but its accuracy is guaranteed over a more limited range of temperature. Thermocouple extension wire can offer advantages in cost or mechanical properties when used for connections between thermocouples and instruments. For base metal types of thermocouples, extension wire is of substantially the same

INITIAL CALIBRATION TOLERANCES FOR THERMOCOUPLE WIRE

THERMOCOUPLE TYPE °C °F

WIRE ALLOYS ANSI TYPE SYMBOL

TEMPERATURE RANGE

STANDARDLIMITS

SPECIALLIMITS

TEMPERATURERANGE

STANDARDLIMITS

SPECIALLIMITS

Copper (+) vs.Constantan (-) T

-200° to -65° 1.5% .8% -330° to -85° 1.5% .8%-65° to +130° 1° .5° -85° to +270° 1.8° .9°

+130° to +350° .75% .4% +270° to +660° .75% .4%*Iron (+) vs.Constantan (-) J 0° to +285° 2.2° 1.1° +32° to +545° 4° 2°

+285° to +750° .75% .4% +545° to +1400° .75% .4%

Chromel™(+) vs.Constantan (-) E

-200° to -170° 1% 1° -330° to -270° 1% 1.8°-170° to +250° 1.7° 1° -270° to +480° 3° 1.8°+250° to +340° 1.7° .4% +480° to +640° 3° .4%+340° to +900° .5% .4% +640° to +1600° .5% .4%

Chromel™(+) vs.*Alumel™(-) K

-200° to -110° 2% -330° to -165° 2%-110° to 0° 2.2° -165° to +32° 4°

0° to +285° 2.2° 1.1° +32° to +545° 4° 2°+285° to +1250° .75% .4% +545° to +2300° .75% .4%

Nicrosil (+) vs.Nisil (-) N 0° to +285° 2.2° 1.1° +32° to +545° 4° 2°

+285° to +1250° .75% .4% +545° to +2300° .75% .4%Platinum - 10% Rhodium (+) vs.Platinum (-) S 0° to +600° 1.5° .6° +32° to +1110° 2.7° 1.1°

+600° to +1450° .25% .1% +1110° to +2650° .25% .1%Platinum - 13% Rhodium (+) vs.Platinum (-) R 0° to +600° 1.5° .6° +32° to +1110° 2.7° 1.1°

+600° to +1450° .25% .1% +1110° to +2650° .25% .1%Platinum - 30% Rhodium (+) vs.Platinum -6% Rhodium (-) B +870° to +1700° .5% .25% +1600° to +3100° .5% .25%

Tungsten (+) vs.Tungsten -26% Rhenium (-) WR† +400° to +2300° 1% +800° to +4200° 1%

Tungsten -3% Rhenium (+) vs.Tungsten -25% Rhenium (-) W3† +400° to +2300° 1% +800° to +4200° 1%

Tungsten -5% Rhenium (+) vs.Tungsten -26% Rhenium (-) W5† +400° to +2300° 1% +800° to +4200° 1%

Temperature Sensors:Thermocouple Wire Calibration Type Characteristics

INITIAL CALIBRATION TOLERANCES FOR THERMOCOUPLE EXTENSION WIRE

THERMOCOUPLE TYPE °C °F

EXTENSION WIRE ALLOYS ANSI TYPE SYMBOL

TEMPERATURE RANGE

STANDARD LIMITS

SPECIAL LIMITS

TEMPERATURERANGE

STANDARD LIMITS

SPECIAL LIMITS

Copper (+) vs. Constantan TX -60° to +100° 1° 5° -75° to +210° 2° 1°*Iron vs. Constantan JX 0° to +200° 2.2° 1.1° +32° to +400° 4° 2°Chromel™ vs. Constantan EX 0° to +200° 1.7° 1.1° +32° to +400° 3° 2°Chromel™ vs. Alumel™ KX 0° to +200° 2.2° 1.1° +32° to +400° 4° 2°Nicrosil vs. Nisil NX 0° to +200° 2.2° 1.1° +32° to +400° 4° 2°Copper vs. Copper Alloy SX +25° to +200° 7° +75° to +400° 12°RXPLCW630 vs. Copper BX 0° to +200° 2.2° +32° to +400° 4°Copper vs. Copper BX 0° to +65° 1° +32° to +150° 2°Alloy 203 vs. Alloy 225 W3X† 0° to +260° 7° +32° to +500° 12°Alloy 405 vs. Alloy 426 W5X† 0° to +870° 7° +32° to +1600° 12°

Accuracy of Convectronics Wiretraceable calibration is available on request. Designate special limit grade wire using a double ANSI symbol (e.g. KK,JJ). Sub-zero and calibration requirements should be spelled out on the Purchase Order.

Thermocouple Extension Wirecomposition as the corresponding thermocouple type. For noble metal types, however, an entirely different alloy is formulated to match the noble metal characteristics over a specified temperature range. This is necessary due to the high cost of the noble metals which could otherwise be necessary for the interconnection. The “X” in the ANSI code denotes extension grade wire.

*Magnetic ™Trademark, Hoskins Mfg. Co. NOTE - Percent limits apply directly to temperatures in °C units, but for °F equivalents are applied† NOT ANSI Type Symbol to the number of °F above or below the ice point (+32°F) (i.e., limit (°F) = (temp.°F-32°) x Percentage)

*Magnetic ™Trademark, Hoskins Mfg. Co. † NOT ANSI Type Symbol


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Temperature Sensors:Thermocouple and Thermocouple Extension Wire - Color Codes

Thermocouple wire can be fabricated intoaccurate and dependable thermocouples byjoining the thermoelements at the sensingend.

Thermocouple wire or T/C extension wire ofthe same type must be used to extend T/C's to

indicating or control instrumentation.RED color code is negative throughout circuit.

Hook-up Red Color-Coded wire to negativeterminal of instrument.

Use T/C connectors if required, they are madeof the same alloy and have the same colorcodes of T/C extension wire. (Except Hi-Temp connectors are all colored red regardless of T/C type).These T/C connectors are molded from strong,non-melting, glass filled thermoset compounds.

Temperature limit of T/C depends on the T/Cwire; wire size; wire insulation; and environmental factors.

1832°F

T(+) Copper

(-) Constantan

(+) Iron (magnetic)

(-) Constantan

(+) Chromel

(-) Constantan

(+) Chromel

(-) Alumel

(+) Nicrosil

(-) Nisil(magnetic)

TM TM

TM

J E K N

(magnetic)

(magnetic)

WHITE(+)

PURPLE(+)

YELLOW(+)

ORANGE(+)

BLUE(+)

-330°F (-200°C)

660°F (350°C)

1400°F (750°C)

32°F (0°C) 32°F (0°C) 32°F (0°C) 32°F (0°C)

1600°F (900°C)2300°F (1250°C) 2300°F (1250°C)

(-)BROWN

RED(-)

BROWN

RED(-)

BROWN

RED(-)

BROWN

RED(-)

BROWN

REDNote: Someinsulations cannot

be color coded

InsulatedThermocouple

Wire Color Code

Note: Smallerwire sizes have

shorter T/Clife at highertemperatures

Bare WireTemperature

Range

Thermocouple WireLetter Designator

Alloy Combination& Polarity

TH

ER

MO

CO

UP

LE

WIR

E

TX(+) Copper

(-) Constantan

(+) Iron (magnetic)

(-) Constantan

(+) Chromel

(-) Constantan

(+) Chromel

(-) Alumel

(+) Nicrosil

(-) Nisil(magnetic)

TM TM

TM

JX EX KX NX

(magnetic)

(magnetic)

WHITE(+)

PURPLE(+)

YELLOW(+)

ORANGE(+)

BLUE(+)

32°F (0°C) 32°F (0°C) 32°F (0°C) 32°F (0°C)

(-)

ORANGE

RED(-)

YELLOW

RED(-)

BLUE

RED(-)

BLACK

RED(-)

PURPLE

RED

InsulatedT/C Extension

WireColor Code

BareExtension

WireTemperature

Range

T/C ExtensionWire

Letter Designator


T/C

EX

TE

NS

ION

WIR

E

-75°F (-60°C)

210°F (100°C)400°F (200°C)400°F (200°C)400°F (200°C)400°F (200°C)

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Temperature Sensors:Thermocouple and Thermocouple Extension Wire - Color Codes

Thermocouple WireLetter Designator


T/C Extension WireLetter Designator


InsulatedThermocouple

Wire Color CodeNote: Some

insulations cannotbe color coded.

Bare WireTemperature

Range

Bare Extension Wire

TemperatureRange

(+) Platinum30% Rhodium

(+) Platinum10% Rhodium

(+) Platinum13% Rhodium(-) Platinum

BSR

3100°F (1700°C)

1600°F (870°C)

32°F (0°C) 32°F (0°C)

2650°F (1450°C)2650°F (1450°C)

(-) Platinum (-) Platinum6% Rhodium

W5(+) Tungsten5% Rhenium

800°F (400°C)

4200°F (2300°C)

(-) Tungsten26% Rhenium

NOTAVAILABLEINSULATED




(for vacuum orinert atmospheres) Note: Smaller

wire sizes haveshorter T/C life at

higher temperatures

TH

ER

MO

CO

UP

LE

WIR

ET

/C E

XT

EN

SIO

N W

IRE

InsulatedT/C Extension

WireColor Code

W5X(+) Copper Alloy 405(-) Copper Alloy 426

(+) Copper Alloy 630(-) Copper

(+) Copper(-) Copper Alloy 11

(+) Copper(-) Copper Alloy 11

BXSXRX

32°F (0°C)

1600°F (870°C)

400°F (200°C)

32°F (0°C)75°F (25°C)75°F (25°C)

400°F (200°C)400°F (200°C)

BLACK(+)

(-)

GREEN

RED

WHITE/RED(+)

(-)

WHITE/ RED

RED

GREY(+)

(-)

GREY

RED

BLACK(+)

(-)

GREEN

RED


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ThermocoupleWire Type

ANSI TypeSymbol

Wire Gauge(AWG)8 ga. 14 ga. 20 ga. 24 ga. 30 ga.

Copper-Constantan T 370°C 260°C 200°C 150°C (700°F) (500°F) (400°F) (300°F)

*Iron-Constantan J 760°C 600°C 500°C 370°C 320°C (1400°F) (1100°F) (900°F) (700°F) (600°F)

Chromel™-Constantan E 870°C 650°C 550°C 430°C 430°C (1600°F) (1200°F) (1000°F) (800°F) (800°F)

Chromel™-*Alumel™ K 370°C 1100°C 1000°C 870°C 760°C (700°F) (2000°F) (1800°F) (1600°F) (1400°F)

Nicrosil-Nisil N 1260°C 1100°C 1000°C 870°C 760°C (2300°F) (2000°F) (1800°F) (1600°F) (1400°F)

Platinum-10% Rhodium S 1480°C (2700°F)

Platinum-13% Rhodium R 1480°C (2700°F)

Platinum-30% vs 6% Rhodium B 1700°C

(3100°F)

Tungsten-26% Rhenium WR† 2300°C(4200°F)

Tungsten-3% vs. 25% Rhenium W3† 2300°C

(4200°F)Tungsten-5% vs. 26% Rhenium W5† 2300°C

(4200°F)

Temperature Sensors:Thermocouple Wire Specifications

InsulationCode Wire Insulation Type Shield Abrasion

ResistanceMoisture

ResistanceInsulation

TemperatureRating

GG Fiberglass Braid Fair Fair 900oF (482oC)GW Fiberglass Wrap Fair Fair 900oF (482oC)HTG Ceramic Braid, High Temperature Poor Poor 2200oF (1205oC)KK Kapton (fused tape) Excellent Excellent 500oF (260oC)NN Nylon Excellent Excellent 350oF (176oC)PM Polyvinyl Chloride (PVC) Mylar Drain Line Good Excellent 221oF (105oC)PV Polyvinyl Chloride (PVC) Good Excellent 221oF (105oC)TF Teflon, TFE (fused tape) Very Good Excellent 500oF (260oC)TT Teflon, FEP Very Good Excellent 400oF (204oC)VS Vitreous Silica Fibre Poor Poor 1400oF (760oC)

*Magnetic ™Trademark Hoskins Mfg. Co. †Not ANSI symbol

American Wire

Gauge(AWG)

SizeDIA.

Inches

7/06/0 0.58005/0 0.51654/0 0.46003/0 0.40962/0 0.36481/0 0.32491 0.28932 0.25763 0.22944 0.20435 0.18196 0.16207 0.14438 0.12859 0.114410 0.101911 0.090712 0.080813 0.072014 0.064115 0.057116 0.050817 0.045318 0.040319 0.035920 0.032021 0.028522 0.025323 0.022624 0.020125 0.017926 0.015927 0.014228 0.012629 0.011330 0.010031 0.0089332 0.0079533 0.0070834 0.0063035 0.0056136 0.050037 0.0044538 0.0039639 0.0035340 0.0031441 0.0028042 0.0024943 0.0022244 0.0019845 0.0017646 0.0015747 0.0014048 0.0012449 0.0011150 0.00099

Temperature limits for standard thermocouples that are protected with a closed-end protection tube are shown. These limits are suggested for continuous temperature sensing where thermal limitation of the insulation is not a factor. For unprotected thermocouples these limits should be reduced for equivalent service life.

Upper Temperature Limits for Thermocouple Wire Gauge

Insulation Characteristics

Wire GaB & S

Wire SizeDIA.

ANSI TYPESJ K T E S R B

6 .162 .014 .023 .012 .027 .007 .007 .008*7 .144 .0218 .128 .022 .036 .019 .044 .010 .010 .01314 .064 .089 .147 .074 .176 .044 .044 .05416 .050 .141 .232 .117 .277 .069 .069 .08618 .040 .229 .377 .190 .450 .112 .113 .13920 .032 .357 .588 .297 .702 .175 .178 .21824 .020 .905 1.488 .745 1.778 .449 .453 .55026 .015 1.441 2.45 1.20 2.84 .701 .708 .87528 .012 2.297 3.59 1.92 4.33 1.062 1.073 1.39230 .010 3.65 6.02 2.94 7.19 1.794 1.813 2.21336 .005 14.66 24.08 12.22 28.80 7.150 7.226 8.897

Nominal Thermocouple Resistance Ohms Double Foot @ 68°F (20°C)

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Temperature Sensors: Thermocouple Wire - Standard Inventory Items

GG INSULATION:

RW--E20GG

RW--E24GG

RW--J20GG

RWS-J20GG

RW--J24GG

RWS-J24GG

RW--K20GG

RWS-K20GG

RW--K24GG

RW--T20GG

RW--T24GG

RW--R/S24GG

GW INSULATION:

RW--J20GW

RW--J24GW

RW--K20GW

RW--K24GW

HTG INSULATION:

RW--J20HTG

RW--K20HTG

RW--K24HTG

NN INSULATION:

RW--J20NN

RW--J24NN

RW--K20NN

RW--K24NN

RW--T20NN

RW--T24NN

KK INSULATION:

RW--J20KK

RW--J24KK

PV INSULATION:

RW--E16PV

RW--E20PV

RW--T16PV

RW--T20PV

RWS-T20PV

RW--J14PV

RW--J16PV

RW--J18PV

RW--J20PV

RWS-J20PV

RW--K14PV

RW--K16PV

RW--K18PV

RW--K20PV

RWS-K20PV

TT INSULATION:

RW--J20TT

RWS-J20TT

RW--J24TT

RWS-J24TT

RW--J30TT

RW--K20TT

RWS-K20TT

RW--K24TT

RWS-K24TT

RW--K30TT

RW--T20TT

RWS-T20TT

RW--T24TT

RW--T30TT

GG - Fiberglass BraidGW - Fiberglass WrapHTG - Ceramic Braid, High TemperatureNN - NylonPV - Polyvinyl Chloride (PVC)TT - Teflon, FEPKK - Kapton

* All of the items listed can have a stainless steel, tinned copper or inconel 600 wire braid added. Consult factory for availability

A - Stainless Steel I - Inconel 600 C - Tinned Copper

* Stock inventory is subject to prior sale. Consult factory for delivery.

Conductor Types:

RWS - Stranded WireRW - Solid Wire

HOW TO ORDER: R W S -Conductor Type (Solid or Stranded)ANSI Type Gauge Size Insulation Type

EXAMPLE: To order a 24 gauge - stranded wire - ANSI type “J” with fiberglass braid overeach and overall, the part number is: R W S -

Conductor Type (Stranded)ANSI Type (“J”)Gauge Size (24 AWG.)Insulation Type (Fiberglass overeach and overall)

J 24 GG


46

Notes and Data

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