20121071 CATALOG TISI.QXD 2/17/12 4:16 AM Page 1 CATALOGOS/02 TEAM - COOPERHEAT/Hea… · 58012200...

20121071_CATALOG TISI.QXD 2/17/12 4:16 AM

TISI-12.1

Table of Contents

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

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

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

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

Power Source Parts ……………………………………………….............……………… 6Casters Fuses and Fuse Holders RelaysCircuit Breakers Hardware Strain ReliefsContactors Indicator Lights SwitchesElectrical Connections Lugs TransformersFans and Filters Panel Meters

Power Cabling …………………………….............……………………………………… 8SplittersTriple Cable SetsPower Cable

Camlock Connectors ……………………………………………............……………….. 9150-Amp 300-Amp

Thermocouple …………………………………………………………............…………. 10Attachment Unit (TAU)ConnectorsJack PanelsSheathed ThermocouplesWire

Test Equipment ……………………………………...…………….............……………... 13TC-100 CalibratorBrinell Hardness Test Kit

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

Insulation …………………………………………………………………….............…… 16Blanket (RCF and non-RCF)CooperknitMeshed MatInsulation Pad

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


1

Power Source

TISI-12.1

09010103

Description

The ability to control temperatures precisely is the key to

accurate heat treatment. The Team Industrial Services,

Inc. (TISI) 6-way control console is designed to provide

six independently controlled, low voltage, high current

outputs which precisely control the work piece

temperature.

Length 24 inches

Width 24 inches

Height 48 inches

(56 inches with casters)

Weight 850 - 900 lbs.

Primary Voltage

Standard 480 VAC

International 380/415/440/480/575 VAC

Secondary Voltage 65/85 VAC

Power 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 of

overloading on control circuit.

• 3/4-amp circuit breaker protection for each secondary

contactor.

• Over-temperature protection of main transformer coils

(275°F/135°C temp. trip).

Features

• Enclosure - The stainless steel enclosure is supported by a 1-1/2 inch

tubular frame for strength and stability. A fold-down door

protects the electronic components from damage.

• Mounting - Each console comes standard with 6-inch steel swivel

casters with brakes on the front two wheels. The casters can

be replaced with skid plates that are mounted to the bottom of

the machine.

• Output Control - The START/STOP switch on the 6-way console

controls the output voltage of the machine to prevent

unintentional power being sent to the heaters on the work piece.

Options To Fit Your Needs

• Local control - Six independent heating cycles can be manually controlled.

• Remote control - Six individual programmable zone controllers that contain

custom firmware to facilitate setpoint programming.

• 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 International

09009901 09009902 6-way, Manual Control

09010101 09010102 6-way, Manual Control with 12-point Recorder

09009903 09009904 6-way, Programmable Control

09010103 09010104 6-way, Programmable Control with 12-point Recorder

See POWER SOURCE PARTS for replacement parts

Contact your TISI sales representative for more information.

5

4

6

3

2

1

ITEM

1

2

3

4

5

6

DESCRIPTION

6-way Power Console

Triple Cable Set

Thermocouple Wire Extension Assembly

Splitter Assembly

Heating Elements

Thermocouple (from work piece)

NOTE: Items 2 through 6 must be ordered

separately depending on job requirements


2TISI-12.1

Twin Heat Module

Description

The Twin Heat Module (THM) uses the output of any AC or DC welding machine or transformer to provide up to two independent

channels 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 temperature

recording. The THM also has the option of a 2-pen temperature recorder. A 16-gauge stainless steel case protects unit components

during 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 widely

separated locations on a job site.

Electrical Specifications

Power circuit to heaters

Input/output voltage 6-60 VDC up to 220 VAC

Input/output current 300-amp

Control circuit, input

Voltage 120 VAC, 50-60 Hz

Control circuit, auxiliary output

Voltage 120 VAC, 50-60 Hz

Current 25-amp (control circuit protected

at 5-amp breaker total)

Temperature controller

Temperature range 0-2400°F

Thermocouple Type K

09002900


09002800 Twin Heat Module, Manual Control

09002900 Twin Heat Module, Programmable Control

09007800 Twin Heat Module, Manual Control with 2-pen Recorder

09007900 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'

or

29001002 Feed/Return Cable with 300-amp connectors, 10'

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


Replacement parts for the Twin Heat Module:

Part Number Description Part Number Description

58012200 UDC-2500 Controller, Manual Control 49008002 TC Jack Panel, Numbered Dual 1

58012900 UDC-3500 Controller, Programmable 49008003 TC Jack Panel, Numbered Dual 2

50000300 Indicator Light, Red 59001300 Contactor, 1-pole, 300A, 120V

57004301 Circuit Breaker, Panel Mount, 5A 56004700 300-amp Panel Mount Connector, Male

54008300 Handle for Front 56000200 300-amp Panel Mount Connector, Female

54008900 Handle, Fold down for Top 56007900 110 VAC Auxiliary Output Receptacle

09002500 Rubber Feet for Base 56007400 110 VAC Supply Input Receptacle


3

Controllers

TISI-12.1

Description

Each zone in a 6-way power source and Twin Heat Module is controlled by a Universal Digital Controller (UDC). The UDC-2500

model 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 allow

up to five programmed segments. The unique feature of the available TISI UDC-3500 model is that it has a special firmware

program which simplifies the programming process. Both models are easy to program, operate and read. All configurations and

alignments are completed prior to shipment so that upon receipt, the controller can be placed immediately into service. Please note

that 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 normal

operation. Straightforward prompts in English allow easy adjustments to the setpoint, process variable, deviations and

output values with minimum time and effort, which are shown on the lower display. Status indicators display degrees

Fahrenheit, 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 easily

readable 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 often

disturb 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 Specifications

Accuracy ±1 digit for display

Temperature stability ±0.01% of full span/°C change typical

Input signal failure protection Upscale, downscale or failsafe burnout

Input impedance 200K ohms

Controller output types Electromechanical or solid state relays,

Current out

Available options Alarm outputs, RS422/485 or ethernet TCP/IP

communications interface, Infrared

communications (standard on UDC-3500)

Sample rate Input sampled 6 times a second

Input filter Off to 120 seconds

Wiring connections Screw terminals on rear of case

Power consumption 20 VA (UDC-2500) / 24 VA (UDC-3500)

maximum (90 to 264 VAC)

Weight 3 lbs.


58012200 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)


58012900


4TISI-12.1

Recorders

Strip Chart Recorder

The strip chart recorder is a multi-point recorder whose field worthiness

and variable configuration makes it ideally suited for on-site

applications. The standard

temperature recorder is

available with 12 channels

for reliable, accurate records

of time-temperature profiles

for all control and monitor

thermocouples. The 12-channel

model of recorder is also

available with 24 channels

(mR-20000) or as a 2-pen or

6-channel model (mR-10000).

Digital Paperless Recorder

Team Industrial Services, Inc. also offers a digital recorder option that allows for paperless recording. The SX has a 12.1-inch, color

active matrix LCD touch screen display for clear viewing and is available with up to 48 analog inputs. The QX is another available

option with only 6 standard inputs. All collected time-temperature data can be saved to a compact flash (CF), USB storage device

reader or linked directly through the internet or LAN via an ethernet connection. The recorder includes the Trend Viewer software

necessary to view the data on a computer. Additional firmware credits are available for purchase to unlock more features if required.

SX (QX) Specifications

Mechanical Software

Weight 22 lbs. (5.3 lbs.) Processor 1 GHz pentium or higher

Height 11 3/8 inches (5.67 inches) Operating System Windows 2000, XP

Width 11 3/8 inches (5.67 inches) RAM 512 Mbyte minimum

Depth 8 5/8 inches (9.74 inches) Free Hard Drive 50 Mbyte minimum

Case Mild steel, zinc-plated

Electrical

Voltage 100 to 250VAC

Current 1/4-Amp at 110VAC

Configuration

Channels 12 standard, up to 48 available (6 standard)

Scan Rate Real-time

Chart Speed Adjustable

Operator Interface

Although it can accommodate

a wide range of DC-voltage

inputs, each channel is

configured for Type K

thermocouples at the Team factory. Printing formats are configurable by means of a convenient menu-driven Setting mode. Chart

speed 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, the

strip chart recorder utilizes a large, easy-to-read full dot matrix display for highly visible read selection and ease of use. Operator

input to the recorder is by means of a seven-button keypad to access and navigate the interactive Operation and Setting modes.

mR-20000 (mR-10000) Specifications

MechanicalWeight 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-gauge

Door Cast aluminum

Electrical

Voltage 100 to 240VAC

Current 1/4-Amp at 110VAC

Configuration

Channels 12 standard, 24 available (2 or 6)

Scan Rate 1 1/4-seconds/channel

Paper Z-fold, 180mm (100mm)

Dot Colors 6 (2)

Chart Speed 2-inch/hour factory set (1-inch/hour)

Printing Digital and analog

Operator Interface

Although it can accommodate a wide range of DC-voltage inputs, each

channel is configured for Type K thermocouples at the TISI factory. The

enclosed stylus allows for easy interaction with the touch screen menus.

Using the menus, each pen can be assigned as well as alarms and chart

speeds set along with many other features. The gathered data can be

analyzed by a variety of graphs either on the LCD display or on a

computer. Other software options are available for use with a computer

that include additional features/options if required.

45007380

45007322


5

Recorders

TISI-12.1

Carrying Case

A recorder is also available as a stand-alone unit that can be installed into a carrying case. The recorder will be ‘socketed’ which

means that an enclosure will be mounted to the back and wired with the thermocouple jack panel and a power cord. The digital

recorders 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 (see page 11), will be able to provide time-temperature profiles. The carrying case is steel reinforced

with a carrying handle and lined with polyurethane foam to protect the recorder during transit and on-site use. The case has

removable front and rear doors for easy access.

RECORDER REPLACEMENT PARTS

RIBBONS & PENS

Part Number Manufacturer Model Description

45020100 Yokogawa mR-1000/0 Ribbon Cartridge

45020200 Yokogawa mR-1000/0 Red Pen

45020300 Yokogawa mR-100/00 Green Pen

45020400 Yokogawa mR-1000/0 Purple Pen/Plotter

45004000 Yokogawa mR-180/0, 20000 Ribbon Cartridge

45033200 Honeywell DPR-100 Ren Pen

45033300 Honeywell DPR-100 Blue Pen

45030800 Honeywell DPR-180, 3000, 250 Ribbon Cartridge

45012000 Chino AL-3000 Ribbon Cartridge

45013000 Chino AH-3000 Ribbon Cartridge

CHART PAPER

Part Number Manufacturer Model Description

45020502 Yokogawa mR-1000/0 0-2000° Scale

45020501 Yokogawa mR-1000/0 0-100% Scale

45000302 Yokogawa mR-180/0, 20000 0-2000° Scale

45000301 Yokogawa mR-180/0, 20000 0-100% Scale

45033100 Honeywell DPR-100 0-100% Scale

45030900 Honeywell DPR-180 0-100% Scale

45031000 Honeywell DPR-3000, 250 0-100% Scale

45011900 Chino AL-3000 0-100% Scale

45009800 Chino AH-3000 0-2000° Scale

45009801 Chino AH-3000 0-100% Scale

45007422 in carrying case


45007321 Recorder, Analog, 12-point


45007380 Recorder, Digital, 12-point


45007521 Recorder, Analog, 12-point, Calibrated


45007580 Recorder, Digital, 12-point, Calibrated


45007421 Recorder, Analog, 12-point, Calibrated and Sockets


45007480 Recorder, Digital, 12-point, Calibrated and Sockets


45001800 Carrying Case (for size recorders above)


45007312 Recorder, Analog, 2-pen



45007512 Recorder, Analog, 2-pen, Calibrated



45007412 Recorder, Analog, 2-pen, Calibrated and Sockets


45001900 Carrying Case (for size recorders above)


6TISI-12.1

Power Source Parts

57004301

6200170050001100

LED Assembly

60003400

62007700

TRANSFORMERS


Primary (Main) Transformer60000100 Transformer, 55kVA, 480 VAC (Standard)60000710 Transformer, 55kVA, 380/415/440/480/575 VAC (International)

Secondary (120V Step Down) Transformer60003400 Transformer, 750VA, 240-480/120-240 (Standard)60001100 Transformer, 750VA, 208-600/120-240 (International)

Current Transformer (CT)60003901 Current Transformer, 5-300A Loop with Leads for Panel Meter 7100180060003902 Current Transformer, 5-150A Loop with Leads for Panel Meter 71002000

60001100

62003801

SWITCHES


62001700 Switch Assembly, START/STOP (Square)

62007700 Switch Assembly, START/STOP (Oval)

62003801 Switch, Pushbutton, 6-station62010100 Aluminum Knob for 6201040062010400 Switch, Rotary, 6-position

FUSES & FUSE HOLDERS


57001305 Fuse, KTK-R, 5A

57001310 Fuse, KTK-R, 10A

57001101** Fuse, AGC, 3/4A for contactor protection

57001104 Fuse, AGC, 2A for cooling fan protection

57000102 Fuse Holder, 2P, 600V

57001700** Fuse Holder, 30A, 250V

for contactor (3/4A) protection

50000500

60003901

PANEL METERS


71001800 Ammeter, 0-300A, Digital Panel Meter

71002000 Ammeter, 0-150A, Digital Panel Meter

71002000T Screw Terminal Adapter for 71002000

71001800

CONTACTORS


Primary Contactors (control output voltage)59005000 Contactor, 3-pole, 90A (Standard)59004900 Contactor, 3-pole, 120A (International)

Secondary (Zone) Contactors59001300 Contactor, 1-pole, 300A, 120V59001400* Repair Kit for 5900130059008500 Contactor, 1-pole, 400A, 120V59008700* Repair Kit for 59008500

*Each repair kit includes:1 - Upper Contact Assembly2 - Lower Contact Assembly

1 - Replacement Spring

59008500

59001300

INDICATOR LIGHTS


50000300 Indicator, Red, 80VAC with Leads

50000500 Bulb for START/STOP Switch

50001000 LED, Bayonet-style, White50001100 LED, Bayonet-style, Green50001200 LED, Bayonet-style, Red

50002000 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

50000300

CIRCUIT BREAKERS


57003704 Circuit Breaker, 1P, 5A, 277V, Rocker-style

57003800 Circuit Breaker, 3P, 125A, 600V (Cutler-Hammer)

57004102 Circuit Breaker, 3P, 125A, 600V (GE)

57004301 Circuit Breaker, Panel Mount, 5A

57004302 Circuit Breaker, Panel Mount, 10A

57004302 Circuit Breaker, Panel Mount, 3/4A

**(replaces fuse holder 57001700 with 3/4A fuse 57001101)

57003704

57001101

62010400


7

Power Source Parts

TISI-12.1

59001700

59001500

57004601

72000101

64004201

54000413

54000414

56006704

57004603

56010400

ELECTRICAL CONNECTIONS


57000601 GFI Receptacle, 15A, 125V, Duplex Edison

57000602 Cover for GFI Receptacle

56012112 Terminal Block, Double Row, 12-Term

57004601 Power Distribution Block, 3P, 175A, 480V

57004603 Power Distribution Block, 3P, 175A, 600V

RELAYS


59001500 Relay Base, 8-pin

59001600 Relay, 24VDC, 8-pin

59001700 Relay, 120VAC, 8-pin, Illuminated

CASTERS


53005200 Dolly for 6-way, 4" casters (CH-style)

54000401 Rigid Caster, 4" without brake

54000403 Swivel Caster, 4" without brake

54000404 Swivel Caster, 4" with brake

54000411 Rigid Caster, 6" without brake

54000413 Swivel Caster, 6" without brake

54000414 Swivel Caster, 6" with brake

STRAIN RELIEF GRIPS


56006701 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"

56006600

LUGS


56010400 Ground Lug, Copper

56012200 Ground Lug, Aluminum

56010304 Crimp Lug, 3/8" Purple56010306 Crimp Lug, 1/2" Purple

56011605 Crimp Lug, 3/8" Green56011610 Crimp Lug, 1/2" GreenCrimp lugs are for cable assemblies

FANS & FILTERS


72000101 Cooling Fan, Axial

72000201 Cord for Cooling Fan, Axial, 24"

72000400 Exhaust Fan, Wire Frame, 12"

52005901 Filter, 20" x 20" x 1"52005902 Filter, 10" x 20" x 1"

7200020172000400

HARDWARE


09002400 Lever Latch for Rear Machine Door (Black)

54009600 Latch, T-Handle for Rear Machine Door (SS)

54012200 Handle for Front Door Pocket

54012300 Magnet for Front Door Catch

09003000 Control Knob for THM (Old Style)

58005100 Energy Regulator / Cycle Timer for THM (Old Style)

54008300 Handle for Top/Front of THM

54008900 Handle, Fold down for Top of THM

09002500 Feet, Rubber for THM


8TISI-12.1

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 jack

panels.

• 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 Cable

Three-way splitters are standard to enable three heaters to be connected in parallel to a single control zone. Two splitter cables are

needed for each zone. Each splitter cable connects one of the two power cables of a triple cable set to one side of the three parallel

heaters. Two-way and four-way splitters are also available.

Specifications

Length 4-foot long

Size #6, approximately 3/8-inch outer diameter

Stranding Seven bundles of 37 strands of 30-gauge

Insulation Ultra-Flex thermoplastic rubber

Ratings -74°F to 221°F, 600-Volt,

300-Amp male and 150-Amp female camlocks

Triple Cable Set

A triple cable consists of a taped assembly of twin power cables and a thermocouple extension cable. The multi-stranded power

cables are flexible and covered with a thermoplastic rubber insulation that is resistant to abrasion, oil, acid, ultraviolet light and high

temperature. 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.

Specifications

Assembly

Length 25-foot, 50-foot or 100-foot standard

Weight 65 lbs./100-foot

Binding Fiberglass tape, 1-foot pitch

Power CableSize #2, approximately 1/2-inch outer diameter

Stranding Seven bundles of 90 strands of 30-gauge

Insulation Ultra-Flex thermoplastic rubber

Ratings -74°F to 221°F, 600-Volt, 300-Amp camlocks

Thermocouple Extension Cable

Type K, Chromel-Alumel

Size 20-AWG, Solid

Insulation PVC with PVC outer jacket

Connectors Polarized male plug and female socket

29001900 29002200

29004003


29001500 Splitter, 2-way, 4' long



29004001 Triple Cable Set, 25'



55002700* Power Cable, 4/4

55004400* Power Cable, 6/4*order in 25-foot increments

Additional cable is available in 10-foot increments:


55002401 #6 Cable, Gray for Splitters

55002601 #2 Cable, Gray for Triple Cables

49000200 Thermocouple Extension Cable


9

Camlock Connectors

TISI-12.1

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.

Specifications

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

Bolted neoprene casing or high-impact plastic

Large In-Line Brass male/female body, 300-Amp

Fiber electrical insulating sleeve

Fiber interlocking pin

Small In-Line Brass male/female body, 150-Amp

Fiber electrical insulating sleeve

Fiber interlocking pin

56000600

56000700

56004800 56005300

56000400

56000500

56004700 56000200

Female In-Line Connectors without Sleeve


56000600 Connector, 150-Amp, Male Complete

56000700 Connector, 150-Amp, Female Complete

56000400 Connector, 300-Amp, Male Complete

56000500 Connector, 300-Amp, Female Complete

Replacement Parts

56002000 Connector, 150-Amp, Male Sleeve Only

56002200 Connector, 150-Amp, Female Sleeve Only

56002300 Connector, 150-Amp, Pin

56001400 Connector, 300-Amp, Male Sleeve Only

56001600 Connector, 300-Amp, Female Sleeve Only

56001700 Connector, 300-Amp, Pin

High-Impact Plastic

56004600 Connector, 150-Amp, Panel Mount, Male

56004300 Connector, 150-Amp, Panel Mount, Female



Neoprene Casing




56000200* Connector, 300-Amp, Panel Mount, Female*Standard on TISI 6-way machines


10TISI-12.1

Thermocouple

Description

To measure the surface temperature of a metallic workpiece, do not rely on contact heat transfer from your workpiece surface to the

separate junction of a sheathed or twisted-wire thermocouple. Instead get the most reliably accurate temperature measurement by

turning the workpiece surface into a thermocouple junction with the use of a capacitance discharge thermocouple welder (TAU,

Thermocouple Attachment Unit).

Operation

The TAU provides major improvements over other methods for attaching thermocouples to both ferrous and non-ferrous metals. It

attaches thermocouples directly to the workpiece and handles high temperatures, up to 2300°F, necessary for stress relieving carbon

and 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 Savings

Expensive 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 operator

with an audio and a visual indicator when the unit has cycled and reached the preset power level.

Specifications

Each TAU is housed in a rugged stainless steel carrying case

equipped 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 recharged

from 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 inches

Width 3 3/4 inches

Length 10 1/2 inches

Battery Type 12V Nickel Cadmium

Voltage 120VAC, 60Hz

Thermocouple E, J, K, T

Wire Capability 16 - 30 Gauge (AWG)

Voltage Discharge 15 - 80 Volts

Energy Discharge 5 - 50 Joules

Replacement parts for the Thermocouple Attachment Unit (TAU):


13000300 Thermocouple Attachment Unit, Series IV

13000100 Enclosure for TAU, Stainless Steel

13001000 Plier Assembly with Male Camlock for TAU

13001100 Operation Label for TAU

13005300 Adjustable Shoulder Strap for TAU

54004500 Magnet for TAU

63002200 Battery for TAU

63012300 Power Cord for TAU

13000300

63002200


11

Thermocouple

TISI-12.1

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, with

a 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 and

jacket) is an excellent choice for most applications because of its abrasion and temperature resistance. Cefir (braided ceramic fiber

insulation and jacket) is appropriate for extreme temperature applications.

Specifications

Type 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


49000200 Wire, K TC, Extension with PVC shielded jacket

49000500 Wire, K TC, Q/Q

49000600 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 wire

has 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.


49004003 TC Cable Assembly, K TC Extension with Male and Female Connectors, 25'



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'


49000900 Plug, TC, Type K

49001000 Socket, TC, Type K

49008100 Plug, TC, Type K, Midget

49008200 Socket, TC, Type K, Midge

49004003

49004202

49000900

49001000


12TISI-12.1

Thermocouple

49008010

Unlike thermocouple wire, sheathed thermocouples can not be capacitance discharge-welded to workpiece surfaces. They must be

attached to the work surface with welded clips or banding, both available from TISI.

Specifications

Construction Thermocouple wire within metal sheath, hollow

Filled with magnesium oxide, grounded junction

Sheath Material 310 Stainless Steel, standard

Inconel, 304 or 316 Stainless Steel available, custom

Sheath Diameter 1/8-inch, standard

0.04-inch to 3/8-inch available, custom

Length 2-foot, 6-foot, 12-foot and 20-foot, standard

Other lengths available, custom

Attachment 1/8-inch, standard

Stainless or mild steel available, single or dual

(dual available in stainless steel only)


49002202 TC Sheathed, 2', 1/8-inch diameter, Type K




49002000 Clip, Single TC, Mild Steel

49001800 Clip, Single TC, Stainless Steel

49001900 Clip, Dual TC, Stainless Steel

37000100 Putty, Moldable, 11 oz. Tube

49002202

49002220


49001101 TC Jack Panel, 2-point, Screw-mount





49008001 TC Jack Panel, Numbered 1-2, Self-mount





49008002 TC Jack Panel, Numbered Dual 1, Self-mount

49008003 TC Jack Panel, Numbered Dual 2, Self-mount

49008012 TC Jack Panel, Numbered Dual 1-6, Self-mount

49001800

49001900

49008012

49001103


13

Test Equipment

TISI-12.1

The TC-100 is a thermocouple simulator which can source or measure ten common thermocouples (J, K, T, E, R, S, B, L, U, C) as

well as mV. Features include high accuracy (±0.3°C for Type J), source resolution of 0.1°F/C and MIN/MAX recall in measure

mode. Three setpoints can be set per thermocouple which are easily set utilizing the arrow buttons and knob control. Connections

can be made either via a mini-plug or bare wires to the terminals. The calibrator is protected with a rugged, shock-resistant case and

comes with a protective rubber boot to prevent damage if dropped. Unit has input protection up to 240 VAC.

Specifications

Mechanical

Weight 12 ounces (0.75 lbs.)

Length 5.7 inches

Width 3.15 inches

Depth 1.43 inches

Case Shock resistant ABS

Accessories Protective rubber boot, battery and charger (sold

separately)

Electrical

Input Voltage -10 to +75.000 mV, 1 mV resolution

Program 9V-battery (alkaline or NiCad rechargeable)

Calibration

Measure J, K, T, E, R, S, B, L, U or C thermocouples, mV

Range -392 to 2501°F (-200 to 1372°C) for Type K

Accuracy ±0.35-0.6°C (based on range), 0.1°F/C resolution

Connection Internal or external cold junction compensation,

mini-plug or bare wires

Program Three setpoints for each TC type, Knob control


65002100 Temperature Calibrator, Martel TC-100

65002100A AC Adapter for use with Rechargeable Battery

65002100B Rechargeable NiCad 9V Battery

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 your

sales representative for more information.

65002100

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 or

the fillet weld tester can be purchased separately.


13005001 Brinell Kit with Large Bar Holder

13005002 Brinell Kit with Fillet Weld Tester

13007600 Fillet Weld Tester

13006600 Scope

13005102 Brinell Bar, 176 Hardness



Other size hardness bars available


14TISI-12.1

Heaters

Construction

Flexible ceramic pad (FCP) heaters are manufactured by weaving multi-stranded 80/20 Nichrome electric resistance heating wire

through passages within interlocking ceramic beads. The beads are molded from sintered 94% Alumina ceramics, more that 3/8-inch

thick. The Alumina has excellent high-temperature dielectric properties which combined with the interlocking bead design provide

FCP heaters with exceptional electrical insulating qualities.

Flexibility

The interlocking bead design imposes rigidity along the heater length while allowing flexibility along the heater width, enabling it to

conform to the curved surfaces of pipes and pressure vessels. A nominal nine-inch length of nickel wire is welded to each end of the

Nichrome wire to create a cold tail to prevent the electrically insulated camlock connectors from being heated.

Thermal Power

FCP heaters are generally available to two standard values: 80VAC, which are the most common, and 60VAC. Custom designed

heaters, however, can also be provided. All 80VAC heaters are rectangular with a surface area of 120 square inches and a thermal

power of 3.6 kW, producing a power density of 30 W/in2 with an electrical current of 45 amps. The 60VAC counterparts are simply

three-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 same

power density and electric current. All 80VAC heaters can be run on 60VAC, but their kW output is reduced from 3.6 to 2. Their

rectangular shapes are available in the following variety of width and length combinations.

CP3

CP4

CP6

CP8

CP10

CP12

CP15

CP18

CP21

CP24

CP29

CP36

CP72

CP120

Type

26000701

26000801

26000901

26001001

26001101

26001201

26001301

26001401

26001501

26001601

26001701

26001801

26001901

26002001

PartNumber

Width (A)(Inches)

Height (B)(Inches)

3

4

6

8

10

12

15

18

21

24

29

36

72

1

39

29

19 1/2

14 1/2

12 1/2

9 3/4

8

6 1/2

5 3/4

5

4

3 1/4

1 3/4

120

28 1/2

21

14 1/2

10

9

7 1/4

5 3/4

5

4

3 1/4

1 3/4

87

3

4

6

8

10

12

15

18

21

26

52

1

26002101

26002201

26002301

26002401

26002501

26002601

26002701

26002801

26002901

26003001

26003101

26003201

CP3

CP4

CP6

CP8

CP10

CP12

CP15

CP18

CP21

CP26

CP52

CP87

Height (B)(Inches)

Width (A)(Inches)

PartNumber

Type

26001301

80VAC HEATERS 60VAC HEATERS


15

Heaters

TISI-12.1

Features

Because 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

Variations

Due 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:


26010500 60V FCP Heater Repair Kit

26010600 80V FCP Heater Repair Kit

51000100 Body Bead, Standard

51000200 Body Bead, Standard with Hole

51000300 End Bead, Male

51000400 End Bead, Female

51000500 Tail Bead, Pink

51000600 Tail Bead, White

26009602 60V Heater Core Wire Assembly

26009600 80V Heater Core Wire Assembly

55001500 Wire, 80/20 Nichrome Heater Body

55001600 Wire, Nickel Cold Tail

80V Heater Core Wire Assembly

60V Heater Core Wire Assembly

Body Bead, Standard

Body Bead, Standard with Hole

End Bead, Male

End Bead, Female

Tail Bead, Pink

Tail Bead, White

Connector, 150A Male Power

26009600

51000500

51000600

5100040051000200

5100030051000100

80VAC KitQuantities

60VAC KitQuantities

Description

-

5

85

8

35

35

35

10

10

5

-

125

10

50

50

50

10

10


16TISI-12.1

Insulation

CooperknitMat

37008002

37008003

37008004

37008006

37008102

37008103

37008104

37008106

37008108

37008110

37008112

37022002

37022003

37022004

-

37022102

37022103

37022104

-

-

-

-

-

-

-

-

37009402

37009403

37009404

37009406

37009408

37009410

37009412

37007802

37007803

37007804

37007806

37007902

37007903

37007904

37007906

37007908

37007910

37007912

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.

Product

SizeMesh�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 high

temperature 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-inch

1-inch

2-inches

1-inch

1-inch1/2-inch1/2-inch

.030-inches

.060-inches1/2-inch

2-foot

2-foot

4-foot

2-foot

2-foot

2-foot

3-foot

3-foot

3-foot

2-foot

25-foot

25-foot

24-foot

25-foot

25-foot

25-foot

25-foot

150-foot

150-foot

25-foot

6 lb/ft3

8 lb/ft3

8 lb/ft3

6 lb/ft3

8 lb/ft3

8 lb/ft3

8 lb/ft3

18 ounce

36 ounce

15.2 lb/ft3

Ceramic Fiber

Ceramic Fiber

Mineral Wool

Superwool

Superwool

Needled Silica

Needled Silica

Welding Cloth

Welding Cloth

Cooperknit

1800°F

1800°F

1000°F

2200°F

2200°F

2000°F

2000°F

2300°F

1800°F

2000°F

Material Thickness Width Length Density Limit

Meshed�Mat

encased in SS mesh

Insulation�Pad

encased in silica cloth

Yes

Yes

Yes

No

No

No

No

No

No

No

RCF

Part�Numbers

Mesh�Mat6�lb.

InsulationPad

Components

A 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�Material

Thermal 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 processing

because of their cost effectiveness in application and heat loss prevention.

RCF

Refractory 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 constructed of

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 preventing

harmful airborne particles and can be reused without any significant deterioration.

37000900

37000800

37000700

37000200

37012500

37003500

37003600

37004500

37009600

37009300

PartNumber

20121071_CATALOG TISI.QXD 3/9/12 4:34 PM

17

Insulation Attachment

TISI-12.1

Insulation is secured to workpiece surfaces by means of steel banding or capacitance discharge-welded studs or pins and retaining

clips. TISI is a source for banding and installation tools as well as insulation studs, pins, retaining clips and stud welders. All stud

welding pins and clips are 12-gauge. Other sizes are available, contact your sales representative for more information.


54000102 Banding, Mild Steel, 1/2", 300'/roll

54004202 Clips, Wing, Mild Steel, 1/2"

54004302 Banding, Stainless Steel, 1/2", 200'/roll

54004402 Clips, Wing, Stainless Steel, 1/2"

13003000 Banding Tension Tool

54008600 Fiberglass Tape, 3/4", 250'/roll, 48 rolls/case

55004700 Wire, Iron Tie, 16-gauge, 3.5 lbs./roll, 20/case


54010501 Pin, Stud Welder, 3", Mild Steel, Pointed

54010502 Pin, Stud Welder, 6", Mild Steel, Pointed

54010503 Pin, Stud Welder, 3", Mild Steel, Blunt

54010504 Pin, Stud Welder, 6", Mild Steel, Blunt

54010401 Pin, Stud Welder, 3", Stainless Steel, Pointed

54010402 Pin, Stud Welder, 6", Stainless Steel, Pointed

54010403 Pin, Stud Welder, 3", Stainless Steel, Blunt

54010404 Pin, Stud Welder, 6", Stainless Steel, Blunt

54010702 Clip, Stud Welder, 1.5", Mild Steel, Round

54010712 Clip, Stud Welder, 2.5", Mild Steel, Square

54010700 Clip, Stud Welder, 1.5", Stainless Steel, Round

54010710 Clip, Stud Welder, 2.5", Stainless Steel, Square

54013401 Lacing Anchor, without pin, Stainless Steel

54013402 Lacing Anchor, 2.5", Stainless Steel

54013403 Lacing Anchor, 4.5", Stainless Steel

54013501 Pin, Quilting, 1.5", Stainless Steel



54004302

13003000

54004402

54010503

54010501

54010700

54010710

54013502

54013402

Eagle Stud Welder

Weight 26 lbs. (without gun and cables)

Height 8 1/2 inches

Width 10 inches

Depth 13 inches

Weld Rate Up to 20/minute

Weldable Materials Mild and Stainless Steel, Aluminum

Pin/Stud Range 14-gauge through 1/4" diameter weld base

Weld Voltage 35-175VDC

Capacitance 70,000 Mfd

Weld Mode Contact

Power Requirement 115VAC, 60 Hz, 20-Amp


13002803 Stud Welder, Eagle

13006417 Collet, Bullet-style (no stop required)

13006401 Collet, ‘B’ (requires stop - 13006414)

13006414 Stop for ‘B’ Collet

13006402 Collet Protector

13006402

13006417

13006401

13006414


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