TISI-07.11

Table of Contents

Power Source ……………………………….............................………………………….. 1

Twin Heat Module ……………………...………………………….............................….. 2

Controllers ……………………………………………………….............……………….. 3

Recorders ……………………………………………………………….............………… 4Strip ChartDigital PaperlessChart Paper and Ribbons

Power Source Parts ……………………………………………….............……………… 6Casters Fans and Filters Panel MetersCircuit Breakers Fuses and Fuse Holders RelaysContactors Hardware Strain ReliefsCoopermaster Indicator Lights SwitchesElectrical Connections Lugs Transformers

Power Cabling …………………………….............……………………………………… 8SplittersTriple Cable SetsPrimary Power Cable

Camlock Connectors ……………………………………………............……………….. 9150-Amp Camlocks300-Amp Camlocks

Thermocouple …………………………………………………………............…………. 10Thermocouple Attachment Unit (TAU)Thermocouple ConnectorsThermocouple Jack PanelsThermocouple WireThermocouples Sheathed

Test Equipment ……………………………………...…………….............……………... 13Brinell Hardness Test KitUnical TC+ Calibrator

Heaters …………………………………………………………………….............……… 14Flexible Ceramic Pad (FCP) Heaters (80 and 60VAC)Repair Kits

Insulation …………………………………………………………………….............…… 16BlanketCooperknitNeedled SilicaWelding Cloth

Insulation Attachment ………………………………………………….............……...… 17Banding and ClipsFiberglass TapeIron WireStud Welder and AccessoriesStud Welding Pins & Washers

Power Source

09011201

DescriptionThe ability to control temperatures precisely is the key toaccurate heat treatment. The Team Industrial Services,Inc. (TISI) 6-way control console is designed to providesix independently controlled, low voltage, high currentoutputs which precisely control the workpiecetemperature. Six electronic temperature controllers witha Coopermaster Temperature Setpoint Programmer allowthe operator to manually or automatically control theheating process.

Length 24 inchesWidth 24 inchesHeight 48 inchesWeight 600 - 675 lbs.Primary Voltage

Standard 480 VACInternational 380/415/440/480/575 VAC

Secondary Voltage 65/85 VACPower Out, Fan-Cooled 72 KW

Safety Is Built In• 125-amp circuit breaker for primary power connection.• 5-amp circuit breaker safety switch in case ofoverloading on control circuit.• Over-temperature protection of main transformer coils(275°F/135°C temp. trip).

Coopermaster III Features Promote Efficiency and Ease of Use• Six commonly used programs based upon heating codes, typical materials, wall thickness and temperatures are permanently storedin memory and can be easily accessed. Any of these six programs may be modified for temporary use.

• Fourteen additional user-designed programs with sixteen segments can beadded by the customer and locked into memory for repeated use.

• Modular construction allows quick replacement of any component.• Dual position power failure protection switch

• Position #1: If input power is lost during the heating cycle and powerreturns within five minutes, the machine will restart,remember the program and continue to run.

• Position #2: The machine will remain off.

Options To Fit Your Needs• Local control - Six independent heating cycles can be controlled with one

manual 6-way unit.• Remote control - Six manual zones can be controlled automatically with a Coopermaster Temperature Setpoint Programmer or six

individual programmable zone controllers.• Temperature recording - A 6-way console is also available with a 12-point or 24-point temperature recorder.• Customized units available - The 6-way power source can be customized to fit most heat treatment requirements.Part Number Description

Standard International09009901 09009902 6-way, Manual Control09010101 09010102 6-way, Manual Control with 12-point Recorder09010501 09010502 6-way, Manual Control with Coopermaster Programmer09011201 09011202 6-way, Manual Control with 12-point Recorder and Coopermaster Programmer09009903 09009904 6-way, Programmable Control09010103 09010104 6-way, Programmable Control with 12-point Recorder

See POWER SOURCE PARTS for replacement parts

Contact your TISI sales representative for more information. 1 TISI-07.11

2TISI-07.11

Twin Heat Module

DescriptionThe Twin Heat Module (THM) uses the output of any AC or DC welding machine or transformer to provide one or two independentchannels of temperature control for heat treatment. This power is typically supplied by a 65 or 85 VAC power source with a 300-amp per zone capacity.The THM includes temperature controllers, contactor control switches and thermocouple output sockets to facilitate temperaturerecording. The THM also has the option of a 2-pen temperature recorder. A 16-gauge stainless steel case protects unit componentsduring field operation.

Without recorder (with recorder)Length 16 3/4 inches (19 inches)Width 10 3/8 inches (11 1/4 inches)Height 11 3/4 inches (12 inches)Weight 27 lbs. (36 lbs.)

On-Site Heat Treatment Is Convenient With The THM• The small size makes the unit suitable for use in confined spaces.• Portability allows the THM to be moved quickly to widelyseparated locations on a job site.

Electrical SpecificationsPower circuit to heaters

Input/output voltage 6-60 VDC up to 220 VACInput/output current 300-amp

Control circuit, inputVoltage 120 VAC, 50-60 Hz

Control circuit, auxiliary outputVoltage 120 VAC, 50-60 HzCurrent 25-amp (control circuit protected

at 5-amp breaker total)Temperature controller

Temperature range 0-2400°FThermocouple Type K

09002900

Part Number Description09002800 Twin Heat Module, Manual Control09002900 Twin Heat Module, Programmable Control09007800 Twin Heat Module, Manual Control with 2-pen Recorder09007900 Twin Heat Module, Programmable Control with 2-pen Recorder

The following accessories are necessary to connect to a power source:29001000 Feed/Return Cable with Lug and 300-amp connector, 10'

or29001002 Feed/Return Cable with 300-amp connectors, 10'

29002004 Power Cable, 110 VAC, 10' (other sizes available)

Contact your TISI sales representative for more information.

Replacement parts for the Twin Heat Module:Part Number Description Part Number Description58012200 UDC-2500 Controller, Manual Control 49008002 TC Jack Panel, Numbered Dual 158012900 UDC-3500 Controller, Programmable 49008003 TC Jack Panel, Numbered Dual 250000300 Indicator Light, Red 59001300 Contactor, 1-pole, 300A, 120V57004301 Circuit Breaker, Panel Mount, 5A 56004700 300-amp Panel Mount Connector, Male54008300 Handle for Top/Front 56000200 300-amp Panel Mount Connector, Female54008900 Handle, Fold down for Top 56007900 110 VAC Auxiliary Output Receptacle09002500 Rubber Feet for Base 56007400 110 VAC Supply Input Receptacle

Controllers

DescriptionEach zone in a 6-way power source and Twin Heat Module is controlled by a Universal Digital Controller (UDC). The UDC-2500model which replaced the UDC-2300 model provides basic manual control using the arrow keys to increase or decrease the rate.The programmable UDC-3500 model which replaced the UDC-3300 model has set point programming (SPP) capabilities that allowup to five programmed segments. The unique feature of the available TISI UDC-3500 model is that it has a special firmwareprogram which simplifies the programming process. Both models are easy to program, operate and read. All configurations andalignments are completed prior to shipment so that upon receipt, the controller can be placed immediately into service. Please notethat if the new controller is replacing a previous model, minor rewiring will be required to install.

• Convenient to configure - The operator can increase or decrease the local setpoint, select local or remote operating mode,or momentarily display information about the current process with simple keystrokes.

• A bright, dedicated display performs two functions. The upper display is dedicated to the process variable during normaloperation. Straightforward prompts in English allow easy adjustments to the setpoint, process variable, deviations andoutput values with minimum time and effort, which are shown on the lower display. Status indicators display degreesFahrenheit, remote or local operation and alarm and output conditions.

• The vacuum fluorescent display clearly presents data. Unlike an LED screen, the vacuum fluorescent display is easilyreadable in direct sunlight.

• The well-designed keyboard encourages quick and accurate data entry.

• Universal inputs are accepted: Nine thermocouple types, RTDs, mA, mV and voltage inputs can be configured simply.

Safety features are programmed into the unit to protect operating information.• Thermocouple failsafe ensures the integrity of data-configurable upscale or downscale burnout or failsafe output level.• Reliable performance is immune to high noises. The unit provides reliable, error-free control in industrial environments that oftendisturb highly noise-sensitive digital equipment.• Input signal smoothing is supplied by the configurable digital filter in 0 to 120 seconds.• Data integrity is ensured during power losses. Nonvolatile memory secures information.• Keyboard security prevents accidental or unauthorized changes to process configurations.

Controller SpecificationsAccuracy ±1 digit for displayTemperature stability ±0.01% of full span/°C change typicalInput signal failure protection Upscale, downscale or failsafe burnoutInput impedance 200K ohmsController output types Electromechanical or solid state relays,

Current outAvailable options Alarm outputs, RS422/485 or ethernet TCP/IP

communications interface, Infraredcommunications (standard on UDC-3500)

Sample rate Input sampled 6 times a secondInput filter Off to 120 secondsWiring connections Screw terminals on rear of casePower consumption 20 VA (UDC-2500) / 24 VA (UDC-3500)

maximum (90 to 264 VAC)Weight 3 lbs.

Part Number Description58012200 UDC-2500, Manual with Single Input (replaces UDC-2300 part number 58001200)58012300 UDC-2500, Manual with Second Input (replaces UDC-2300 part number 58001300)58012500 UDC-2500, Manual with Single Input and Setpoint Programming (replaces UDC-2300 part number 58001500)58012600 UDC-2500, Manual with Second Input and Setpoint Programming (replaces UDC-2300 part number 58001600)58012900 UDC-3500, Programmable with TSI Prom (replaces UDC-3300 controller part number 58012700)

Contact your TISI sales representative for more information.

58012900

3 TISI-07.11

4TISI-07.11

Recorders

Strip Chart RecorderThe strip chart recorder is a multi-point recorder whose field worthinessand variable configuration makes it ideally suited for on-siteapplications. The standardtemperature recorder isavailable with 12 channelsfor reliable, accurate recordsof time-temperature profilesfor all control and monitorthermocouples. Recordersare also available with 6 and24 channels (µR-20000) oras a 2-pen model (µR-10000).

Digital Paperless RecorderTeam Industrial Services, Inc. also offers a digital recorder option that allows for paperless recording. The SX has a 12.1-inch, coloractive matrix LCD touch screen display for clear viewing and is available with up to 48 analog inputs. The QX is another availableoption with only 6 standard inputs. All collected time-temperature data can be saved to a compact flash (CF), USB storage devicereader or linked directly through the internet or LAN via an ethernet connection. The recorder includes the software necessary toview the data on a computer. Additional firmware credits are available for purchase to unlock more features if required.

SX (QX) Specifications

Mechanical SoftwareWeight 22 lbs. (5.3 lbs.) Processor 1 GHz pentium or higherHeight 11 3/8 inches (5.67 inches) Operating System Windows 2000, XPWidth 11 3/8 inches (5.67 inches) RAM 512 Mbyte minimumDepth 8 5/8 inches (9.74 inches) Free Hard Drive 50 Mbyte minimumCase Mild steel, zinc-plated

ElectricalVoltage 100 to 250VACCurrent 1/4-Amp at 110VAC

ConfigurationChannels 12 standard, up to 48 available (6 standard)Scan Rate Real-timeChart Speed Adjustable

Operator InterfaceAlthough it can accommodatea wide range of DC-voltageinputs, each channel isconfigured for Type Kthermocouples at the Team factory. Printing formats are configurable by means of a convenient menu-driven Setting mode. Chartspeed can be programmed from 0.04 to 480-inch/hour and is set for 2-inch/hour at the Team factory. In addition to chart paper, thestrip chart recorder utilizes a large, easy-to-read full dot matrix display for highly visible read selection and ease of use. Operatorinput to the recorder is by means of a seven-button keypad to access and navigate the interactive Operation and Setting modes.

µµR-20000 (µµR-10000) SpecificationsMechanicalWeight 19 lbs. (4.85 lbs.)Height 11 3/8 inches (5.67 inches)Width 11 3/8 inches (5.67 inches)Depth 8 5/8 inches (9.74 inches)Case Drawn steel, 16-gaugeDoor Cast aluminum

ElectricalVoltage 100 to 240VACCurrent 1/4-Amp at 110VAC

ConfigurationChannels 12 standard, 24 available (2 or 6)Scan Rate 1 1/4-seconds/channelPaper Z-fold, 180mm (100mm)Dot Colors 6 (2)Chart Speed 2-inch/hour factory set (1-inch/hour)Printing Digital and analog

Operator InterfaceAlthough it can accommodate a wide range of DC-voltage inputs, eachchannel is configured for Type K thermocouples at the TISI factory.The enclosed stylus allows for easy interaction with the touch screenmenus. Using the menus, each pen can be assigned as well as alarmsand chart speeds set along with many other features. The gathered datacan be analyzed by a variety of graphs either on the LCD display or ona computer.

45007380

45007322

5

Recorders

TISI-07.11

Carrying CaseA recorder is also available as a stand-alone unit that can be installed into a carrying case. The recorder will be ‘socketed’ whichmeans that an enclosure will be mounted to the back and wired with the thermocouple jack panel and a power cord. The digitalrecorders also include an ethernet port. It can be plugged into any 110-volt power source and, with the use of male-to-male thermocouple jumper cables, will be able to provide time-temperature profiles. The carrying case is steel reinforced with a carryinghandle and lined with polyurethane foam to protect the recorder during transit and on-site use. The case has removable front andrear doors for easy access.

RECORDER REPLACEMENT PARTS

RIBBONS & PENSPart Number Manufacturer Model Description45020100 Yokogawa µR-1000/0 Ribbon Cartridge45020200 Yokogawa µR-1000/0 Red Pen45020300 Yokogawa µR-100/00 Green Pen45020400 Yokogawa µR-1000/0 Purple Pen/Plotter 45004000 Yokogawa µR-180/0, 20000 Ribbon Cartridge45033200 Honeywell DPR-100 Ren Pen45033300 Honeywell DPR-100 Blue Pen45030800 Honeywell DPR-180, 3000, 250 Ribbon Cartridge45012000 Chino AL-3000 Ribbon Cartridge45013000 Chino AH-3000 Ribbon Cartridge

CHART PAPERPart Number Manufacturer Model Description45020502 Yokogawa µR-1000/0 0-2000° Scale45020501 Yokogawa µR-1000/0 0-100% Scale45000302 Yokogawa µR-180/0, 20000 0-2000° Scale45000301 Yokogawa µR-180/0, 20000 0-100% Scale45033100 Honeywell DPR-100 0-100% Scale45030900 Honeywell DPR-180 0-100% Scale45031000 Honeywell DPR-3000, 250 0-100% Scale45011900 Chino AL-3000 0-100% Scale45009800 Chino AH-3000 0-2000° Scale 45009801 Chino AH-3000 0-100% Scale

45007422 in carrying case

Part Number Description45007321 Recorder, Analog, 12-point45007322 Recorder, Analog, 24-point45007380 Recorder, Digital, 12-point45007390 Recorder, Digital, 24-point45007521 Recorder, Analog, 12-point, Calibrated45007522 Recorder, Analog, 24-point, Calibrated45007580 Recorder, Digital, 12-point, Calibrated45007590 Recorder, Digital, 24-point, Calibrated45007421 Recorder, Analog, 12-point, Calibrated and Sockets45007422 Recorder, Analog, 24-point, Calibrated and Sockets45007480 Recorder, Digital, 12-point, Calibrated and Sockets45007490 Recorder, Digital, 24-point, Calibrated and Sockets45001800 Carrying Case (for size recorders above)

45007310 Recorder, Analog, 6-point45007312 Recorder, Analog, 2-pen45007370 Recorder, Digital, 6-point45007510 Recorder, Analog, 6-point, Calibrated45007512 Recorder, Analog, 2-pen, Calibrated45007570 Recorder, Digital, 6-point, Calibrated45007410 Recorder, Analog, 6-point, Calibrated and Sockets45007412 Recorder, Analog, 2-pen, Calibrated and Sockets45007470 Recorder, Digital, 6-point, Calibrated and Sockets45001900 Carrying Case (for size recorders above)

6TISI-07.11

Power Source Parts

CIRCUIT BREAKERSPart Number Description57003704 Circuit Breaker, 1P, 5A, 277V, Rocker-style57003800 Circuit Breaker, 3P, 125A, 600V, CH-style57004101 Circuit Breaker, 3P, 100A, 600V, TSI-style57004201 Circuit Breaker, 3P, 100A, 600V, Hill-style57004301 Circuit Breaker, Panel Mount, 5A57004302 Circuit Breaker, Panel Mount, 10A57004302 Circuit Breaker, Panel Mount, 3/4A

(replaces 57001700 with 57001101)

CONTACTORSPart Number Description59001300 Contactor, 1-pole, 300A, 120V59001400 Repair Kit for 59001300*59003600 Contactor, 1-pole,200A, 120V59004600 Repair Kit for 59003600*59005000 Contactor, 3-pole, 90A (Standard)59004900 Contactor, 3-pole, 120A (International)

*Each repair kit includes:1 - Upper Contact Assembly2 - Lower Contact Assembly1 - Replacement Spring

ELECTRICAL CONNECTIONSPart Number Description57000601 GFI Receptacle, 15A, 125V, Duplex Edison57000602 Cover for GFI Receptacle56009300 Socket, Midget, Panel Mount, 15A, 125V56012102 Terminal Block, Double Row, 2-Term56012112 Terminal Block, Double Row, 12-Term57004601 Power Distribution Block, 3P, 175A, 480V

FUSES & FUSE HOLDERSPart Number Description57001305 Fuse, KTK-R, 5A57001310 Fuse, KTK-R, 10A57001101 Fuse, AGC, 3/4A for contactor protection57001104 Fuse, AGC, 2A for cooling fan protection57000102 Fuse Holder, 2P, 600V57001700 Fuse Holder, 30A, 250V for contactor (3/4A)

PANEL METERSPart Number Description71001800 Ammeter, 0-300A, Digital Panel Meter, CH-style71002000 Ammeter, 0-150A, Digital Panel Meter, TSI-style

SWITCHESPart Number Description62001700 Switch Assembly, START/STOP62003801 Switch, 6-station for CH-style62010100 Aluminum Knob for 6201040062010400 Switch, Rotary, 6-position for TSI-style

RELAYSPart Number Description59001500 Relay Base, 8-pin59001600 Relay, 24VDC, 8-pin59001700 Relay, 120VAC, 8-pin, Illuminated

INDICATOR LIGHTSPart Number Description50000300 Indicator, Red, 80VAC with Leads50000500 Bulb for START/STOP Switch50001000 LED, Bayonet-style, White50001100 LED, Bayonet-style, Green50001200 LED, Bayonet-style, Red50002000 Mounting Flange for LED Assembly50002100 Actuator Sleeve for LED Assembly50002200 Lamp Holder for LED Assembly50002300 Contact Block for LED Assembly50002400 Lens Holder for LED Assembly50002500 Green Lens for LED Assembly50002600 Red Lens for LED Assembly50002700 Bezel for LED Assembly

59001300

59003600

59005000

59004900

57003800

57003704

57004301

57001700

57001101

62001700

50000500

50001100

LED Assembly

6201040062003801

71001800

50000300

59001700

59001500

57004601

7

Power Source Parts

TISI-07.11

CASTERSPart Number Description53005200 Dolly for 6-way, 4" casters54000401 Rigid Caster, 4" without brake54000403 Swivel Caster, 4" without brake54000404 Swivel Caster, 4" with brake54000411 Rigid Caster, 6" without brake54000413 Swivel Caster, 6" without brake54000414 Swivel Caster, 6" with brake

STRAIN RELIEF GRIPSPart Number Description56006701 Strain Relief Grip, Oval, 1/2"56006704 Strain Relief Grip, Oval, 1 1/4"56006705 Strain Relief Grip, Oval, 1 1/2"56006600 Strain Relief Grip, Straight, 1 1/4"64004201 Strain Relief Grip, Mesh, 1"64004202 Strain Relief Grip, Mesh, 1 1/4"

COOPERMASTERPart Number Description46003300 Coopermaster III Assembly46003203 Distribution Board for CM III55005700 Cable, PC Board Jumper for CM III56008800 Connector Block, 22-pin for CM III56006900 Connector, Socket, Panel Mount for CM 62001800 Switch, Toggle, DPDT for CM III

FANS & FILTERSPart Number Description72000100 Cooling Fan, Axial72000200 Cord for Cooling Fan, Axial, 24"72000400 Exhaust Fan, Wire Frame, 12"52005901 Filter, 20" x 20" x 1" for CH-style52005902 Filter, 10" x 20" x 1" for TSI-style

LUGSPart Number Description56010400 Ground Lug, Copper56012200 Ground Lug, Aluminum56010304 Crimp Lug, 3/8" Purple56010306 Crimp Lug, 1/2" Purple56011605 Crimp Lug, 3/8" Green56011610 Crimp Lug, 1/2" Green

TRANSFORMERSPart Number Description60000100 Transformer, 55kVA, 480 VAC (Standard)60000710 Transformer, 55kVA, 380/415/440/480/575 VAC (International)60006000 Transformer, 77kVA, 480 VAC (TSI-style)60003400 Transformer, 750VA, 240-480/120-240 (Standard)60001100 Transformer, 750VA, 208-600/120-240 (International)60003901 Current Transformer, 5-300A Loop with Leads for CH-style60003902 Current Transformer, 5-150A Loop with Leads for TSI-style

72000100

72000200

72000400

56006900

56008800

62001800

60001100

60003400

60003901

64004201

56006600

54000413

54000414

56006704

HARDWAREPart Number Description09002400 Lever Latch for Rear Machine Door54012200 Handle for Front Door Pocket54012300 Magnet for Front Door Catch54001601 Latch Hinge, Left-Handed (TSI-style)54001602 Latch Hinge, Right-Handed (TSI-style)09003000 Control Knob for THM (Old Style)58005100 Energy Regulator / Cycle Timer (Old Style)54008300 Handle for Top/Front of THM54008900 Handle, Fold down for Top of THM

8TISI-07.11

Power Cabling

A typical electric resistance heating circuit consists of the following components:

• A multi-zone power console (e.g. 6-way) with female camlock electrical power connectors and female thermocouple jackpanels.• A triple cable set to bring power and thermocouple cabling from the power source to the heaters with male camlock and thermocouple connectors on the power console end and female connectors on the heater end.• A splitter cable to connect multiple heaters in parallel in the same zone circuit with one large male camlock connector and multiple small female camlock connectors.• A control thermocouple with a male polarized plug connector.

Splitter CableThree-way splitters are standard to enable three heaters to be connected in parallel to a single control zone. Two splitter cables areneeded for each zone. Each splitter cable connects one of the two power cables of a triple cable set to one side of the three parallelheaters. Two-way and four-way splitters are also available.

SpecificationsLength 4-foot longSize #6, approximately 3/8-inch outer diameterStranding Seven bundles of 37 strands of 30-gaugeInsulation Ultra-Flex thermoplastic rubberRatings -74°F to 221°F, 600-Volt,

300-Amp male and 150-Amp female camlocks

Triple Cable SetA triple cable consists of a taped assembly of twin power cables and a thermocouple extension cable. The multi-stranded powercables are flexible and covered with a thermoplastic rubber insulation that is resistant to abrasion, oil, acid, ultraviolet light and hightemperature. The type K thermocouple extension cable is solid 20-AWG PVC-sheathed shielded wire that is encased in a PVC abrasion-resistant jacket and equipped with a polarized male plug and female socket.

SpecificationsAssemblyLength 25-foot, 50-foot or 100-foot standardWeight 65 lbs./100-footBinding Fiberglass tape, 1-foot pitch

Power CableSize #2, approximately 1/2-inch outer diameterStranding Seven bundles of 90 strands of 30-gaugeInsulation Ultra-Flex thermoplastic rubberRatings -74°F to 221°F, 600-Volt, 300-Amp camlocks

Thermocouple Extension CableType K, Chromel-AlumelSize 20-AWG, SolidInsulation PVC with PVC outer jacketConnectors Polarized male plug and female socket

29001900 29002200

29004003

Part Number Description29001500 Splitter, 2-way, 4' long29001900 Splitter, 3-way, 4' long29002200 Splitter, 4-way, 4' long

29004001 Triple Cable Set, 25'29004002 Triple Cable Set, 50'29004003 Triple Cable Set, 100'

55002700* Power Cable, 4/4 55004400* Power Cable, 6/4

*order in 25-foot increments

Additional cable is available in 10-foot increments:

Part Number Description55002401 #6 Cable, Gray for Splitters55002601 #2 Cable, Gray for Triple Cables49000200 Thermocouple Extension Cable

9

Camlock Connectors

TISI-07.11

Camlock electrical power connectors achieve an insulated locking connection with an approximate 1/2-turn for high-amperage circuits. Connector sets are available in panel mount and in-line styles.

SpecificationsPanel Mount Brass male/female body, 150- or 300-Amp

Bolted neoprene casing or high-impact plastic

Large In-Line Brass male/female body, 300-AmpFiber electrical insulating sleeveFiber interlocking pin

Small In-Line Brass male/female body, 150-AmpFiber electrical insulating sleeveFiber interlocking pin

56000600

56000700

56004800 56005300

56000400

56000500

56004700 56000200

Female In-Line Connectors without Sleeve

Part Number Description56000600 Connector, 150-Amp, Male Complete56000700 Connector, 150-Amp, Female Complete

56000400 Connector, 300-Amp, Male Complete56000500 Connector, 300-Amp, Female Complete

Replacement Parts56002000 Connector, 150-Amp, Male Sleeve Only56002200 Connector, 150-Amp, Female Sleeve Only56002300 Connector, 150-Amp, Pin

56001400 Connector, 300-Amp, Male Sleeve Only56001600 Connector, 300-Amp, Female Sleeve Only56001700 Connector, 300-Amp, Pin

High-Impact Plastic56004600 Connector, 150-Amp, Panel Mount, Male56004300 Connector, 150-Amp, Panel Mount, Female

56004800 Connector, 300-Amp, Panel Mount, Male56005300 Connector, 300-Amp, Panel Mount, Female

Neoprene Casing56004500 Connector, 150-Amp, Panel Mount, Male56004200 Connector, 150-Amp, Panel Mount, Female

56004700 Connector, 300-Amp, Panel Mount, Male56000200* Connector, 300-Amp, Panel Mount, Female

*Standard on TISI 6-way machines

10TISI-07.11

Thermocouple

DescriptionTo measure the surface temperature of a metallic workpiece, do not rely on contact heat transfer from your workpiece surface to theseparate junction of a sheathed or twisted-wire thermocouple. Instead get the most reliably accurate temperature measurement byturning the workpiece surface into a thermocouple junction with the use of a capacitance discharge thermocouple welder (TAU,Thermocouple Attachment Unit).

OperationThe TAU provides major improvements over other methods for attaching thermocouples to both ferrous and non-ferrous metals. Itattaches thermocouples directly to the workpiece and handles high temperatures, up to 2300°F, necessary for stress relieving carbonand low alloy steels. The portable, rugged TAU can reach any job easily. The unit attaches thermocouples quickly so that heat treating can be done promptly and the workpiece returned to use.

Cost SavingsExpensive errors occur when thermocouples are not directly attached to the workpiece and do not accurately measure the heat treating temperatures. The TAU eliminates these errors and minimizes downtime. The penetration depth is minimal: .007 in. (.18 mm) and .003 in. (.07 mm) in the heat-affected zone. Marring is easily removed by light filing. The TAU will alert the operatorwith an audio and a visual indicator when the unit has cycled and reached the preset power level.

SpecificationsEach TAU is housed in a rugged stainless steel carrying caseequipped with a padded nylon shoulder strap and designed with storage space for the attached pliers, magnet and power cord. Power for the solid state system is supplied by the internal nickel-cadmium battery. The battery can be rechargedfrom 120-volt supply and allows up to 150 uses per charge. Not only can the unit be operated while charging, but it can also be completely recharged within just 3 hours.

Weight 11 1/2 lbs.Height 8 1/2 inchesWidth 3 3/4 inchesLength 10 1/2 inchesBattery Type 12V Nickel CadmiumVoltage 120VAC, 60HzThermocouple E, J, K, TWire Capability 16 - 30 Gauge (AWG)Voltage Discharge 15 - 80 VoltsEnergy Discharge 5 - 50 Joules

Replacement parts for the Thermocouple Attachment Unit (TAU):Part Number Description13000300 Thermocouple Attachment Unit, Series IV13000100 Enclosure for TAU, Stainless Steel13001000 Plier Assembly with Male Camlock for TAU13001100 Operation Label for TAU13005300 Adjustable Shoulder Strap for TAU54004500 Magnet for TAU63002200 Battery for TAU63012300 Power Cord for TAU

13000300

63002200

11

Thermocouple

TISI-07.11

A typical thermocouple circuit consists of the following components:

• A thermocouple containing the hot junction on the workpiece surface.It can be either a sheathed, twisted-wire or capacitance discharge welded thermocouple.

• A male polarized plug attached to the connection end of the thermocouple.Its large diameter prong and small diameter prong avoid cross-connecting +/- leads.

• A thermocouple extension cable connecting the thermocouple to the recorder.It has a female socket on the thermocouple end and a male plug on the recorder end.

• A recorder or similar measuring instrument to indicate and/or document the temperature value.A polarized female jack panel is needed to accept the thermocouple extension cable.

There are a variety of types of thermocouple wire with different metallic combinations; however, type K Chromel-Alumel wire, witha temperature range of 32°F to 2300°F, is best suited for most of the thermal processes conducted in heat treating. The Chromel element is the non-magnetic positive lead with yellow insulation. The Alumel element is the magnetic negative lead with red insulation. In addition, there is a variety of individual wire insulation and overall jacket materials. Q/Q (braided quartz glass insulation andjacket) is an excellent choice for most applications because of its abrasion and temperature resistance. Cefir (braided ceramic fiberinsulation and jacket) is appropriate for extreme temperature applications.

SpecificationsType K (Chromel-Alumel)Wire 20-gauge (AWG)Maximum Range

Q/Q 1200°F, continuous (1600°F, single)Cefir 2200°F, continuous (2400°F, single)

Quality Certificate of Conformance

Part Number Description49000200 Wire, K TC, Extension with PVC shielded jacket49000500 Wire, K TC, Q/Q49000600 Wire, K TC, Cefir

4900060049000500

TISI has a variety of thermocouple extension wires and cables available as well as connectors and jack panels. The extension wirehas a PVC wire insulation and shielded jacket. All standard parts are Type K, 20-gauge (AWG) but other types and sizes are available. Contact your TISI sales representative for more information.

Part Number Description49004003 TC Cable Assembly, K TC Extension with Male and Female Connectors, 25'49004004 TC Cable Assembly, K TC Extension with Male and Female Connectors, 50'49004005 TC Cable Assembly, K TC Extension with Male and Female Connectors, 100'

49004203 TC Cable Assembly, Jumper, K TC Extension with Male Connectors, 6'49004202 TC Cable Assembly, Jumper, K TC Extension with Male Connectors, 10'

49004100 TC Cable Assembly, K TC Q/Q with Male Connector, 10'

Part Number Description49000900 Plug, TC, Type K49001000 Socket, TC, Type K

49008100 Plug, TC, Type K, Midget49008200 Socket, TC, Type K, Midg

49004003

49004202

49000900

49001000

12TISI-07.11

Thermocouple

49001103

49008010

Unlike thermocouple wire, sheathed thermocouples can not be capacitance discharge-welded to workpiece surfaces. They must beattached to the work surface with welded clips or banding, both available from TISI.

SpecificationsConstruction Thermocouple wire within metal sheath, hollow

Filled with magnesium oxide, grounded junction

Sheath Material 310 Stainless Steel, standardInconel, 304 or 316 Stainless Steel available, custom

Sheath Diameter 1/8-inch, standard0.04-inch to 3/8-inch available, custom

Length 2-foot, 6-foot, 12-foot and 20-foot, standardOther lengths available, custom

Attachment 1/8-inch, standardStainless or mild steel available, single or dual (dual available in stainless steel only)

Part Number Description49002202 TC Sheathed, 2', 1/8-inch diameter, Type K49002206 TC Sheathed, 6', 1/8-inch diameter, Type K49002212 TC Sheathed, 12', 1/8-inch diameter, Type K49002220 TC Sheathed, 20', 1/8-inch diameter, Type K

49002000 Clip, Single TC, Mild Steel49001800 Clip, Single TC, Stainless Steel49001900 Clip, Dual TC, Stainless Steel

37000100 Putty, Moldable, 14.5 oz. Tube

49002202

49002220

49001800

49001900

Part Number Description49001101 TC Jack Panel, 2-point, CH-style49001102 TC Jack Panel, 4-point, CH-style49001103 TC Jack Panel, 6-point, CH-style49001105 TC Jack Panel, 12-point, CH-style49001106 TC Jack Panel, 24-point, CH-style

49008001 TC Jack Panel, Numbered 1-2, TSI-style49008004 TC Jack Panel, Numbered 1-6, TSI-style49008005 TC Jack Panel, Numbered 7-12, TSI-style49008010 TC Jack Panel, Numbered 1-12, TSI-style49008011 TC Jack Panel, Numbered 13-24, TSI-style49008002 TC Jack Panel, Numbered Dual 1, TSI-style49008003 TC Jack Panel, Numbered Dual 2, TSI-style49008012 TC Jack Panel, Numbered Dual 1-6, TSI-style

49008012

13

Test Equipment

TISI-07.11

The Unical TC+ is a thermocouple simulator which can source or measure all normalized IEC, DIN and JIS thermocouples (J, K, T,R, S, B, C, U, L N, E, F) as well as mV. It includes programmable scale factors, engineering units, quickstep simulation proceduresand averaging. Output values are easily sent digitally via the tactile keypad. Input fuse protection prevents damage from inappropriate connections. The calibrator is protected with a rugged, shock-resistant case and an internal metal coating for shielding.For optimal cold junction compensation, the calibrator has a thin film RTD placed directly within the connection terminals. TheUnical TC+ has a memory capability that will allow programming and storing of up to seven simulation programs with up to sixtyvalues, allowing a true simulation of your specific thermal system for verification of the on-line instruments.

SpecificationsMechanicalWeight 3 lbs.Length 8.3 inchesWidth 3.8 inchesDepth 1.6 inchesCase Shock resistant ABSAccessories Carrying case, battery charger

ElectricalInput Voltage 50V, maximumProgram 9V-battery back up

CalibrationMeasure IEC, DIN and JIS thermocouples, mVRange -454 to 2498°F (-234 to 1370°C) for Type KAccuracy 0.04% of the reading, 0.1°F/C resolutionConnection Internal or external cold junction compensationProgram Up to seven simulations using up to 60 values,

Selectable temperature scale

Part Number Description65001900 Temperature Calibrator, Unical TC+

According to our company standards, calibration of our equipment is required every six months. Team Industrial Services Inc. provides calibration services for all applicable equipment. Please contact yoursales representative for more information.

65001900

13005001

The standard Brinell kit includes the following in a carrying case:• Large Bar Holder• Five Random Test Bars• Scope• Computing Wheel• Computation Pad

The large bar holder can be substituted for a fillet weld tester orthe fillet weld tester can be purchased separately.

Part Number Description13005001 Brinell Kit with Large Bar Holder13005002 Brinell Kit with Fillet Weld Tester13007600 Fillet Weld Tester13006600 Scope13005102 Brinell Bar, 176 Hardness13005105 Brinell Bar, 194 Hardness13005108 Brinell Bar, 229 Hardness

Other size hardness bars available

14TISI-07.11

Heaters

ConstructionFlexible ceramic pad (FCP) heaters are manufactured by weaving multi-stranded 80/20 Nichrome electric resistance heating wirethrough passages within interlocking ceramic beads. The beads are molded from sintered 94% Alumina ceramics, more that 3/8-inchthick. The Alumina has excellent high-temperature dielectric properties which combined with the interlocking bead design provideFCP heaters with exceptional electrical insulating qualities.

FlexibilityThe interlocking bead design imposes rigidity along the heater length while allowing flexibility along the heater width, enabling it toconform to the curved surfaces of pipes and pressure vessels. A nominal nine-inch length of nickel wire is welded to each end of theNichrome wire to create a cold tail to prevent the electrically insulated camlock connectors from being heated.

Thermal PowerFCP heaters are generally available to two standard values: 80VAC, which are the most common, and 60VAC. Custom designedheaters, however, can also be provided. All 80VAC heaters are rectangular with a surface area of 120 square inches and a thermalpower of 3.6 kW, producing a power density of 30 W/in2 with an electrical current of 45 amps. The 60VAC counterparts are simplythree-quarters the size of an 80VAC pad with a surface area of 90 square inches and a 2.7 kW thermal power but with the samepower density and electric current. All 80VAC heaters can be run on 60VAC, but their kW output is reduced from 3.6 to 2. Theirrectangular shapes are available in the following variety of width and length combinations.

CP3CP4CP6CP8CP10CP12CP15CP18CP21CP24CP29CP36CP72CP120

Type

2600070126000801260009012600100126001101260012012600130126001401260015012600160126001701260018012600190126002001

PartNumber

Width (A)(Inches)

Height (B)(Inches)

34681012151821242936721

392919 1/214 1/212 1/29 3/486 1/25 3/4543 1/41 3/4120

28 1/22114 1/21097 1/45 3/4543 1/41 3/487

3468101215182126521

260021012600220126002301260024012600250126002601260027012600280126002901260030012600310126003201

CP3CP4CP6CP8CP10CP12CP15CP18CP21CP26CP52CP87

Height (B)(Inches)

Width (A)(Inches)

PartNumber

Type

26001301

80VAC HEATERS 60VAC HEATERS

15

Heaters

TISI-07.11

FeaturesBecause of their design and components, FCP heaters have the following benefits:

• Durability - The ductility of multi-stranded Nichrome wire means a longer heater life• Uniformity - Evenly woven wire means temperature uniformity throughout the heater• Ruggedness - Abrasion resistant ceramic means heaters withstand rough handling

VariationsDue to the availability of different bead configurations and different grades and gauges of electric resistance wires, a variety of custom heater designs can be made available:

• Shapes - Combinations of rectangles, trapezoids and triangles• Fingers - Non-interlocking designs that can conform to conical workpiece surfaces• Higher Temperature - Special heaters for temperatures up to 2300°F• Sizes - Smaller heaters that can be connected in series for standard voltages• Voltages - Different size heaters can be made for non-standard voltages• Reconditioned - Lower cost heaters are available, manufactured with used ceramic beads• Insulated Pads - FCPs can be assembled to custom mesh mats for insulated modules

Custom heaters are available, contact your TISI sales representative for more information.

Replacement parts for the FCP Heaters:Part Number Description26010500 60V FCP Heater Repair Kit26010600 80V FCP Heater Repair Kit

51000100 Body Bead, Standard51000200 Body Bead, Standard with Hole51000300 End Bead, Male51000400 End Bead, Female51000500 Tail Bead, Pink51000600 Tail Bead, White

26009602 60V Heater Core Wire Assembly26009600 80V Heater Core Wire Assembly55001500 Wire, 80/20 Nichrome Heater Body55001600 Wire, Nickel Cold Tail

80V Heater Core Wire Assembly60V Heater Core Wire AssemblyBody Bead, StandardBody Bead, Standard with HoleEnd Bead, MaleEnd Bead, FemaleTail Bead, PinkTail Bead, WhiteConnector, 150A Male Power

26009600

51000500

51000600

5100040051000200

5100030051000100

80VAC KitQuantities

60VAC KitQuantities

Description

-58583535351010

5-125105050501010

16TISI-07.11

Insulation

CooperknitMat

3700800237008003370080043700800637008102370081033700810437008106370081083700811037008112

370220023702200337022004

-370221023702210337022104

----

----

37009402370094033700940437009406370094083700941037009412

3700780237007803370078043700780637007902370079033700790437007906370079083700791037007912

1' x 2'1' x 3'1' x 4'1' x 6'2' x 2'2' x 3'2' x 4'2' x 6'2' x 8'2' x 10'2' x 12'

Additional sizes are also available, contact your TISI sales representative for more information.

ProductSize Mesh Mat

8 lb.

Team Industrial Services, Inc. manufactures a variety of standard and custom insulation mats in which the insulating material(Ceramic Fiber or Needled Silica) is encased in a stapled or stitched protective outer layer of stainless steel-knitted mesh or hightemperature silica welding cloth respectively. Cooperknit is also available as mats but does not require an outer protective layer.The material is cut to size and sewn at both ends.

1-inch1-inch2-inches1-inch1-inch1/2-inch1/2-inch

.030-inches

.060-inches1/2-inch

2-foot2-foot4-foot2-foot2-foot2-foot3-foot3-foot3-foot2-foot

25-foot25-foot24-foot25-foot25-foot25-foot25-foot150-foot150-foot25-foot

6 lb/ft3

8 lb/ft3

8 lb/ft3

6 lb/ft3

8 lb/ft3

8 lb/ft3

8 lb/ft3

18 ounce36 ounce15.2 lb/ft

Ceramic FiberCeramic FiberMineral WoolSuperwoolSuperwool

Needled SilicaNeedled SilicaWelding ClothWelding ClothCooperknit

1800°F1800°F1000°F2200°F2200°F2000°F2000°F2300°F1800°F2000°F

Material Thickness Width Length Density Limit

Meshed Matencased in SS mesh

Insulation Padencased in silica cloth

YesYesYesNoNoNoNoNoNoNo

RCF

Part NumbersMesh Mat6 lb.

InsulationPad

ComponentsA thermal insulating system has two primary components: the insulation material and the means to secure the insulation to the surfaces of the workpiece. Team Industrial Services Inc. is a source of supply for a variety of products in both component categories.

Insulation MaterialThermal insulation is available in a wide variety of materials and forms. TISI makes available those materials and forms that are best suited for on-site thermal processingbecause of their cost effectiveness in application and heat loss prevention.

RCFRefractory ceramic fiber (RCF) blanket is the most widely used insulation for elevated temperature applications and is available in various thicknesses, widths and densities.However, mineral wool delta board is the most cost sensible option for single-use applications.

Non-RCF Superwool (Silica) is a non-RCF blanket alternative. Needled silica mat insulation blanket is a non-RCF product that is constructedof 98% amorphous silica, whose construction imparts fiber integrity for high temperature reusable applications. Cooperknit is a silica-based knitted textile that offers the advantage over other types of insulation because the fabric does not break down preventingharmful airborne particles and can be reused without any significant deterioration.

37000900370008003700070037000200370125003700350037003600370045003700960037009300

PartNumber

17

Insulation Attachment

TISI-07.11

Insulation is secured to workpiece surfaces by means of steel banding or capacitance discharge-welded studs or pins and retainingclips. TISI is a source for banding and installation tools as well as insulation studs, pins, retaining clips and stud welders. All studwelding pins and clips are 12-gauge. Other sizes are available, contact your sales representative for more information.

Part Number Description54000102 Banding, Mild Steel, 1/2", 300'/roll54004202 Clips, Wing, Mild Steel, 1/2"

54004302 Banding, Stainless Steel, 1/2", 200'/roll54004402 Clips, Wing, Stainless Steel, 1/2"

13003000 Banding Tension Tool54008600 Fiberglass Tape, 3/4", 250'/roll, 48 rolls/case55004700 Wire, Iron Tie, 16-gauge, 3.5 lbs./roll, 20/case

Part Number Description54010501 Pin, Stud Welder, 3", Mild Steel, Pointed54010502 Pin, Stud Welder, 6", Mild Steel, Pointed54010503 Pin, Stud Welder, 3", Mild Steel, Blunt54010504 Pin, Stud Welder, 6", Mild Steel, Blunt

54010401 Pin, Stud Welder, 3", Stainless Steel, Pointed54010402 Pin, Stud Welder, 6", Stainless Steel, Pointed54010403 Pin, Stud Welder, 3", Stainless Steel, Blunt54010404 Pin, Stud Welder, 6", Stainless Steel, Blunt

54010702 Clip, Stud Welder, 1.5", Mild Steel, Round54010712 Clip, Stud Welder, 2.5", Mild Steel, Square

54010700 Clip, Stud Welder, 1.5", Stainless Steel, Round54010710 Clip, Stud Welder, 2.5", Stainless Steel, Square

54013401 Lacing Anchor, without pin, Stainless Steel54013402 Lacing Anchor, 2.5", Stainless Steel54013403 Lacing Anchor, 4.5", Stainless Steel

54013501 Pin, Quilting, 1.5", Stainless Steel54013502 Pin, Quilting, 2.5", Stainless Steel54013503 Pin, Quilting, 4.5", Stainless Steel

54004302

13003000

54004402

54010503

54010501

54010700

54010710

54013502

54013402

Eagle Stud WelderWeight 26 lbs. (without gun and cables)Height 8 1/2 inchesWidth 10 inchesDepth 13 inchesWeld Rate Up to 20/minuteWeldable Materials Mild and Stainless Steel, AluminumPin/Stud Range 14-gauge through 1/4" diameter weld baseWeld Voltage 35-175VDCCapacitance 70,000 MfdWeld Mode ContactPower Requirement 115VAC, 60 Hz, 20-Amp

Part Number Description13002803 Stud Welder, Eagle13006417 Collet, Bullet-style (no stop required)13006401 Collet, ‘B’13006414 Stop for ‘B’ Collet13006402 Collet Protector

13006402

13006417

13006401

13006414

www.teamindustrialservices.com

Mechanical Services, ProductsAlabamaDecatur .................. 256-355-3322Mobile ................... 800-370-4889AlaskaKenai ..................... 907-335-1446CaliforniaSan Francisco ........ 925-676-0390Los Angeles ........... 562-531-0797ColoradoDenver ................... 800-782-7365FloridaTampa .................... 800-326-5325GeorgiaAugusta.................. 706-860-0899IllinoisChicago.................. 800-443-8609IowaDavenport .............. 800-443-8609LouisianaBaton Rouge.......... 225-644-4839New Orleans.......... 504-733-2991Lake Charles.......... 337-625-7533MaineBangor ................... 207-848-2500MinnesotaMinneapolis/St. Paul.. 800-397-2712MissouriSt. Louis ................ 314-487-2110MontanaBillings .................. 800-782-7365New HampshireBedford.................. 603-623-5814New JerseyNewark-NYC..........908-587-9630(Service to Northern New Jersey,New York City, Connecticut)New YorkSyracuse................. 315-432-9144North CarolinaCharlotte ................ 800-433-5325Wilmington............ 800-433-5325OhioCincinnati .............. 800-852-6230Toledo.................... 800-969-7108OklahomaTulsa ...................... 918-234-9600PennsylvaniaPhiladelphia............ 856-374-0403Pittsburgh............... 412-429-5500South CarolinaNorth Augusta ....... 888-201-3837TennesseeChattanooga........... 423-332-0494TexasAngleton ................ 979-549-9970Beaumont............... 409-835-7958Borger .................... 806-273-6565Corpus Christi ....... 361-289-6291Freeport ................. 800-617-7756Houston ................. 713-378-8600Longview............... 800-521-2689Odessa ................... 800-432-6196Texas City.............. 409-965-8200UtahSalt Lake City........ 800-782-7365VirginiaRichmond .............. 804-743-5597WashingtonMt. Vernon............. 360-848-0353West VirginiaCharleston.............. 304-344-0477

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Mechanical ServicesEdmonton, AlbertaPhone: ........................866-437-0860Fax: ............................780-462-0805Fort McMurray, AlbertaPhone: ........................780-715-1648Fax: ............................780-799-4383Sarnia, OntarioPhone: ........................866-500-8326Fax: ............................519-344-9312

Field Heat Treating,Edmonton, AlbertaPhone: ........................780-467-8070Fax: ............................780-449-1216Sarnia, OntarioPhone: ........................800-230-4328Fax: ............................519-344-7020Milton, OntarioPhone: ........................905-878-7546Fax: ............................905-878-7944

NDE/NDT and InspectionsEdmonton, AlbertaPhone: ........................780-417-7777Fax: ............................780-417-1185Red Deer, AlbertaPhone: ........................403-347-8666Fax: ............................403-342-1205Calgary, AlbertaPhone: ........................403-279-8854Fax: ............................403-279-8856Grande Prairie, AlbertaPhone: ........................780-532-0509Fax: ............................780-402-7351Slave Lake, AlbertaPhone: ........................780-805-6384Fax: ............................780-849-5321Lloydminster, AlbertaPhone: ........................780-875-3001Fax: ............................780-875-3082Campbell River, British ColombiaPhone: ........................250-286-4568Fax: ............................250-286-4545White Rock, British ColombiaPhone: ........................604-541-9005Fax: ............................604-541-9006Mount Pearl, NewfoundlandPhone: ........................709-745-1818Fax: ............................709-745-5401Dartmouth, Nova ScotiaPhone: ........................902-463-3363Fax: ............................902-481-2542Kitchener, OntarioPhone: ........................519-893-6760Fax: ............................519-893-2191Oakville, OntarioPhone: ........................905-845-9542Fax: ............................905-845-9551Sarnia, OntarioPhone: ........................519-337-2375Fax: ............................519-337-2376Thunder Bay, OntarioPhone: ........................807-345-7447Fax: ............................807-344-0801Whitby, OntarioPhone: ........................905-666-4511Fax: ............................905-666-4921Weyburn, SaskatchewanPhone: ........................306-842-2616Fax: ............................306-842-2663

UNITED STATESLOCATIONS

INTERNATIONALLOCATIONS

CANADALOCATIONS

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VIRGIN ISLANDSChristianstedPhone ......................340-692-7562Fax: .........................340-692-3548

Heat Treating and Inspection Services

Mechanical Services

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