Power Source... 1 Twin Heat Module... 2 Controllers... 3 Recorders... 4 Strip Chart Digital Paperless Chart Paper and Ribbons

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2 Table of Contents Power Source..... Twin Heat Module Controllers Recorders... 4 Strip Chart Digital Paperless Chart Paper and Ribbons Power Source Parts... 6 Casters Fuses and Fuse Holders Relays Circuit Breakers Hardware Strain Reliefs Contactors Indicator Lights Switches Electrical Connections Lugs Transformers Fans and Filters Panel Meters Power Cabling... 8 Splitters Triple Cable Sets Power Cable Camlock Connectors Amp 300Amp Thermocouple Attachment Unit (TAU) Connectors Jack Panels Sheathed Thermocouples Wire Test Equipment TC00 Calibrator Brinell Hardness Test Kit Heaters... 4 Flexible Ceramic Pad (FCP) Heaters (80 and 60VAC) Repair Kits Insulation... 6 Blanket (RCF and nonrcf) Cooperknit Meshed Mat Insulation Pad Insulation Attachment Banding and Clips Fiberglass Tape Iron Wire Stud Welder and Accessories Stud Welding Pins & Washers

3 Power Source Description The ability to control temperatures precisely is the key to accurate heat treatment. The Team Industrial Services, Inc. (TISI) 6way control console is designed to provide six independently controlled, low voltage, high current outputs which precisely control the work piece temperature. Length Width Height Weight Primary Voltage Standard International Secondary Voltage Power Out, FanCooled 24 inches 24 inches 48 inches (56 inches with casters) lbs. 480 VAC 380/45/440/480/575 VAC 65/85 VAC 72 KW Features Enclosure The stainless steel enclosure is supported by a /2 inch tubular frame for strength and stability. A folddown door protects the electronic components from damage. Mounting Each console comes standard with 6inch 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 6way console controls the output voltage of the machine to prevent unintentional power being sent to the heaters on the work piece. Safety Is Built In 25amp circuit breaker for primary power connection. 5amp circuit breaker safety switch in case of overloading on control circuit. 3 /4amp circuit breaker protection for each secondary contactor. Overtemperature protection of main transformer coils (275 F/35 C temp. trip). ITEM DESCRIPTION 6way 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 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 6way console is also available with a 2point or 24point temperature recorder. Customized units available The 6way power source can be customized to fit most heat treatment requirements. Part Number Description Standard International way, Manual Control way, Manual Control with 2point Recorder way, Programmable Control way, Programmable Control with 2point Recorder See POWER SOURCE PARTS for replacement parts Contact your TISI sales representative for more information. 3 2

4 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 2pen temperature recorder. A 6gauge stainless steel case protects unit components during field operation. Without recorder (with recorder) Length 6 3 /4 inches (9 inches) Width 0 3 /8 inches ( /4 inches) Height 3 /4 inches (2 inches) Weight 27 lbs. (36 lbs.) OnSite 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 Input/output current Control circuit, input Voltage Control circuit, auxiliary output Voltage Current Temperature controller Temperature range Thermocouple 660 VDC up to 220 VAC 300amp 20 VAC, 5060 Hz 20 VAC, 5060 Hz 25amp (control circuit protected at 5amp breaker total) F Type K Twin Heat Module, Manual Control Twin Heat Module, Programmable Control Twin Heat Module, Manual Control with 2pen Recorder Twin Heat Module, Programmable Control with 2pen Recorder The following accessories are necessary to connect to a power source: Feed/Return Cable with Lug and 300amp connector, 0' or Feed/Return Cable with 300amp connectors, 0' Power Cable, 0 VAC, 0' (other sizes available) Contact your TISI sales representative for more information. Replacement parts for the Twin Heat Module: UDC2500 Controller, Manual Control TC Jack Panel, Numbered Dual UDC3500 Controller, Programmable TC Jack Panel, Numbered Dual Indicator Light, Red Contactor, pole, 300A, 20V Circuit Breaker, Panel Mount, 5A amp Panel Mount Connector, Male Handle for Front amp Panel Mount Connector, Female Handle, Fold down for Top VAC Auxiliary Output Receptacle Rubber Feet for Base VAC Supply Input Receptacle 2

5 Controllers Description Each zone in a 6way power source and Twin Heat Module is controlled by a Universal Digital Controller (UDC). The UDC2500 model which replaced the UDC2300 model provides basic manual control using the arrow keys to increase or decrease the rate. The programmable UDC3500 model which replaced the UDC3300 model has set point programming (SPP) capabilities that allow up to five programmed segments. The unique feature of the available TISI UDC3500 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 welldesigned 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 dataconfigurable upscale or downscale burnout or failsafe output level. Reliable performance is immune to high noises. The unit provides reliable, errorfree control in industrial environments that often disturb highly noisesensitive digital equipment. Input signal smoothing is supplied by the configurable digital filter in 0 to 20 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 Temperature stability Input signal failure protection Input impedance Controller output types Available options Sample rate Input filter Wiring connections Power consumption Weight ± digit for display ±0.0% of full span/ C change typical Upscale, downscale or failsafe burnout 200K ohms Electromechanical or solid state relays, Current out Alarm outputs, RS422/485 or ethernet TCP/IP communications interface, Infrared communications (standard on UDC3500) Input sampled 6 times a second Off to 20 seconds Screw terminals on rear of case 20 VA (UDC2500) / 24 VA (UDC3500) maximum (90 to 264 VAC) 3 lbs UDC2500, Manual with Single Input (replaces UDC2300 part number ) UDC2500, Manual with Second Input (replaces UDC2300 part number ) UDC2500, Manual with Single Input and Setpoint Programming (replaces UDC2300 part number ) UDC2500, Manual with Second Input and Setpoint Programming (replaces UDC2300 part number ) UDC3500, Programmable with TSI Prom (replaces UDC3300 controller part number ) Contact your TISI sales representative for more information

6 Recorders Strip Chart Recorder The strip chart recorder is a multipoint recorder whose field worthiness and variable configuration makes it ideally suited for onsite applications. The standard temperature recorder is available with 2 channels for reliable, accurate records of timetemperature profiles for all control and monitor thermocouples. The 2channel model of recorder is also available with 24 channels (mr20000) or as a 2pen or 6channel model (mr0000). Operator Interface Paper Zfold, 80mm (00mm) Although it can accommodate Dot Colors 6 (2) a wide range of DCvoltage Chart Speed 2inch/hour factory set (inch/hour) inputs, each channel is Printing Digital and analog configured for Type K thermocouples at the Team factory. Printing formats are configurable by means of a convenient menudriven Setting mode. Chart speed can be programmed from 0.04 to 480inch/hour and is set for 2inch/hour at the Team factory. In addition to chart paper, the strip chart recorder utilizes a large, easytoread full dot matrix display for highly visible read selection and ease of use. Operator input to the recorder is by means of a sevenbutton keypad to access and navigate the interactive Operation and Setting modes. Digital Paperless Recorder Team Industrial Services, Inc. also offers a digital recorder option that allows for paperless recording. The SX has a 2.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 timetemperature 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 GHz pentium or higher Height 3 /8 inches (5.67 inches) Operating System Windows 2000, XP Width 3 /8 inches (5.67 inches) RAM 52 Mbyte minimum Depth 8 5 /8 inches (9.74 inches) Free Hard Drive 50 Mbyte minimum Case Mild steel, zincplated Electrical Voltage 00 to 250VAC Current /4Amp at 0VAC Configuration Channels 2 standard, up to 48 available (6 standard) Scan Rate Realtime Chart Speed Adjustable Operator Interface Although it can accommodate a wide range of DCvoltage 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. 4 mr20000 (mr0000) Specifications Mechanical Weight 9 lbs. (4.85 lbs.) Height 3 /8 inches (5.67 inches) Width 3 /8 inches (5.67 inches) Depth 8 5 /8 inches (9.74 inches) Case Drawn steel, 6gauge Door Cast aluminum Electrical Voltage 00 to 240VAC Current /4Amp at 0VAC Configuration Channels 2 standard, 24 available (2 or 6) Scan Rate /4seconds/channel

7 Recorders Carrying Case A recorder is also available as a standalone 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 0volt power source and, with the use of maletomale thermocouple jumper cables (see page ), will be able to provide timetemperature profiles. The carrying case is steel reinforced with a carrying handle and lined with polyurethane foam to protect the recorder during transit and onsite use. The case has removable front and rear doors for easy access. Part Number Description Recorder, Analog, 2point Recorder, Analog, 24point Recorder, Digital, 2point Recorder, Digital, 24point Recorder, Analog, 2point, Calibrated Recorder, Analog, 24point, Calibrated Recorder, Digital, 2point, Calibrated Recorder, Digital, 24point, Calibrated Recorder, Analog, 2point, Calibrated and Sockets Recorder, Analog, 24point, Calibrated and Sockets Recorder, Digital, 2point, Calibrated and Sockets Recorder, Digital, 24point, Calibrated and Sockets Carrying Case (for size recorders above) Recorder, Analog, 6point Recorder, Analog, 2pen Recorder, Digital, 6point Recorder, Analog, 6point, Calibrated Recorder, Analog, 2pen, Calibrated in carrying case Recorder, Digital, 6point, Calibrated Recorder, Analog, 6point, Calibrated and Sockets Recorder, Analog, 2pen, Calibrated and Sockets RECORDER REPLACEMENT PARTS Recorder, Digital, 6point, Calibrated and Sockets Carrying Case (for size recorders above) CHART PAPER Part Number Manufacturer Model Description Yokogawa mr000/ Scale Yokogawa mr000/0 000% Scale Yokogawa mr80/0, Scale Yokogawa mr80/0, % Scale Honeywell DPR00 000% Scale Honeywell DPR80 000% Scale Honeywell DPR3000, % Scale Chino AL % Scale Chino AH Scale Chino AH % Scale RIBBONS & PENS Part Number Manufacturer Model Description Yokogawa mr000/0 Ribbon Cartridge Yokogawa mr000/0 Red Pen Yokogawa mr00/00 Green Pen Yokogawa mr000/0 Purple Pen/Plotter Yokogawa mr80/0, Ribbon Cartridge Honeywell DPR00 Ren Pen Honeywell DPR00 Blue Pen Honeywell DPR80, 3000, 250 Ribbon Cartridge Chino AL3000 Ribbon Cartridge Chino AH3000 Ribbon Cartridge 5

8 Power Source Parts CONTACTORS Primary Contactors (control output voltage) Contactor, 3pole, 90A (Standard) Contactor, 3pole, 20A (International) Secondary (Zone) Contactors Contactor, pole, 300A, 20V * Repair Kit for Contactor, pole, 400A, 20V * Repair Kit for *Each repair kit includes: Upper Contact Assembly 2 Lower Contact Assembly Replacement Spring FUSES & FUSE HOLDERS Fuse, KTKR, 5A Fuse, KTKR, 0A 57000** Fuse, AGC, 3 /4A for contactor protection Fuse, AGC, 2A for cooling fan protection Fuse Holder, 2P, 600V ** Fuse Holder, 30A, 250V for contactor ( 3 /4A) protection CIRCUIT BREAKERS Circuit Breaker, P, 5A, 277V, Rockerstyle Circuit Breaker, 3P, 25A, 600V (CutlerHammer) Circuit Breaker, 3P, 25A, 600V (GE) Circuit Breaker, Panel Mount, 5A Circuit Breaker, Panel Mount, 0A Circuit Breaker, Panel Mount, 3 /4A (replaces fuse holder with 3/4A fuse 57000) ** PANEL METERS Ammeter, 0300A, Digital Panel Meter Ammeter, 050A, Digital Panel Meter T Screw Terminal Adapter for INDICATOR LIGHTS Indicator, Red, 80VAC with Leads Bulb for START/STOP Switch LED, Bayonetstyle, White LED, Bayonetstyle, Green LED, Bayonetstyle, Red Mounting Flange for LED Assembly Actuator Sleeve for LED Assembly Lamp Holder for LED Assembly Contact Block for LED Assembly Lens Holder for LED Assembly Green Lens for LED Assembly Red Lens for LED Assembly Bezel for LED Assembly LED Assembly SWITCHES Switch Assembly, START/STOP (Square) Switch Assembly, START/STOP (Oval) Switch, Pushbutton, 6station Aluminum Knob for Switch, Rotary, 6position TRANSFORMERS Primary (Main) Transformer Transformer, 55kVA, 480 VAC (Standard) Transformer, 55kVA, 380/45/440/480/575 VAC (International) Secondary (20V Step Down) Transformer Transformer, 750VA, /20240 (Standard) Transformer, 750VA, /20240 (International) Current Transformer (CT) Current Transformer, 5300A Loop with Leads for Panel Meter Current Transformer, 550A Loop with Leads for Panel Meter

9 Power Source Parts FANS & FILTERS Cooling Fan, Axial Cord for Cooling Fan, Axial, 24" Exhaust Fan, Wire Frame, 2" Filter, 20" x 20" x " Filter, 0" x 20" x " ELECTRICAL CONNECTIONS RELAYS GFI Receptacle, 5A, 25V, Duplex Edison Relay Base, 8pin Cover for GFI Receptacle Relay, 24VDC, 8pin Terminal Block, Double Row, 2Term Relay, 20VAC, 8pin, Illuminated Power Distribution Block, 3P, 75A, 480V Power Distribution Block, 3P, 75A, 600V LUGS Ground Lug, Copper Ground Lug, Aluminum Crimp Lug, 3 /8" Purple Crimp Lug, /2" Purple Crimp Lug, 3 /8" Green Crimp Lug, /2" Green Crimp lugs are for cable assemblies HARDWARE Lever Latch for Rear Machine Door (Black) Latch, THandle for Rear Machine Door (SS) Handle for Front Door Pocket Magnet for Front Door Catch Control Knob for THM (Old Style) Energy Regulator / Cycle Timer for THM (Old Style) Handle for Top/Front of THM Handle, Fold down for Top of THM Feet, Rubber for THM STRAIN RELIEF GRIPS Strain Relief Grip, Oval, /2" Strain Relief Grip, Oval, /4" Strain Relief Grip, Oval, /2" Strain Relief Grip, Straight, /4" Strain Relief Grip, Mesh, " Strain Relief Grip, Mesh, /4" CASTERS Dolly for 6way, 4" casters (CHstyle) Rigid Caster, 4" without brake Swivel Caster, 4" without brake Swivel Caster, 4" with brake Rigid Caster, 6" without brake Swivel Caster, 6" without brake Swivel Caster, 6" with brake

10 Power Cabling A typical electric resistance heating circuit consists of the following components: A multizone power console (e.g. 6way) 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 Threeway 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. Twoway and fourway splitters are also available. Specifications Length Size Stranding Insulation Ratings 4foot long #6, approximately 3 /8inch outer diameter Seven bundles of 37 strands of 30gauge UltraFlex thermoplastic rubber 74 F to 22 F, 600Volt, 300Amp male and 50Amp female camlocks Triple Cable Set A triple cable consists of a taped assembly of twin power cables and a thermocouple extension cable. The multistranded 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 20AWG PVCsheathed shielded wire that is encased in a PVC abrasionresistant jacket and equipped with a polarized male plug and female socket. Specifications Assembly Length 25foot, 50foot or 00foot standard Weight 65 lbs./00foot Binding Fiberglass tape, foot pitch Power Cable Size #2, approximately /2inch outer diameter Stranding Seven bundles of 90 strands of 30gauge Insulation UltraFlex thermoplastic rubber Ratings 74 F to 22 F, 600Volt, 300Amp camlocks Thermocouple Extension Cable Type K, ChromelAlumel Size 20AWG, Solid Insulation PVC with PVC outer jacket Connectors Polarized male plug and female socket Splitter, 2way, 4' long Splitter, 3way, 4' long Splitter, 4way, 4' long Triple Cable Set, 25' Triple Cable Set, 50' Triple Cable Set, 00' * Power Cable, 4/ * Power Cable, 6/4 *order in 25foot increments Additional cable is available in 0foot increments: #6 Cable, Gray for Splitters #2 Cable, Gray for Triple Cables Thermocouple Extension Cable

11 Camlock Connectors Camlock electrical power connectors achieve an insulated locking connection with an approximate /2turn for highamperage circuits. Connector sets are available in panel mount and inline styles. Specifications Panel Mount Brass male/female body, 50 or 300Amp Bolted neoprene casing or highimpact plastic Large InLine Small InLine Brass male/female body, 300Amp Fiber electrical insulating sleeve Fiber interlocking pin Brass male/female body, 50Amp Fiber electrical insulating sleeve Fiber interlocking pin Connector, 50Amp, Male Complete Connector, 50Amp, Female Complete Connector, 300Amp, Male Complete Connector, 300Amp, Female Complete Replacement Parts Connector, 50Amp, Male Sleeve Only Connector, 50Amp, Female Sleeve Only Connector, 50Amp, Pin Connector, 300Amp, Male Sleeve Only Connector, 300Amp, Female Sleeve Only Connector, 300Amp, Pin HighImpact Plastic Connector, 50Amp, Panel Mount, Male Connector, 50Amp, Panel Mount, Female Connector, 300Amp, Panel Mount, Male Connector, 300Amp, Panel Mount, Female Neoprene Casing Connector, 50Amp, Panel Mount, Male Connector, 50Amp, Panel Mount, Female Connector, 300Amp, Panel Mount, Male * Connector, 300Amp, Panel Mount, Female *Standard on TISI 6way machines Female InLine Connectors without Sleeve

12 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 twistedwire 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 nonferrous 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. (.8 mm) and.003 in. (.07 mm) in the heataffected 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 nickelcadmium battery. The battery can be recharged from 20volt supply and allows up to 50 uses per charge. Not only can the unit be operated while charging, but it can also be completely recharged within just 3 hours. Weight Height Width Length Battery Type Voltage Thermocouple Wire Capability Voltage Discharge Energy Discharge /2 lbs. 8 /2 inches 3 3 /4 inches 0 /2 inches 2V Nickel Cadmium 20VAC, 60Hz E, J, K, T 6 30 Gauge (AWG) 5 80 Volts 5 50 Joules Replacement parts for the Thermocouple Attachment Unit (TAU): Thermocouple Attachment Unit, Series IV Enclosure for TAU, Stainless Steel Plier Assembly with Male Camlock for TAU Operation Label for TAU Adjustable Shoulder Strap for TAU Magnet for TAU Battery for TAU Power Cord for TAU 0

13 Thermocouple 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, twistedwire 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 crossconnecting +/ 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 ChromelAlumel 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 nonmagnetic 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 (ChromelAlumel) Wire 20gauge (AWG) Maximum Range Q/Q 200 F, continuous (600 F, single) Cefir 2200 F, continuous (2400 F, single) Quality Certificate of Conformance Wire, K TC, Extension with PVC shielded jacket Wire, K TC, Q/Q Wire, K TC, Cefir 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, 20gauge (AWG) but other types and sizes are available. Contact your TISI sales representative for more information TC Cable Assembly, K TC Extension with Male and Female Connectors, 25' TC Cable Assembly, K TC Extension with Male and Female Connectors, 50' TC Cable Assembly, K TC Extension with Male and Female Connectors, 00' TC Cable Assembly, Jumper, K TC Extension with Male Connectors, 6' TC Cable Assembly, Jumper, K TC Extension with Male Connectors, 0' TC Cable Assembly, K TC Q/Q with Male Connector, 0' Plug, TC, Type K Socket, TC, Type K Plug, TC, Type K, Midget Socket, TC, Type K, Midge

14 Thermocouple Unlike thermocouple wire, sheathed thermocouples can not be capacitance dischargewelded to workpiece surfaces. They must be attached to the work surface with welded clips or banding, both available from TISI. Specifications Construction Sheath Material Sheath Diameter Length Attachment Thermocouple wire within metal sheath, hollow Filled with magnesium oxide, grounded junction 30 Stainless Steel, standard Inconel, 304 or 36 Stainless Steel available, custom /8inch, standard 0.04inch to 3 /8inch available, custom 2foot, 6foot, 2foot and 20foot, standard Other lengths available, custom /8inch, standard Stainless or mild steel available, single or dual (dual available in stainless steel only) TC Sheathed, 2', /8inch diameter, Type K TC Sheathed, 6', /8inch diameter, Type K TC Sheathed, 2', /8inch diameter, Type K TC Sheathed, 20', /8inch diameter, Type K Clip, Single TC, Mild Steel Clip, Single TC, Stainless Steel Clip, Dual TC, Stainless Steel Putty, Moldable, oz. Tube TC Jack Panel, 2point, Screwmount TC Jack Panel, 4point, Screwmount TC Jack Panel, 6point, Screwmount TC Jack Panel, 2point, Screwmount TC Jack Panel, 24point, Screwmount TC Jack Panel, Numbered 2, Selfmount TC Jack Panel, Numbered 6, Selfmount TC Jack Panel, Numbered 72, Selfmount TC Jack Panel, Numbered 2, Selfmount TC Jack Panel, Numbered 324, Selfmount TC Jack Panel, Numbered Dual, Selfmount TC Jack Panel, Numbered Dual 2, Selfmount TC Jack Panel, Numbered Dual 6, Selfmount

15 Test Equipment The TC00 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. 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 miniplug or bare wires to the terminals. The calibrator is protected with a rugged, shockresistant case and comes with a protective rubber boot to prevent damage if dropped. Unit has input protection up to 240 VAC. Specifications Mechanical Weight Length Width Depth Case Accessories Electrical Input Voltage Program Calibration Measure Range Accuracy Connection Program 2 ounces (0.75 lbs.) 5.7 inches 3.5 inches.43 inches Shock resistant ABS Protective rubber boot, battery and charger (sold separately) 0 to mv, mv resolution 9Vbattery (alkaline or NiCad rechargeable) J, K, T, E, R, S, B, L, U or C thermocouples, mv 392 to 250 F (200 to 372 C) for Type K ± C (based on range), 0. F/C resolution Internal or external cold junction compensation, miniplug or bare wires Three setpoints for each TC type, Knob control Temperature Calibrator, Martel TC A AC Adapter for use with Rechargeable Battery B 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. 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 Brinell Kit with Large Bar Holder Brinell Kit with Fillet Weld Tester Fillet Weld Tester Scope Brinell Bar, 76 Hardness Brinell Bar, 94 Hardness Brinell Bar, 229 Hardness Other size hardness bars available 3

16 Heaters Construction Flexible ceramic pad (FCP) heaters are manufactured by weaving multistranded 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 /8inch thick. The Alumina has excellent hightemperature 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 nineinch 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 20 square inches and a thermal power of 3.6 kw, producing a power density of 30 W/in 2 with an electrical current of 45 amps. The 60VAC counterparts are simply threequarters 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. Part Number VAC HEATERS Type Width (A) (Inches) CP3 3 CP4 4 CP6 6 CP8 8 CP0 0 CP2 2 CP5 5 CP8 8 CP2 2 CP24 24 CP29 29 CP36 36 CP72 72 CP20 Height (B) (Inches) /2 4 /2 2 /2 9 3 /4 8 6 /2 5 3 / /4 3 /4 20 Part Number VAC HEATERS Type CP3 CP4 CP6 CP8 CP0 CP2 CP5 CP8 CP2 CP26 CP52 CP87 Width (A) (Inches) Height (B) (Inches) 28 /2 2 4 / /4 5 3 / /4 3 /4 87 4

17 Heaters Features Because of their design and components, FCP heaters have the following benefits: Durability The ductility of multistranded 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 Noninterlocking 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 nonstandard 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: V FCP Heater Repair Kit V FCP Heater Repair Kit Body Bead, Standard Body Bead, Standard with Hole End Bead, Male End Bead, Female Tail Bead, Pink Tail Bead, White V Heater Core Wire Assembly V Heater Core Wire Assembly Wire, 80/20 Nichrome Heater Body Wire, Nickel Cold Tail Description 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, 50A Male Power 80VAC Kit Quantities VAC Kit Quantities

18 Insulation 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. InsulationMaterial Thermal insulation is available in a wide variety of materials and forms. TISI makes available those materials and forms that are best suited for onsite 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 singleuse applications. NonRCF Superwool (Silica) is a nonrcf blanket alternative. Needled silica mat insulation blanket is a nonrcf product that is constructed of 98% amorphous silica, whose construction imparts fiber integrity for high temperature reusable applications. Cooperknit is a silicabased 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. Part Number Material RCF Thickness Width Length Density Limit Ceramic Fiber Ceramic Fiber Mineral Wool Superwool Superwool Needled Silica Needled Silica Welding Cloth Welding Cloth Cooperknit Yes Yes Yes No No No No No No No inch inch 2inches inch inch /2inch /2inch.030inches.060inches /2inch 2foot 2foot 4foot 2foot 2foot 2foot 3foot 3foot 3foot 2foot 25foot 25foot 24foot 25foot 25foot 25foot 25foot 50foot 50foot 25foot 6 lb/ft 3 8 lb/ft 3 8 lb/ft 3 6 lb/ft 3 8 lb/ft 3 8 lb/ft 3 8 lb/ft 3 8 ounce 36 ounce 5.2 lb/ft F 800 F 000 F 2200 F 2200 F 2000 F 2000 F 2300 F 800 F 2000 F 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 steelknitted 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. PartNumbers Product Size MeshMat MeshMat Insulation Cooperknit 6lb. 8lb. Pad Mat ' x 2' ' x 3' ' x 4' ' x 6' 2' x 2' 2' x 3' 2' x 4' 2' x 6' 2' x 8' 2' x 0' 2' x 2' Additional sizes are also available, contact your TISI sales representative for more information. MeshedMat encased in SS mesh InsulationPad encased in silica cloth 6

19 Insulation Attachment Insulation is secured to workpiece surfaces by means of steel banding or capacitance dischargewelded 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 2gauge. Other sizes are available, contact your sales representative for more information Banding, Mild Steel, /2", 300'/roll Clips, Wing, Mild Steel, /2" Banding, Stainless Steel, /2", 200'/roll Clips, Wing, Stainless Steel, /2" Banding Tension Tool Fiberglass Tape, 3 /4", 250'/roll, 48 rolls/case Wire, Iron Tie, 6gauge, 3.5 lbs./roll, 20/case Pin, Stud Welder, 3", Mild Steel, Pointed Pin, Stud Welder, 6", Mild Steel, Pointed Pin, Stud Welder, 3", Mild Steel, Blunt Pin, Stud Welder, 6", Mild Steel, Blunt Pin, Stud Welder, 3", Stainless Steel, Pointed Pin, Stud Welder, 6", Stainless Steel, Pointed Pin, Stud Welder, 3", Stainless Steel, Blunt Pin, Stud Welder, 6", Stainless Steel, Blunt Clip, Stud Welder,.5", Mild Steel, Round Clip, Stud Welder, 2.5", Mild Steel, Square Clip, Stud Welder,.5", Stainless Steel, Round Clip, Stud Welder, 2.5", Stainless Steel, Square Lacing Anchor, without pin, Stainless Steel Lacing Anchor, 2.5", Stainless Steel Lacing Anchor, 4.5", Stainless Steel Pin, Quilting,.5", Stainless Steel Pin, Quilting, 2.5", Stainless Steel Pin, Quilting, 4.5", Stainless Steel Eagle Stud Welder Weight Height Width Depth Weld Rate Weldable Materials Pin/Stud Range Weld Voltage Capacitance Weld Mode Power Requirement 26 lbs. (without gun and cables) 8 /2 inches 0 inches 3 inches Up to 20/minute Mild and Stainless Steel, Aluminum 4gauge through /4" diameter weld base 3575VDC 70,000 Mfd Contact VAC, 60 Hz, 20Amp Stud Welder, Eagle Collet, Bulletstyle (no stop required) Collet, B (requires stop ) Stop for B Collet Collet Protector

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