HEATCON - Sumincol CATALOGUE.pdfMaterials HEATCON AS9100 and ISO 9001:2008 Certified COMPOSITE SYSTEMS COMPOSITE REPAIR SOLUTIONS ® training equipMent PRODUCT CATALOG accessories

Materials

AS9100 and ISO 9001:2008 CertifiedHEATCONCOMPOSITE SYSTEMS

COMPOSITE REPAIR SOLUTIONS

®

training equipMent

accessories

PROD

UCT C

ATAL

OG COMPOSITEREPAIR SOLUTIONS

Delivering Innovationto the

Composite Repair Industry!

MISSION STATEMENT

The Management of HEATCON® and its subsidiaries is committed to quality and continual improvement in all areas of the organization. As individuals we believe that teamwork and customer satisfaction are the foundation of our past and future success.We are committed, through the skills of every one of our employees to be a vibrant, innovative and responsible world market leader in HEATCON®’s portfolio of products and services. HEATCON®’s target for quality is to maintain and to improve the quality of products and service, in order to meet or exceed customer requirements and internal needs. Our management is committed to the safety of the company’s operations and, in particular, to the health and safety of employees, customers and the public in general.Under observance of the aforementioned, customer satisfaction is the company’s main priority: we want to be our customers’ preferred supplier.

NOTES

Please Recycle

For more information call: USA 1-206-575-1333 • UK +44 (0) 1480-410740 • ASIA [email protected] 11.0.0 | 1

Email: [email protected] • www.heatcon.com HEATCON®

COMPOSITE SYSTEMSComposite Repair Solutions

NOTES



2 | 11.0.0 For more information call: USA 1-206-575-1333 • UK +44 (0) 1480-410740 • ASIA [email protected]



Table of ContentsProduct Catalog

* All products, prices, services, or availability are subject change without notice.

Equipment

Heat Blankets

Materials

Hot Bonder Comparison Guide 4Hot Bonder Comparison Guide continued 5Single and Dual Zone Hot Bonders 6Single and Dual Zone EV Series 7 Single and Dual Zone Flightline Series 8 Features and Options 9 Confi guring Your Hot Bonder Package 10 Military Dual Zone Hot Bonder - N Model 11Military Dual Zone Hot Bonder - M Model 12HCS8800 “Micro Bonder” 13Protection and Services 14 B-Model Equipment Input Cables 15 B-Model Equipment Output Cables 15 B-Model Equipment Output Cables 16 B-Model Equipment Output Cables 17 A and B-Model Paper and Ink 17 Data Capture and Analysis Software 18 Bonder Calibration Kit 18 Thermographic Inspection Kits 19 Portable Autoclave 20 Portable Autoclave continued 21 Power Booster Box 22 Phosphoric Acid Containment System (PACS) 23 PACS Replacement Parts 24PACS Accessory Assortment 25 PACS Accessory Assortment continued 26 PACS Welding Accessory Assortment 27 Ovens and Controllers 28 Hot Air Curing System 29 Infrared Curing Systems 30 Heat Lamps 31 Debulking and Curing Table 32 Walk-In Freezers 33Moderate-Cold Cabinets 34 Circular Chart Recorder 35 Downdraft Tables 36 Dust Collection Equipment 37 Custom Control Panels 38HCS2034 Series Blade Clamps 39

Thermowelder 39 Thermocouples 40 Thermocouple Accessory Assortment 41Temperature Indicator 42 Vacuum Generator 43 Electric Vacuum Pumps 44 Vacuum Leak Checker 45 Vacuum Hose/Sniffer Assembly 45 Vacuum Accessory Assortment 46 Vacuum Accessory Assortment continued 47 Radome Moisture Meter 48 Portable Electronic Scales 49 Ultrasonic Leak Detector 50 Magnehelic® Pressure Gauges 50 Heat Blanket Tester 51

Heat Blankets 52 Heat Blankets Continued 53 Heat Blankets Continued 54 Stretchable Heat Blankets 55 Stretchable Heat Blankets Continued 56Thermal Uniformity Testing 56 Supervisory Heat Blankets 57 Radome Heat Blankets 58 Abdradable/Fantrack Replacement 59 Custom Formed Heat Blankets 60 Custom Formed Our Process 61 Heat Blanket Construction 62Plugs and Receptacles 63 Plugs and Receptacles continued 64

Materials Capabilities 65 Material Recertifi cation 66 Material Cutting and Kitting 66Pre-assembled Kits 67Pre-Assembled Kits 68 Resin Kits 69 Tack Rags 70




Table of ContentsProduct Catalog

Tool Kits

Technical Services

NSN’s

* All products, prices, services, or availability are subject change without notice.

Fiberglass - Prepreg 71 Carbon Fabrics and Kevlar™ - Prepreg 72 Film and Foaming - Adhesive 73 Airbus Silicone Adhesive Foam Tape 74 Aluminum Foil 75 Corrosion Inhibiting - Primer 75 Fillers, Resins, Potting, and Edge 75 Fiberglass, Carbon, and Kevlar™ - Dry Fabric 76Release Peel Ply 77 Nylon Bagging Film 78 Breather/Bleeder Cloth 78 Tefl on® Release Fabric - Porous 79 Tefl on® Release Fabric - Non-Porous 79 Release Film - Perforated 80 Release Film - Non-Perforated 80 Flash Tape 81 Polyester Discs 81 Sealant Tape 81 Pre-Formed Core Materials 82Aluminum and Non-Metallic - Honeycomb 83

Composite Repair Tool Kit 84Drill Motor and Grinder Motor 85Router Motor and Orbital Sander 86 Grinder Motor Accessories 87 Additional Tools and Accessories 88 Composite Repair Tool Kit 89 Metal Bond Tool Kit 90 Metal Bond Tool Kit Continued 91 Floor Panel Repair Tool Kit 92 Floor Panel Repair Tool Kit Accessories 92UAV Composite Repair Tool Kit 93UAV Composite Repair Tool Kit Continued 94UAV Composite Repair Tool Kit Continued 95Storage Solutions 96Storage Solutions Continued 97 Drill Motor and Bits 98 Drill Motor Accessories and Counter Bores 99 Drill Motor Accessories and Reamers 100

Consultations/Facility Design/Installation 115 Composite Repair Training 115 Phase 1 Fabrication/Damage Repair 116Phase 2 Fabrication/Damage Repair 117 Combo (Combination of Phases 1 and 2) 118 Phase 3 Fabrication/Damage Repair 119 Bonded Aluminum Repair - 5 days 120 Course Descriptions 121 2011 Course Schedule 122 2011 Course Schedule continued 123 Available Training Materials 124

Router Motor and Bits 101 Router Motor Kevlar™ Bits 102 Router Motor Bits, Collets, and Templates 103 Router Motor Lay-up Cutting Templates 104 Grinder Motor and Sanding Barrels 105 Grinder Motor Sanding Disks and Bayonets 106Grinder Motor Sanding Disks and Bayonets 107 Grinder Motor Accessories 108 Orbital Sander and Three Way Air Manifold 109 Belt Sander, Accessories, and Cleco® Pliers 110Additional Repair Tools and Accessories 111 Additional Repair Tools and Accessories 112 Additional Repair Tools and Accessories 113 Composite Repair Safety Items 114

National Stock Numbers 125 National Stock Numbers 126 National Stock Numbers 127




Single Zone Dual Zone Military

HC

S88

00H

CS

9000

BH

CS

9000

B-E

VH

CS

9000

-FL

HC

S92

00B

HC

S92

00B

-EV

HC

S92

00-F

LH

CS

9200

M-0

4H

CS

9200

N-0

2

HOT BONDERCOMPARISON

GUIDENumber of Zones 1 1 1 1 2 2 2 2 2

Input Amperage per Zone (Amps) 20 30 30 30 30 30 30 30 30

FEATURES

Operating Voltage (VAC) 90-264 90-264 90-264 90-264 90-264 90-264 90-264 90-264 90-264

Input Frequency (Hz) 47-63 47-63 400-440

47-63 400-440

47-63 400-440

47-63 400-440

47-63 400-440

47-63 400-440

47-63 400-440

47-63 400-440

Operating Temperature (°F) 500 1000 1000 1000 1000 1000 1000 1000 1000

Heating System Blanket

Blanket Hot Air Radiant Lamp


Flightline Blanket



Flightline Blanket



Upper Blanket Size Limitations @ 5 Watts in2 at 120V / 220V

480960

720 1440

7201440

7201440

7201440

7201440

7201440

7201440

7201440

Network Functionality (Large Area Repair) (Requires Controller Console) No Yes Yes Yes Yes Yes Yes No No

Operating Environmental Limitations Temperature °F 0-130 32-122 32-122 32-122 32-122 32-122 32-122 14-130 14-130

Relative Humidity % ± 5% 0-99 0-93 0-93 0-93 0-93 0-93 0-93 0-93 0-93

Vacuum Source None Shop AirShop

Air / Int Pump

Shop Air

Shop Air

Shop Air / Ext Pump

Shop Air

Shop Air / Int Pump

Shop Air

Vacuum Lines 1 - 10ft 2 - 10ft 2 - 10ft 2 - 10ft 4 - 10ft 4 - 10ft 4 - 10ft 4 - 10ft 2 - 10ft

Vacuum MonitoringOn

Screen Display

On Screen Display

On Screen Display

On Screen Display

On Screen Display

On Screen Display

On Screen Display

On Screen Display

On Screen Display

Return Vacuum Monitoring Yes Yes Yes Yes Yes Yes Yes Yes No

Thermocouple Type J J or K J or K J or K J or K J or K J or K J J

Thermocouples per Zone 4 10 10 10 10 10 10 10 8

Temperature Accuracy ± 1°F ± 1°F ± 1°F ± 1°F ± 1°F ± 1°F ± 1°F ± 1°F ± 1°F

Number of Storable Cure Programs 8 30 30 30 30 30 30 30 30

Dwell Time 0-480 Min

0-2000 Min

0-2000 Min

0-2000 Min

0-2000 Min

0-2000 Min

0-2000 Min

0-2000 Min

0-2000 Min

Max Program Time 0-720 Min

0-2880 Min

0-2880 Min

0-2880 Min

0-2880 Min

0-2880 Min

0-2880 Min

0-2880 Min

0-2880 Min

Run Separate Programs on each Zone N/A N/A N/A N/A Yes Yes Yes Yes Yes

Run Same Program on Both Zones at the same time N/A N/A N/A N/A Yes Yes Yes Yes Yes

Ramp Rate 1-99 1-99 1-99 1-99 1-99 1-99 1-99 1-99 1-99

Programmable without a Personal Computer Yes Yes Yes Yes Yes Yes Yes Yes Yes

Modify a Program in Process Yes Yes Yes Yes Yes Yes Yes Yes Yes

Number of Dwell Cycles in a Cure Program

3 Ramps

2 Dwells

9 Ramps

8 Dwells

9 Ramps

8 Dwells

9 Ramps

8 Dwells

9 Ramps

8 Dwells

9 Ramps

8 Dwells

9 Ramps

8 Dwells

9 Ramps

8 Dwells

9 Ramps

8 Dwells

Full Functionality without a Personal Computer Yes Yes Yes Yes Yes Yes Yes Yes Yes





HC

S88

00H

CS

9000

BH

CS

9000

B-E

VH

CS

9000

-FL

HC

S92

00B

HC

S92

00B

-EV

HC

S92

00-F

LH

CS

9200

M-0

4H

CS

9200

N-0

2


HC

S88

00H

CS

9000

BH

CS

9000

B-E

VH

CS

9000

-FL

HC

S92

00B

HC

S92

00B

-EV

HC

S92

00-F

LH

CS

9200

M-0

4H

CS

9200

N-0

2

Full Text-based GUI, Real Language screens Yes Yes Yes Yes Yes Yes Yes Yes Yes

Variable Units of Measure

F / C InHgkPa

mBar

F / C InHg kPa

mBar

F / C InHgkPa

mBar

F / C InHg kPa

mBar

F / C InHg kPa

mBar

F / C InHg kPa

mBar

F / C InHg kPa

mBar

F / C InHg kPa

mBar

FInHg

FEATURES

Display Type Monochrome

Color LCD

Color LCD

Color LCD

Color LCD

Color LCD

Color LCD

Color LCD

Color LCD

Sunlight Readable Yes Yes Yes Yes Yes Yes Yes Yes Yes

User Interface 4 Button Prompts Prompts Prompts Prompts Prompts Prompts Prompts Prompts

Printout of Program and Cure No Yes Yes Yes Yes Yes Yes Yes Yes

Vacuum Pressure Presented Visually Yes Yes Yes Yes Yes Yes Yes Yes Yes

All TC’s Status Presented Visually at Once Yes Yes Yes Yes Yes Yes Yes Yes Yes

TC Test / Blanket Test Prior to Start Cure Yes Yes Yes Yes Yes Yes Yes Yes Yes

Data Export USB USB USB USB USB USB USB USB USB

Stored Cured Data Last 6 Cures

Last 12 Cures

Last 12 Cures

Last 12 Cures

Last 12 Cures

Last 12 Cures

Last 12 Cures

Last 12 Cures

Only Last

Cure on Each Zone

Data Logging Interval 1 Min 1 Min 1 Min 1 Min 1 Min 1 Min 1 Min 1 Min 1 Min

Print Interval N/A 1-99 Min

1-99 Min

1-99 Min

1-99 Min

1-99 Min

1-99 Min

1-99 Min

1-99 Min

Password Protection No Optional Optional Optional Optional Optional Optional Optional No

Printer No 1 per Zone

1 per Zone

1 per Zone

1 per Zone

1 per Zone

1 per Zone

1 per Zone 1

Audible Alarm Yes Yes Yes Yes Yes Yes Yes Yes Yes

High Limit Relay Yes Yes Yes Yes Yes Yes Yes Yes Yes

Power Loss Recovery Yes2 Min

Yes0-15 Min

Yes0-15 Min

Yes0-15 Min

Yes0-15 Min

Yes0-15 Min

Yes0-15 Min

Yes0-15 Min

Yes5 Min

Weight (lbs) 4.1 15 29 25 28 38 37 42.5 37

Dimensions (L x W x H)10 in x 6.5 in x 2.5 in

18 in x 13 in x 5.75 in

21.75 in x 14.25 in x 6.5

in

23.5 in x 17 in x 7.75 in

21.75 in x 14.25 in x 6.5

in

21.75 in x 14.25 in x 6.5

in

29 in x 19 in x 9.5 in

23.75 in x 18 in x

7 in

29 in x 18 in x

8 in

Removable Lid N/A Yes Yes Yes Yes Yes Yes Yes Yes

Equipment Storage in Lid Separate Case Optional Optional Optional Optional Optional No No No

30 Amp Standard Circuit Breaker No Yes Yes Yes Yes Yes Yes Yes Yes

CE Compliant Yes Yes Yes Yes Yes Yes Yes Yes Yes

This and other information from HEATCON® Composite Systems provides product or system options for further investigation by users having technical expertise. Before you select or use any product or system it is important that you analyze all aspects of your technical application and review the information concerning the product in the current product catalog. The user, through their own analysis and testing, is responsible for making the final selection of the system and components and assuring that all performance, safety, and warning requirements of the application are met.

HOT BONDERCOMPARISON

GUIDE




Applications:The primary system application is composite and metal bond repairs, by heating and curing prepregs, resins or adhesives.

Manufacturing applications include secondary bonding processes normally accomplished with autoclaves or ovens. Hot bonders are also useful in R&D projects for materials and processes.

The line of HEATCON® Composite Repair Systems can also be used to control other resistive heat sources for a wide variety of manufacturing and repair applications.

Hot Bonder of Choice for Major Airlines, Repair

Stations and the Military!See page 9 for Full Features and Options

HCS9000B / HCS9200BSingle & Dual Zone Hot Bonders

HCS9000B Specifi cations:Weight - Only 15lbs (6.8kg)Dimensions - 18in x 13in x 5.75in (45.7cm x 33.02cm x 14.6cm)NSN: 4920-01-462-4658

RELIABLEEASY TO USEUPGRADEABLE

SUPERIOR CAPABILITIESCOMPACT SIZE/PORTABLE

Accessories Included:• Heat Blankets • Power Cords• Thermocouples• Vacuum Hose • Air Filter• Extra Printer Ribbon

and Printer Paper

• Accessory Storage in Removable Lid

• Data Capture Analysis Software

• USB drive

Specifi c accessories are described by quotation

Thermographic Inspection (NDT)Compatible

See page 19 for Details

HCS9200B Specifi cations:Weight - Only 28lbs (12.7kg)Dimensions - 21.75in x 14.25in x 6.5in (55.25cm x 36.2cm x 16.5cm)NSN: 4920-01-462-4666




HCS9000B-EV / HCS9200B-EVEV Series Hot Bonders

Applications:This line of HEATCON® Composite Repair Systems has a built-in vacuum system to allow easier mobility to the repair site and without the need for a alternative air source. The primary system application is composite and metal bond repairs, by heating and curing prepregs, resins or adhesives.

Manufacturing applications include secondary bonding processes normally accomplished with autoclaves or ovens. Hot bonders are also useful in R&D projects for materials and processes.

Built in Vacuum SystemSee page 9 for Full Features and Options

HCS9000B-EV Specifi cations:Weight - Only 29lbs (13.2kg)

Dimensions - 21.75in x 14.25in x 6.5in (552.5mm x 362mm x 165.1mm)

RELIABLEEASY TO USEUPGRADEABLE

SUPERIOR CAPABILITIESCOMPACT SIZE/PORTABLE

Accessories Included:• Heat Blankets • Power Cords• Thermocouples• Vacuum Hose • Air Filter• Extra Printer Ribbon

and Printer Paper

• Accessory Storage in Removable Lid

• Data Capture Analysis Software

• USB drive

Specifi c accessories are described by quotation

Built in Electric Vacuum Pump Max. fl ow is 0.75 cubic ft/min (354

cm3/sec) and Max. level is 28+ in/Hg (0.967kgs/cm2)

HCS9200B-EV Specifi cations:Weight - Only 38lbs (17.4kg) (Vacuum Pump located in Lid Assembly)

Dimensions - 21.75in x 14.25in x 6.5in (552.5mm x 362mm x 165.1mm)




Applications:The Flightline Composite Repair Systems include the same basic features, operation and capabilities as the HCS9000 and HCS9200 systems, but are further designed to meet the requirements of Class I, Division II, hazardous environment operation per the U.S. National Electric Code (NEC), as promulgated by the National Fire Protection Association (NFPA).

The primary application is composite and metal bond repairs on fueled aircraft and in other Class I, Division II environments.

Heat blankets* for the fl ightline systems include a supervisory grid for over- temperature safety and a ground plane for sensing faulty circuits.

Distinctive Specifi cations:

• These Units are Purged and Pressurized for Use in Hazardous Environments.

• Dynamic Alarm/Control Integration with Indicators for Pressure Status, Purge Cycle Initiation and System Ready

• Arc Suppressing Power Connectors are Specifi cally Designed for Hazardous Environments

• A Ground Fault Interrupter (GFI) to Maximize Equipment Safety.

• Independent High Limit Controller Disables Power in the Event of Over-Temperature Conditions.

* System requires special heat blankets for vapor volatile environments. Heat blankets must be ordered separately. Please ask your sales engineer for more information regarding Supervisory Heat Blankets.

HCS9000FL / HCS9200FL

HCS9200FL Specifi cations:Weight - Only 37lbs (16.9kg)

Dimensions - 29in x 19in x 9.5in (73.66cm x 48.26cm x 24.13cm)

NSN: 4920-01-462-4675

HCS9000FL Specifi cations:Weight - Only 25lbs (11kg)Dimensions - 23.5in x 17in x 7.75in (59.69cm x 43.18cm x 19.68cm)NSN: 4920-01-462-4673

Flightline / HazardousDESIGNED SPECIFICALLY FOR HAZARDOUS AND

FLIGHTLINE ENVIRONMENTS!

See page 9 for Full Features and Options




Options:• Software Security Lock with password access• Foreign language menu systems• Software modifi cations for special applications• Customized silicone rubber heat blankets

B / EV / FL SeriesFeatures and Options

• Accessory Kits and tool packages• Type “K” Thermocouples• Special Hot Bonder/cure process training

Standard Features:• Operate by easy to follow menus on High-

Resolution, High-Contrast, Sunlight readable LCD Screen (5.25in x 6.75in) (13.33cm x 17.14cm)

• Easy change of any cure parameter while program is running

• In progress graphic and numeric displays are easy to interpret

• Store 30 programs, enter or revise from key pad• Temperature control by TC 1 or 2, hottest/

coolest (automatically locates) or average of all thermocouples, mode selected by operator

• 10 thermocouple inputs per zone per aerospace manufacturers recommendations

• Temperature adjustments made in increments of 1°F or C.

• Exceptional integration of alarm and control systems:

1. Scans all thermocouples for alarm and control

2. High/low temperature deviation alarms for both ramp and dwell

3. Select low vacuum alarm level4. Alarm system advises specifi c problem5. Any alarm causes hold condition, not

shut down6. Alarm hold is automatically released when

problem is corrected7. Easy to silence audible alarm 8. Adjustable loudness

• Precise PID control, plus Auto-Tune for unusual situations

• Automatic management of thermocouple break or malfunction

• Intelligent, automatic restart function after power loss

• Dot matrix printer offers the following:1. Standard paper tape and ribbon2. Time, date, and full program/cure

description

3. Record of Tag Number, P/N, Employee ID4. Graph of actual cure showing time and

temperature5. Setpoint, actual temperatures and vacuum

are printed at selected intervals6. Print - Temperature Summary or all

Thermocouples7. Record of alarm conditions and alarm

clear8. Prints any program changes or

adjustments made during cure• Quiet internal vacuum system runs off plant air• Vacuum system capable of up to 28 in/Hg• Monitor vacuum by separate line from repair• External fi lter/trap cleans plant air• Adjustable vacuum level, readable before

starting cure• Shock mounted components• Operates on 90 - 270V, 47 - 63Hz• 30 amps per zone allows bigger blankets and

more heat• Both zones on HCS9200B can be independently

powered/operated• HCS9200B “Slave” function runs two zones or

blankets as one• Temperature display in Celsius or Fahrenheit,

user selectable• Vacuum display in Millibars, in, Hg or Kpa, user

selectable• Easy to upgrade hardware, software, and other

features• Multiple blanket per zone capability• All aluminum, scratch resistant, anodized

faceplate• Ergonomic design, convenient hookup of all

accessories• Removable lid, lightweight, portable and rugged• Circuit breakers are on front panel, no fuses to

replace• Handles on three sides for convenient handling




B / EV / FL SeriesConfi guring Your Hot Bonder Package

STEP 1: Select Composite Repair UnitModel Page

HCS9000B / HCS9200B 3HCS9000B-EV / HCS9200B-EV 4HCS9000FL / HCS9200FL 5

STEP 2: Select OptionsItem Yes/No

Accessory Storage Lid StandardAccessory Storage Case HCS1011-05Type K Thermocouple Operation (p 38)Special Vacuum Fitting OptionsSpecial Software OptionSecurity Password Protection

1000°F (537.77°C) Operation (standard is 500°F (260°C))

STEP 3: Select Voltage for Repair Unit120V240V

STEP 4: Select Input Power CableItem Voltage Page

HCS9000-70-145 (US) 120V 11HCS9000-70-140 (US, Asia) 100V/220V 11HCS9000-70-150 (Europe) 100V/220V 11HCS9000-70-160 (China) 250V

STEP 5: Select Output Power CableItem Voltage Page

HCS9000-71-145 125V/15A 13HCS9000-72-180 250V/15A 13HCS9000-71-220 125V/30A 11HCS9000-72-220 250V/30A 11Other (specify)

STEP 6: Thermocouple TypeItem Page

Standard (Type J Disposable) 37Type J 37Type K (must select Type K Operation in Step 2) 37

STEP 7: Select Heat BlanketsItem Voltage Page

Standard 120V 220V/240V 49-51Flightline (for use ONLY with fl ightline bonders) 120V 220V/240V 54

Stretchable 120V 220V/240V 58-59

To properly confi gure your hot bonder, please follow the steps outlined here. This will help ensure you get the right product and meet your specifi c requirements. Consult the manufacturer’s SRM for specifi c details and application procedures.




HCS9200NMilitary Dual Zone Hot Bonder

The Hot Bonder Designed for and Preferred

by the Navy!

Applications:The HCS9200N Series, Composite Repair Set; Temperature/Vacuum Controller (Hot Bonder/Controller) is a computer monitored and controlled, electrical heating, dual zone composite repair system with multiple sensor inputs and various graphical status display screens with complete process documentation printout.

The unit provides fi nite control of the temperature, vacuum and time necessary to cure critically sensitive composite resins and adhesives. The controller is compact and portable for use in a shop or fl ight line environment.

Specifi cations:Weight - Only 37lbs (16.78kg) (Accessory Set - 70lbs (31.75kg))Dimensions - 29in x 18in x 8in (73.66cm x 45.72cm x 20.32cm)(Accessory Set - 25in x 19in x 9.5in (63.5cm x 48.26cm x 24.13cm))Full Sunlight Readable EL Display (5in x 4.75in) (12.7cm x 12.06cm)

Power - 90 – 264VAC (47 – 63Hz ), Auto SwitchingOperating Enviromental Limitations: Temperature: 14ºF - 130°F (-10°C - 54.4°C)

Relative Humidity (non-condensing): 0 – 95 ±5%Cure Temp. Range - Ambient to 500°F (260°C) (Heat Blankets Limited to 450ºF (232.22°C))Audible Alarm; 90dB, Adjustable Volume30 Separate, Operator Entered ProgramsAccessory Set Cables Rated at 20 Amps

TESTED AND CERTIFIED TO MIL-STD-461E EMI AND

MIL-STD810E ENVIRONMENTAL

(NSN: 4920-01-528-7446)

Accessories Included:• Heat Blankets • Power Cords• Thermocouples• Vacuum Hose/Gauge

• Air Filter• Data Download Cable




HCS9200M-04Military Dual Zone Hot Bonder

Applications:The primary system application is composite and metal bond repairs, by heating and curing prepregs, resins or adhesives.

Designed specifi cally for the military, the HCS9200M-04 has been certifi ed to MIL-STD-810E. This rugged and explosion proof hot bonder is capable of operating under real world and adverse conditions.

The HCS9200M-04 hot bonder also features an internal electric vacuum pump and two low temperature (heated) pneumatic vacuum pumps, capable of operating in temperatures from 140° F (60°C) to 14° F (-10°C).

• Heat Blankets • Power Cords• Thermocouples• Vacuum Hose

• Air Filter • Extra Printer Ribbon

and Printer Paper

Specifi cations:Weight: 42.5 lbs. (19.28kg)

Dimensions: 23.75in x 18in x 7in (60.33cm x 45.72cm x 17.78cm)

Control Operating Voltage: 90-264VAC/45-65Hz/1 PhasePower System Operating Voltage: 120/240VAC/45-65Hz/1 Phase, 30 Amps per zone maximumInternal Electric Vacuum Pump (12 Volt DC)Internal GFI Protection(2) Low Temperature Operation (Heated) Pneumatic Vacuum PumpsMIL Spec Metal Case

Accessories Included:MIL-STD 810E Certifi ed:• Explosive Atmosphere • High Temperature Operation ( 140°F) (60°C)• Low Temperature Operation ( 14°F ) (-10°C)

TESTED AND CERTIFIED TO MIL-STD810E ENVIRONMENTAL

(NSN: 4920-01-588-4308)




Applications:The HCS8800 series “Micro Bonder” is a compact and portable composite curing controller designed to accomplish localized repairs on composite structures or for use in other composite curing / training applications.

Lightweight, Portable and Easy to Operate...Ideal for Training Environments!

HCS8800“Micro Bonder”

FEATURESLCD Graphic Display

Audible AlarmType J Thermocouples

4 Key Operator InterfaceUSB Data Connection

Integrated Circuit Breaker and Power Switch

Vacuum Monitoring Capability

ONLY4.1 lbs

(1.9 kg)

SPECIFICATIONSOperating Voltage: 120 or 240V, single phaseCurrent (Amps) Maximum Load: 20 AmpsOperating Environmental Limitations:• Temperature: 0 - 130° F (-18° - 54.4° C)• Relative Humidity: 0 - 99%

Cure Temperature Range: 0 - 500° F (-18° - 260° C)

Control Parameters:• Internal Control System Resolution: 0.5° F (0.28° C)

• Display Resolution: 1.0° F (0.55° C)• Program Resolution: 1.0° F (0.55° C)• Temperature Accuracy: +/- 1° F (0.55° C)

Control Methods:• Hottest TC• Coolest TC• TC Average

Vacuum Monitoring Capability: 0 - 30 HgTemperature Feedback: 4 Type J ThermocouplesOperation Interface:

• 4 Push Buttons with Menu Selected/Real Language Screens on a Dark and Sunlight Readable 2.8 in. (71.1mm) Liquid Crystal Display (LCD)

Power Failure/Recovery: • Power Recovery within 2 minutes of power loss

results in continued program operationAlarm Volume: 77 dB (Adjustable)Programs Stored to Memory: 8 Separate programs – either downloaded via USB, or operator-enteredCure Data Download: USB Uploadable to HEATCON®

Composite Systems DCAS SoftwareDimensions and Weight Control Unit:

• 10 in. x 6.5 in. x 2.5 in. (254mm x 165.1mm x 63.5mm)

• 4.1 lbs (1.9kg)




Our calibration program is in accordance with ISO10012-1 and MIL-STD-45662A. All instruments used for calibration are certifi ed and have traceability back to N.I.S.T. We provide calibration services for most makes and models of equipment, not just HEATCON® composite repair systems. Email: [email protected]

Protection & Services

HEATCON® Composite Systems now warrants all of our “Hot Bonders” for 3 full years and 1 full year on all of our HCS manufactured products against parts and workmanship defects from date of delivery, provided such products are properly applied, used, and maintained. Should any product fail under warranty conditions, it will be repaired or replaced at no charge. If you need warranty service for your product contact us for instructions on where to send your product. (See actual written warranty for complete coverage details and conditions.)

Calibration Services

Warranty Services

HCS9000B / EV / FL HCS9200B / EV / FLPart Number Part Number

HCS9000-ESP1 HCS9200-ESP1

Equipment Support ProgramA 3-year optional package that includes

the following:Free annual calibrationFree software upgrades

Note: Term effective from date of shipment on new equipment. Standard software revisions only. No options included.

Leasing Advantages

We can offer leasing, on our equipment,through our leasing company or yours.

Rentals

Short term rentals are also available at weekly or monthly rates.

Leasing / Rentals




Input Power Cables

Output Power Cables

B-Model Equipment Input CablesDescription Image Part Number2 Color Code Wire Support

Input Power Cable -

with plugHCS9000-70-145

U.S. BlackWhiteGreen

Up to 30A @ 125VAC

15A Installed Plug

Input Power Cable -

without plug1HCS9000-70-140

U.S./ASIABlackWhiteGreen

Up to 30A @ 250VAC

Input Power Cable -

without plug1HCS9000-70-150

EUROPEANBrownBlue

Green

Up to 30A @ 250VAC

1User installs plug.2Part of Standard Accessory Package. Based on Customer Requirements.

B-Model Equipment Output CablesDescription Image Part Number Lead Length Blade Type NEMA Volts Amps

Output Power Cable -with Receptacle

HCS9000-71-220

5ft(1.52m) Twist Lock

L5-30 125V 30A

HCS9000-72-220 L6-30 250V 30A

B-Model Equipment Input Cables

B-Model Equipment Output Cables




Output Power Cables

B-Model Equipment Output CablesDescription Image Part Number Lead

Length Blade Type NEMA Volts Amps

Output Power Cable -

with Receptacle

HCS9000-72-22510ft

(3.05m)Twist Lock

L6-30 250V

30A

HCS9000-71-225 L5-30 120V


4-Gang Box

HCS9000-71-175

5ft(1.52m)

Straight

5-15 125V 4-15A

HCS9000-72-175 6-15 250V 4-15A


4-Gang Box

HCS9000-71-155

5ft(1.52m)

Twist Lock

L5-15 125V 4-15A

HCS9000-72-155 L6-15 250V 4-15A

Output PowerCable -Duplex

Receptacle

HCS9000-71-230

5ft (1.52m)

1 @ 30A Twist Lock

2 @ 15A (Straight

Available in any output

confi guration)

L5-30 /5-15 125V 1-30A/

2-15A

HCS9000-72-230 L6-30 /6-15 250V 1-30A/

2-15A

HCS9000-72-24510ft

(3.05m)L6-30 /6-15

250V1-30A/ 2-15A

HCS9000-71-245 120V

B-Model Equipment Output CablesB-Model Equipment Output Cables




Output Power Cables

Documentation

B-Model Equipment Output CablesDescription Image Part Number Lead

LengthBlade Type NEMA Volts Amps

Output Power Cable -Duplex Receptacle

HCS9000-71-170

5ft(1.52m)

Straight

5-15 125V 2-15A

HCS9000-72-170 6-15 250V 2-15A

Output Power Cable -Duplex Receptacle

HCS9000-71-145

5ft(1.52m)

Twist Lock

L5-15 125V 2-15A

HCS9000-72-180 L6-15 250V 2-15A

A and B-Model Paper and InkDescription Image Part Number Details

Printer Paper HCS2045-03Roll of paper used for hard copy text

and graphic printouts of repair information.

Printer Ribbon HCS2045-04

Continuous loop ink ribbon used for hard copy printouts of repair

information. Use with HCS2045-03 printer paper.

B-Model Equipment Output Cables

A and B-Model Paper and Ink




HCS-DCAS

Software Package Includes:• Data Capture Software Flash Drive• Interface Cable with USB Adapter (HCS-DCAS-01 only)

• Installation GuideSystem Requirements:• Windows® 98 or Newer Operating System1

• Serial (DB9) or USB Connector• 120Mb Disk Space for Installation

Note: Bonder software revisions .8A - .8H require Data Export Software to be installed on the Hot Bonder1Windows is a Registered Trademark of Microsoft Corporation. All Rights Reserved.

Available as a FREE Download at HEATCON.COM

Part NumberHCS-DCAS-01 for Bonder Software Revisions .8A - .8H

HCS-DCAS-02 for Hot Bonders with USB Port Installed

HCS-DCAS-03 for Hot Bonders with USB Port Installed

Data Capture and Analysis Software

Applications:The HCS2051 Hot Bonder Calibration Kit is used to perform equipment calibration, traceable to N.I.S.T. standards for FAA and other regulatory body certifi cation.

Proper use of this equipment may eliminate the requirement to send your composite repair system off-site for calibration and certifi cation, saving valuable production down time.

If an in-house calibration facility exists, this kit allows the Cal Lab to be functional with a single purchase. Items provided can be used to calibrate all makes and models of composite repair systems. “Yearly Calibration Recommended.”

Protective Case Included

HCS2051

Specifi cations:Weight - 5.5lbs (2.5kg)

Dimensions - 17.25in x 12.25in x 3.5in (43.82cm x 31.12cm x 8.89cm)

Includes:• Programmable Thermocouple Calibrator• Thermocouple Interconnect Cable• Calibrated Vacuum Gauge• Hose Assembly & Adapter

Bonder Calibration Kit




HCS2052 SeriesThermographic Inspection Kits

Applications:The primary system application is the inspection of composite sandwich structures using thermographic techniques to detect trapped water inside the honeycomb cells.

• 120V or 220V blanket confi gurations• Standard 20ft. Tefl on® Leads• Heat Blanket Plugs installed• External Thermocouples• Durable / Transportable Case

* Program linking or Multi-Step Programming is required for thermographic inspection.If you do not have a HEATCON® composite repair system, please contact us for a variety of options.

Increase Your Hot Bonder Capabilites* (no need for a dedicated controller)

INDUSTRY APPROVED THERMAL IMAGING CAMERASTHERMAL IMAGING CAMERAS

• Portable and Lightweight• High Thermal Sensitivity for Max. Temp. Accuracy• Large Color Touch-Screen LCD

(Sold Separately and Subject to Availability)

APPLICATION COMPLETE KIT**

BLANKETS ONLY 120V

BLANKETS ONLY 220V

A318, A319, A320, A321Elevators (3 Blankets)

HCS2052-01 HCS2000-19 HCS2000-20

A330Elevators (6 Blankets)

HCS2052-02 HCS2000-21 HCS2000-22

A310Elevators (6 Blankets)

HCS2052-03 HCS2000-23 HCS2000-24

Thermal imaging camera is required for thermographic inspection per OEM specifi cations. (Camera Sold Separately and Subject to Availabilty. Contact Us Directly for options)

**Complete Kits include: HCS9000B-AV Controller, Cables, Heat Blankets, and Transport Case (You must specify voltage when ordering)

(HCS2000-19 shown)

Flir® is a Registered Trademark of Flir Systems™




Our patented HCS3100 (Series) Portable Autoclaves are custom built semi-portable pressure vessels. They are designed to provide controlled temperature, vacuum, and pressure during composite and metal bond repair processes. The positive internal pressure applied to the repair enables operators to achieve the higher pressure when required by aircraft manufacturer repair manuals. Heat is applied only where required using specially constructed silicone rubber heat blankets. This method results in reduced operational costs and fewer problems due to temperature induced part damage.

This Unit Features:• Lighted Interior• Removable Part Carrier• Internal Connections for Heat blankets,

Vacuum, and Thermocouples• Built in Electric Vacuum Pump• Adjustable Operating Pressures• Custom Sizes to Suit your Applications• Safety Indicator for Vessel Pressure• Flanged Access Ports for Additional Options

Typical Applications:• Rotor Blades • Ailerons • Rudders• Wing Flaps • Winglets • Elevators

Portable AutoclaveModel Number Diameter Length Cart Required

HCS3100-01-36-10 36in (91.44cm)

10ft (3.05m) HCS3200-36-10

HCS3100-01-36-16 36in (91.44cm)

16ft (4.88m) HCS3200-36-16

HCS3100-01-36-20 36in (91.44cm)

20ft (6.1m) HCS3200-36-20

HCS3100-01-42-10 42in (106.68cm)

10ft (3.05m) HCS3200-42-10

HCS3100-01-42-16 42in (106.68cm)

16ft (4.88m) HCS3200-42-16

HCS3100-01-42-20 42in (106.68cm)

20ft (6.1m) HCS3200-42-20

HCS3100-01-48-10 48in (121.92cm)

10ft (3.05m) HCS3200-48-10

HCS3100-01-48-16 48in (121.92cm)

16ft (4.88m) HCS3200-48-16

HCS3100-01-48-20 48in (121.92m)

20ft (6.1m) HCS3200-48-20

HCS3100Portable Autoclave

Model Shown: HCS3100-01-36-10 US Patent - 7,137,799




HCS3100Portable Autoclave continuedPortable Autoclave

OptimizedInteriorSpace

InternalConnectors

for easeof use

Built-inVacuumSystem

CustomizedControlPanels

SPECIFICATIONSDimensions: • Standard Lengths Available: 3ft - 35ft (.9m -

10.6m) • Inside Diameter: 3ft - 6ft (.9m - 1.82m)• Length and Diameter are Customizable upon

RequestRecommended Power Requirements:• Minimum - 240V, Single Phase - 60 Amps

to 480V, 3 Phase - Amperage Depends on customer confi guration requirements

• Other Voltages, Multiple Zones, and Phase Confi gurations Available

Operating Pressure: • ASME Certifi ed Vessel is designed to operate

from 0 - 100 psi @ 400°F• Certifi ed Pressure Relief Valve built in, per

ASME, for your safety• Higher Operating Pressures are available upon

RequestConstruction:• Vessel: Constructed from certifi ed rolled

plate steel material (SA516-70). ID Label Stamped with Final ASME Hydrostatic Test Documentation and Data Plate

• Closures: Hinged Closure - Various Mechanical Locking Devices

• Fixed (Closed) End - Welded Domed Tank Head• Locking Casters and Floor Jacks for Mobility and

Stablization• Additional Auxiliary Ports for Future ExpansionCalibration: • 1 Year Intervals recommended by HEATCON®

Composite SystemsRe-Certifi cation:• No Annual Certifi cation of the Pressure Vessel

required(Please check local government directives which may supercede this requirement)




Applications:The HCS2040 series Power Booster Boxes are designed to connect directly to the output from your HCS9000/HCS9200 bonder. Three-phase power is supplied to the booster on a separate circuit, and is internally switched to control your large repair. An emergency stop is included for operator safety.

Power Booster BoxesModel Number Maximum Output

LoadInput Voltage

30Amps Output 3 Phase Output 1 Phase

HCS2040-09 19.7kW 380V/3 Phase WYE 2ea @ 380V/20A 6ea @ 220V/15AHCS2040-16 21.5kW 415V/3 Phase WYE 2ea @ 415V/20A 6ea @ 230V/15A

HCS2040

Hot Bonder PowerBooster

Box

HeatBlanket

HeatBlanket

HeatBlanket

Allows theuser to operate

up to 6Large Heat

Blankets, at thesame time!

Power In3 Phase

Power In120/240V

Specifi cations:Weight - Only 40lbs (18.1kg)

Dimensions - 24.5in x 15in x 12in (62.2cm x 38.1cm x 30.4cm)

Supplied with:• Input Power Cable• Bonder Interface Cable

Power Booster Box

Typical Setup:




Under Licensing agreement from Boeing

Applications:The HCS2046-02 Phosphoric Acid Containment System (PACS) includes all equipment necessary for trained operators to perform a phosphoric acid anodizing process. The control methods for this unit are automatic timing and voltage monitoring and manual fl ow adjustment. Operator Interface is 20 character, backlit LCD display, 5 push-button operation, and fl ow control valve for fl ow adjustment. The HCS2046-02 also includes an alarm for both voltage shorts and low fl ow rate with 85dB and adjustable volume.

HCS2046-02

Specifi cations:Weight - Only 15lbs (10kg)


Input Power - 90VAC - 264VAC (45 - 65Hz)

Output Power - 3-10V, 10A maximum Includes:PACS Console, Flow Control Head, Inlet Air Filter, Power Lead Set, and Two each Carbon Filter for Vacuum ExhaustStainless Steel Screens, Fluid Recovery / Supply Bottles, and Connectors must be ordered separately or from the available kits listed below

Phosphoric Acid Containment System (PACS)

HCS2046-02-200 (5 Liter Kit)

HCS2046-02-300 (10 Liter Kit)

Stainless Steel Screens used in Kits:

Mesh Size: 16in x 16in Mesh (40.64cm x 40.64cm), 0.018AWG

Stainless Grade: 304 Sizes - One each:

12in x 12in (30.48cm x 30.48cm)

10in x 10in (25.4cm x 25.4cm)

8in x 8in (20.32cm x 20.32cm)

6in x 6in (15.24cm x 15.24cm)




HCS2046-02

PACS Replacement PartsDescription Image Part Number Details

Fluid fi lter - Inline HCS1016-017 Replacement fi lters for fl uid supply lines

Fluid fi lter - Inline Assembly HCS2046-02-018 Replacement Assembly and fi lter for fl uid supply lines - Acid

Fluid fi lter - Inline Assembly HCS2046-02-019 Replacement Assembly and fi lter for fl uid supply lines - Water

Fluid Stop Filter HCS1015-019 Replacement fl uid stop fi lter

Power Lead Set HCS2046-02-020 Replacement leads for screen attachment

Lid, Venting Closure HCS2046-01-003Replacement Lid, 3.26in (8.3cm),

for 4, 5, 10L Bottles

Lid, Venting Closure HCS2046-01-014 Replacement Lid, 2.08in (5.3cm), for 2L Bottles

Insert, Coupler HCS1016-003

Replacement Coupler, Male, Hose 0.25in (6.35mm),

Miniature 0.125in (3.175mm) Nomi-nal Flow - used on HCS1016-16

Insert, Coupler HCS1016-004

Replacement Coupler, Male, Hose 0.25in (6.35mm),

0.25in (6.35mm) Nominal Flow - used on HCS1016-15

Coupler, Female HCS1016-015Replacement Coupler, Female,

Hose, 0.25in (6.35mm) Barb - Used on HCS1016-04

Coupler, Female HCS1016-016

Replacement Coupler, Female, Hose, 0.25in (6.35mm) Barb, Min-iature 0.125in (3.175mm) - used

on HCS1016-03

Coupler, Insert HCS1016-014Replacement Coupler, 0.25in (6.35mm) NPT Male Threads -

Used on HCS1432 Vacuum Port

PACS Replacement Parts




HCS2046-02PACS Accessory AssortmentPACS Accessory Assortment

Description Image Part Number Details

Service Cart(Console) HCS2046-02-021

Acid Resistant24in x 36in x 32.5in

(60.96cm x 91.44cm x 82.55cm)

Phosphoric AcidSolution - 1 Liter HCS2046-02-002 12%, 1L Package

Phosphoric AcidSolution - 4 Liter HCS2046-02-002-4 12%, 4L Package - Cubitainer

Acid DisposalContainer HCS2046-02-003

Polyethylene Drum55gal Capacity

(208.17L)

Spill ContainmentPallet HCS2046-02-004

51.5in x 51.5in x 10in(130.81cm x 130.81cm x 25.4cm)

62gal Spill Capacity(234.67L)

Sodium BicarbonatePowder HCS2046-02-005 500g

(0.5kg)

Emergency SpillKit HCS2046-02-006 For chemical/acid spill cleanup

Acid StorageCabinet - 2 Door HCS2046-02-007 65in x 43in x 18in

(165.1cm x 109.22cm x 45.72cm)

Polarizing InspectionFilter HCS2046-02-008




PACS Accessory AssortmentDescription Image Part Number Details

Fluorescent InspectionLamp HCS2046-02-009 15W, 120V, 60Hz

25ft (7.62m) CordpHydrion™

INSTA-CHEK 0-13 Jumbo

pH Testing Paper

HCS2046-02-010 Dispenser w/paper0-13pH

Safety Goggles HCS2046-02-011 Chemical Splash resistant, anti-fog design

Safety GlovesNitrile HCS2046-02-012 S, M, L or XL when

ordering 50 Pair/box

Safety Apron HCS2046-02-013 Heavy-Duty Nitrile coated with adjustable neck and waist

Stainless SteelScreens

HCS2046-01-016 6in x 6in(15.2cm x 15.2cm)

HCS2046-01-017 8in x 8in(20.3cm x 20.3cm)

HCS2046-01-018 10in x 10in(25.4cm x 25.4cm)

HCS2046-01-023 12in x 12in(30.5cm x 30.5cm)

HCS2046-01-022 Bulk Screen, 12in x 24in(30.5cm x 61cm)

Vacuum Bottles

HCS2046-01-019 4L, Heavy Duty with Protective Lid1



Acid Supply Bottle HCS2046-01-021 2L, Heavy Duty, Non-Vacuum Grade, with Protective Lid1

1Venting Closure Lid for PACS System Sold SeparatelypHydrion is a registered trademark of Micro Essential Laboratory

HCS2046-02PACS Accessory Assortment continuedPACS Accessory Assortment continuedPACS Accessory Assortment




PACS Welding Accessory AssortmentDescription Image Part Number Details

Safety Glasses, Shaded 5.0, Welding HCS2032-02 Provides fi ltration requirements outlined in

ANSI Z87.1-1989

Spot Welder - 120V HCS2046-01-024A

Rated 1.5KVA @ 50% Duty Cycle

Welds uncoated stock as thick as 0.125in (3.175mm)

Spot Welder - 230V HCS2046-01-024B

Rated 2.5KVA @ 50% Duty Cycle

Welds uncoated stock as thick as 0.19in (4.7625mm)

Rod, Stainless Steel HCS1008-050.09in x 36in

(2.38mm x 914.4mm)(Sold in Quantities of 10 each)

Tongs, Welder Replacement HCS2046-01-024C

15° angle top jaw, straight bottom jaw Copper construction

0.624in x 14in (overall) (15.85mm x 355.6mm)

Tip diameter: 0.25in (6.35mm)

Tips, Replacement, Welder Tongs HCS2046-01-024D Screw-in replacement tip for welder tongs

(2 required)

Miscellaneous Kits

Bottle Kit, Large

Designed for Larger Repair Areas

HCS2046-02-300

Fluid Containment Bottles- 2 ea 10L bottles - 2 ea 4L bottles

Stainless Steel Screens12in x 12in, 10in x 10in, 8in x 8in, 6in x 6in (30.48cm x 30.48cm, 25.4cm x 25.4cm, 20.32cm x

20.32cm, 15.24cm x 15.24cm)(1ea) Connectors

Bottle Kit HCS2046-02-200

Fluid Containment Bottles- 2 ea 5L bottles - 2 ea 2L bottle

Stainless Steel Screens12in x 12in, 10in x 10in, 8in x 8in, 6in x 6in (30.48cm x 30.48cm, 25.4cm x 25.4cm, 20.32cm x

20.32cm, 15.24cm x 15.24cm)(1ea) Connectors

HCS2046-02PACS Welding Accessory Assortment




Standard Construction:• Insulated panels and fl ooring• Aluminized steel surfaces• Electric or gas heating option• Double front opening doors• Double wall construction• Industrial grade hinges with FM approved safety latches• High temperature insulation and gaskets• Painted in medium blue, or your choice of color• Internal vacuum connections• Internal temperature monitoring thermocouple jacksControl panel options:1) Ramping/Profi ling temperature controller with circular chart recorder and high limit control.2) HCS2040-12 oven controller - See below

Standard Capabilities:• Ramp rates to 350°F (177°C) at up to 8°F / minute• Cool down rate controlled to 3°F / minute• Temperature uniformity +/- 10°F • Recirculating airfl ow• Maximum operation temperature of 450°F (232.°C)

HCS2910 SeriesComposite Curing Ovens

HCS2910 Oven shown with HCS2040-12 Oven Controller

HCS2040-12Oven ControllerApplications:The primary application for the HCS2040-12 Oven Controller is to control small to large walk-in ovens used in composite repair. The HCS2040-12 can also be used to control other resistive heat sources for a wide variety of manufacturing and repair applications.

Our HCS2910 series ovens have been designed to meet demanding composite curing requirements. Airfl ow patterns maximize temperature uniformity throughout the oven and provide rapid ramp rates. Digital controls and power switching components ensure accurate temperature control. With every oven, we offer installation

and startup assistance. Consult your sales representative for a quotation.

Specifi cations:Weight - Only 15lbs (6.8kg)

Dimensions - 20.5in x 8.5in x 7.5in (52.07cm x 21.59cm x 19.05cm) Hi-Contrast, Sunlight Readable LCD screenOn-Screen Text-Based Prompts/Help ScreensDynamic Alarm/Control IntegrationSelect by Hottest, Coldest, Average of All or No. 1/No. 2 Thermocouple (10 Thermocouple Inputs)Selectable Metric or English Units90-264VAC (45-65Hz)Hard Copy PrintoutPower Failure Auto RecoveryStores up to 30 cure profi les




HCS2041

Replacement PartsDescription Part Number Details

Hose, Silicone Rubber/Wire HCS2041-01-001 .075in ID x 4ft

(1.9mm x 1219.2mm)

Hose, Silicone Rubber/Wire HCS2041-01-002 2.5in ID x 2.5ft

(6.35cm x 76.2cm)

Clamp, Stainless Steel HCS2041-01-003 Small HoseClamp, Stainless Steel HCS2041-01-004 Large Hose

Tube, Aluminum HCS2041-01-005 Hot Air Diffuser 24in (60.96cm)

Clamp HCS2041-01-006 Diffuser Tube

Tape, Insulation HCS2041-01-007 Fiberglass Diffuser Tube, 10ft (3.05m)

Shroud, Insulated HCS2041-01-130 11in H x 16in D (27.94cm x 40.64cm)

Shroud, Insulated HCS2041-01-131 12in H x 22in D (30.48cm x 55.88cm)

Hot Air Curing System

Applications:This Portable Hot Air Composite Curing System fills an important gap in composite repair techniques by applying heat to diffi cult shapes or hard to reach areas. Primary app l i ca t ions a re compos i te repairs, secondary bonding, and modifications to composite structures. Powered and controlled by a Hot Bonder, it can be effectively used in place of standard silicone rubber heat blankets. More importantly, it provides even heating of contoured surfaces where a heat blanket cannot be used.

A typical procedure involves vacuum bagging the repair area and placing thermocouples in strategic locations. A second bag, and the supplied insulation shroud, is applied to make a tent which fi lls with hot air. To provide consistent temperature, hot air enters the tent through a controllable diffuser and may be recirculated by way of a return hose. The system is easy to set up and operate and includes the hot air generator as well as high temperature hoses, an air diffuser and insulation shrouds. It will heat an approximate surface area of up to 30in x 30in (76.2cm x 76.2cm) at 250°F (121.11°C) with ease. Depending on the application and techniques used, it is capable of heating a larger area at higher temperatures.

Applications are constantly evolving, so call for the latest developments.

Specifi cationsModel Power Input Coverage Area

HCS2041-01 1800W 110 / 220V 19in x 19in(48cm x 48cm)



Standard ALL ModelsSize - 22in x 8in x 6.5in (55.39cm x 20.3cm x 16.5cm)

Weight - 9 lbs (4kg)

Safety - Internal High LimitPlant Air - 80psi / 4CFM




Applications:The primary system application is to accelerate the cure of two part resin systems, paint, primers and other coatings. Advanced control functions make these units truly self supporting. A built in selector switch enables automatic temperature control or manual control from 0 to 100% power. In automatic and manual control mode, an infrared sensor, continuously measures part temperature and adjusts power to maintain accurate temperature.

High-efficiency, electric quartz infrared heat elements emit radiant energy that penetrates into the surface of the heated part. An adjustable head allows heat to be directed where it is needed.

HCS2044

HCS2044-20-TLamp Assembly

Infrared Curing SystemsModel Dimensions Curing

AreaPart

DistanceThermal Sensor

Output Power

Input Power Required

HCS2044-10-T90.5in x 33in x 43in (229.87cm x 83.82cm x

109.22cm)

39in x 31.5in (99.06cm x 80.01cm)

19.5in (50cm) Yes 3kW 220/240V, 60Hz.,

1 Phase, 20A

HCS2044-20-T 90.5in x 36in x 47in (229.87cm x 92cm x 119.38cm)

39in x 63in (99.06cm x 160.02cm)

19.5in (50cm) Yes 6kW 220/240V, 60Hz.,

1 Phase, 27A

Specifi cations:Automatic Operation2 Sizes - 3kW (3 Modules) or 6kW (6 Modules)Welded Steel ConstructionIndustrial Grade ComponentsPowder Coated FinishSpecially Designed and Tested Heat Units - no “Hot-Spots”Instant On/Off, Energy Effi cientEasy to Operate & Control

Infrared Curing Systems

HCS2044-10-TLamp Assembly

Controller




Hot Bonder Controlled

Capabilities:

• Custom designed to meet your specifi c requirements.

• Can be designed to be controlled by hot bonders or with built in controllers.

• High-effi ciency, electric quartz infrared heat elements emit radiant energy that penetrates into the surface of the heated part. An adjustable head allows heat to be directed where it is needed.

Portable Heat Lamp Assembly

HCS2044-30-02-120 (120V)HCS2044-30-02-220 (220/240V)

Standard Stand Size

Height - 68in (172.72cm)

Width - 31in (78.74cm)

Depth - 40in (101.6cm)

Heat Lamps

Specifi cations:Wattages - 1600WHead Dimension - 12in W x 12in H x 2in D (30.48cm W x 30.48cm H x 5.08cm D)

Controlled with Hot Bonder

Specifi cations:Wattages - 3600WHead Dimension - 28in W x 12in H x 2in D (71.12cm W x 30.48cm H x 5.08cm D)

Controlled with Hot Bonder

Portable Heat Lamp Assembly

HCS2044-30-01-120 (120V)HCS2044-30-01-220 (220/240V)




Applications:The primary system application is curing and debulking of large size composite parts. This is a diffi cult process, but HEATCON® Composite Systems has addressed this with our HCS7500 Series of Heated Vacuum Debulking and Curing Tables. By utilizing this equipment, debulking and curing of large panels can be accomplished with less time and expense as compared with other methods. There are four different sizes and multiple options to choose from. Custom manufacturing of tables to customer requirements are also available.

Standard Features:• Welded Aluminum Tube Frame • Locking Caster Wheels• Reusable Vacuum Bag Assembly• Electric Vacuum Pump System• Temperature Range to 500°F (260°C)• HCS9000 Panel Mount Control System• 8 Thermocouple Ports

MAKING EASY WORK OF LARGE PART REPAIRS!

Options:• Voltage - 240V (Model -06), 380V, 480V (3 Phase)• None, Standard, or Insulated Lid• None (plumbing only) or Electric Vacuum Pump• Vacuum Gauge (Inches Mercury and kiloPascals or Millibars)

HCS7500

Specifi cations:HCS7500 -06 -07 -08 -09

Length 60in (152.4cm)

72in (182.9cm)

72in (182.9cm)

120in (304.8cm)

Width 48in (121.9cm)

48in (121.9cm)

60in (152.4cm)

60in (152.4cm)

Height 36in (91.4cm)

36in (91.4cm)

36in (91.4cm)

36in (91.4cm)

Debulking and Curing Table

HCS7500-07 shown




Applications:The HCS2710 Walk-in freezers are a necessity for larger composite repair facilities. Sizes starting at 8ft x 8ft (2.43m x 2.43m) allow for bulk material storage with easy access. Standard and custom sizes are available to suit your storage needs.

Accessories:Many accessories are available to complete your system. Items such as ramps, racking, freezer curtains, and non-skid coating can be purchased with the HCS2710 or separately. Contact a sales representative for more information.

Standard Features:• 26ga embossed galvanized steel, aluminum

coated• Smooth aluminum fl oor• Integral thermometer and lighting• Heavy duty hinges and hardware• Designed for CFC-free (R-404A Refrigerant)• 36in (91.44cm) wide self-closing door with

emergency release• Temperature rating to -10°F (-23°C)• Timed defrost system built in

Options:• External access ramp• Temperature chart recorder • Strip curtains

Model HCS2710-0808 Shown

Refrigeration Units must be matched to the freezer/voltage requirements.

You will need to hire a refrigeration contractor to install the freezer and charge the system with refrigerant (not

included with purchase).

HCS2710

Model1 Length Width Height

HCS2710-0808 8ft (2.43m)

8ft(2.43m)

8ft 7in(2.61m)

HCS2710-0812 8ft(2.43m)

12ft(3.65m)

8ft 7in(2.61m)

HCS2710-1212 12ft (3.65m)

12ft(3.65m)

8ft 7in(2.61m)

HCS2710-1216 12ft (3.65m)

16ft(4.87m)

8ft 7in(2.61m)

HCS2710-1220 12ft (3.65m)

20ft(6.09m)

8ft 7in(2.61m)

1Specify voltage when ordering.

Walk-In Freezers

Sizes from 8ft x 8ft

(2.43m x 2.43m) available for quick shipment!




Moderate-Cold Cabinets

HCS2700Model

Cubic Feet/Liter

TempDimension to nearest inch/centimeter Amps

115V/230V

Approx.ShipWeightlb/kg

Approx.Net

Weightlb/kg

Outside Inside

°C °F H W D H W D

-34-20-1 20.3/566 -34 -30 35/89 72/183 30/76 30/76 56/142 23/58 10/5 350/159 225/102 -34-25-1 24.9/705 -34 -30 35/89 83/211 30/76 30/76 69/175 23/58 10/5 380/173 234/106

1 1 = 115V/60Hz, 2 = 230V/50Hz, Add “-C” to part number if CO2 standby system is requiredNote: Please specify voltage (115V/60Hz or 230V/50Hz) and special options when ordering.

Applications:These large capacity cabinets are specifi cally engineered to meet storage requirements for prepreg composite material and our standard 44in (1.12m) cores. Standard models are confi gured to include a digital temperature recorder, chart recorder and an audible over-temperature alarm system. An optional CO2 standby system is available.

Convenient, Safe and Economical Cold Storage!

Standard Features:• Outer cabinet of welded steel, two-

coat enamel fi nish, zinc coated• Inner compartment; welded steel,

zinc coated, epoxy enamel fi nish• Cabinet sealed to minimized

moisture accumulation• Insulation is environmentally safe,

high density, non-settling fi berglass or urethane foam

• Rigid compartment support• Controls are conveniently mounted

in instrument panel• Refrigerants are CFC-free (non-

ozone depleting)• Color is attractive two-tone gray;

optional colors available• Breaker strips of ABS• Casters (recessed) are heavy duty

swivel type• Counterbalanced lid, easy opening

and safe with magnetic gasket• Handle, chrome plated, solid die

casting, with cylinder key lock• Sub-lids for added content

protection• Compressor is permanently

lubricated and hermetically sealed• Refrigerant is nontoxic,

noncombustible• Temperature recorder• Digital Temperature Controller• Sonalarm Signal System (HCS2700-34-20 Shown)

HCS2700Moderate-Cold Cabinets




Applications:The HCS1335 is a circular chart recorder like no other. Programmable alarm options combined with “ease of setup” provide the fl exibility required for multiple recording applications. The HCS1335 is the fi rst recorder to “self document” setup confi guration and can operate using standard or competitive charts, another fi rst in the industry. Eliminate “multi-vendor” chart inventories while reducing operator confusion. Protect your process with the battery backup option, continuous recording for up to 48 hours in the event of power loss.

Recording:Chart Size: 10in (25.4cm)Recording Accuracy: ±0.5% of span (100 division span)Sensor Break: Full scale pen < 10 secondsChart Speed: Confi gurableInput Filtering: Programmable up to 120 seconds

Miscellaneous Features:Operating Temperature: 32°F to 140°F (0 to 60°C)Storage Temperature: -°F to 149°F (-40 to 65°C)Humidity: 0-90% RH (non-condensing)Vibration: 0.3 to 100Hz @ 0.2gMounting: ± 20 degrees of vertical ± 10 degrees of horizontal Moldings: Fire retardant Noryl w/acrylic windowPanel Rating: Nema 3 std (Nema4 option)Panel Cutout: Industry Standard: 12.7in x 12.7in (32.25cm x 32.25cm)

HCS1335Circular Chart Recorder

Specifi cations:Weight - Only 7lbs Maximum (3.17kg)

Dimensions - 14in x 14in x 3.8in (35.56cm x 35.56cm x 9.65cm)

Line Voltage - 110/220VAC, 50/60HzPower Consumption - 15VA MaximumThermocouple (T/C) - Type J,K,T,R,B,SLinear - 4-20 mA, 0-5VDCCommon Mode Rejection - > 120dB at 60HzCold Junction Accuracy - ±0.2°C @ 25°C ambientAmbient Error - ±0.01% span /°C from 25°C ambientIsolation - PV inputs isolated from all alarm outputs

10in (25.4cm) Chart Paper HCS1335-01Replacement Pen Units HCS1335-02

1Not available on single pen ink model 248 hours of continuous recording

UL Pending, CE, CUL

HCS1335-1110111 (shown)




Standard Features:• Semi-Circle Cartridge Baffl es• Baffl e Tray• Angle Drawer Baffl es• Effi ciency - 92% or better

Recommended Options:• Stack Silencer w/ HEPA Filter (not

shown)• Fiberglass Grating• Hinged side and back walls

HCS2037Downdraft Tables

Model HCS2037-15 shown

Downdraft TablesPart Number1 Table Work Surface

Dimensions Motor Avg. Air Flow (cfm) Avg. Open Face Velocity (fpm) Weight

Single Phase ONLY Models

HCS2037-10 38in x 30in x 34in (96.52cm x 76.2cm x 86.36cm)

38in x 30in (96.52cm x 76.2cm) 1hp 1200cfm@ 2.5in H20 200fpm 145lbs


32in x 48in (81.2cm x 121.92cm) 1.5hp 1500cfm@ 4in H20 190fpm 280lbs

3 Phase ONLY Models

HCS2037-12 42in x 48in x 36in(106.68cm x 121.92cm x 91.44cm)





42in x 96in (106.68cm x 243.84cm) 10hp 5050cfm@ 4in H20 210fpm 750lbs






48in x 96in (121.92cm x 243.84cm) 10hp 5050cfm@ 4in H20 270fpm 800lbs

1All units available in 50Hz confi gurations. Air fl ow is reduced approx. 17%.NOTE: Please specify voltage, frequency, and other options when requesting quote.




Dust CollectorsPart

Number1 Dimensions Weight Motor Avg. Air Flow (cfm)

Inlet Velocity

Single Phase ONLY Models


400lbs(181.43kg)

TEFC 1.5hp 120/220/1/60 1000cfm 3000fpm


350lbs(158.76kg)

1hp TEFC 1725 rpm 120/220/1/60 900cfm 2600fpm


340lbs(154.22kg) 1.5hp 120/220/1/60 1000cfm 5000fpm

3 Phase ONLY Models


400lbs(181.43kg)

7.5hp 208/230/460/5757/3/60

1800cfm (900cfm/arm)

4500fpm per arm

HCS2037-19C(ceiling mounted)

30in x 35in (includes hopper)

(76.2cm x 88.9cm)

500lbs(226.8kg)

7.5hp 208/230/460/5757/3/60

1800cfm (900cfm/arm)

4500fpm per arm


340lbs(154.22kg)

3hp 208/230/460/5757/3/60 1800cfm 5000fpm

per arm1All units available in 50Hz confi gurations. Air fl ow is reduced approx. 17%.Note: Please specify voltage, frequency, and other options when requesting quote.

HCS2037Dust Collection Equipment

Applications:Our series of dust collectors are designed for installation in industrial applications for the removal of smoke, dust, and other airborne contaminants. With removal of particulate as small as 0.5 micron, the unit’s self-supporting arm capture pollutants before they reach the worker’s breathing zone. Additionally, the standard fi lters act as heat recovery devices to drastically reduce heating cost by cleaning and recycling plant air.

Model HCS2037-19 shown

Model HCS2037-19C shown




Capabilities:Simply provide us with your requirements and we will provide the solution.• UL 508 Listed Industrial• Standard or Made-to-Order• Single and Multiple OEM• Complete Systems Integration - through a network of Trained Professionals

Available Options:• Controls: - Single and Multizone - Temperature Limit - Timers, Counters, Panel Meters - Chart Recorders - Programmable Logic - Operator Interface Terminals• Relays: - Contractor - Mercury Displacement - Solid State - Motor Starters and Drives• Enclosure Ratings: - NEMA 12 Dust Resistant (standard) - NEMA 4 Moisture Resistant - NEMA 4X Corrosion Resistant - NEMA 4/7 Moisture/Explosion Resistant - NEMA 7 Explosion Resistant

Front of Control Panel

Inside Control Panel

Control PanelsCustom Capabilities

Applications:For those applications where a portable composite repair system is not the best choice, we can provide custom heat control systems to suit your requirements. • Composite Fabrication• Larger Infrared Heat Lamps• Oven Control• Refrigeration Control




Applications:Our HCS2030 Thermowelder provides a full proof system for ensuring quality welded junctions for both type “J” and “K” thermocouples. Few things are more exasperating than having a composite part ruined by faulty thermocouple readings during its cure. Twisted wire junctions are susceptible to splitting open under pressure, and silver solder type welds often leave unwanted marks on the fi nished product. Our thermowelder provides a low profi le micro-bead welded junction which eliminates thermocouple mark-off and breaks.

HTW-WP Weldpowder 4oz (for use in our Thermowelder)

HCS2030

Specifi cations:Weight - 5lbs (2.3kg)

Dimensions - 10in x 7in x 6in (25.4cm x 17.75cm x 15.24cm)

Input Power - 120V or 240V/50-60Hz

Thermowelder

HCS2034 SeriesBlade Clamps

The HCS2034 series Blade Clamps are custom designed to be used on-location or localized “on-blade” repairs that require a positive pressure application.

By having the ability to repair blades on the aircraft, the need for track and balance is greatly reduced, giving you additional labor and operation cost savings.

The bladder assembly and/or padded base can be reversed for even greater possibilities.

Custom confi gurations are available upon request.Specifi cations:

Weight - 31lbs (2.3kg)Dimensions - 39.375in x 14.75in (100cm x 37.47cm)Operating Pressure: 15psiPressure Bladder Area: 12.5in x 12.5in (31.75cm x 31.75cm)Adjustable Height and Pressure Area Placement




Applications:Our HCS2010-25 “Teflon® Insulated” series thermocouple assemblies are vacuum sealed to prevent air leakage and a cost effective alternative to our HCS2010-01 Kapton® Insulated thermocouples.Our HCS2010-01 thermocouples are designed to provide accurate temperature readings every time. Standard 10ft (3.05m) long assemblies are wrapped in a high temperature Kapton® sheath for kink and vacuum leak resistance. Alternate lengths available upon request. Our thermocouple assemblies also come with a low profi le micro-bead welded junction and plug strain relief. We also supply bulk quantities of thermocouple wire in a wide variety of types (J, K) and gauges; as well as a selection of thermocouple plugs. In this way you can manufacture your own thermocouples to fi t your unique requirements. Please contact us for more information.

HCS2010

Thermocouple Accessory AssortmentDescription Image Part Number Details

Thermocouple Plug -Type “J” HCS1353

The HCS1353 is a type “J”, 2-pole connector plug that provides

dependable connections to the receptacle.

This plug provides a continuous temperature rating to 400°F (200°C).

Thermocouple Clamp HCS1354

The HCS1354 strain relief attaches directly to the HCS1353 plug,

relieving wire tension that can cause thermocouple failure.

Thermocouple Plug -Type “K” HCS1362

The HCS1362 is a type “K”, 2-pole connector plug that provides

dependable connections to the receptacle. This plug provides a continuous temperature rating

to 400°F (200°C).

Mini-Thermocouple Plug HCS1355

This is a type “J”, 2-pole connector plug that provides dependable connections to the receptacle. This plug provides

a continuous temperature rating to 400°F (200°C).

HCS2010-01

Thermocouples

HCS2010-25




Thermocouple

Thermocouple Accessory AssortmentDescription Image Part Number Details

Thermocouple Wire Stripper HCS2036-01-049

One light squeezestrips wire clean up to

0.88in (22.35mm).

Thermocouple Wire -Kapton® HCS1351

This is a type “J”, 24ga thermocouple wire with Kapton® Insulation. It offers precise temperature readings along

with exceptional kink resistance. This wire is rated to 600°F (316°C) and is

available by the foot (30.48cm) or rolls of 500ft (152.4m).

Thermocouple Wire -Fiberglass HCS1352

This is a type “J”, 24ga thermocouple wire with Fiberglass Insulation. It is an excellent choice for higher

temperature applications such as thermoplastics. This wire has a

continuous temperature rating to 900°F (482°C) and is available by the foot (30.48cm) or rolls of 500ft (152.4m).

Thermocouple Wire -Tefl on® HCS1350

This is a type “K”, 24ga thermocouple wire with Tefl on® Insulation. It offers precise temperature readings and

calibrated conductors for high system accuracy. This wire is rated to 400°F

(204°C) and is available by the foot (30.48cm) or rolls of 500ft (152.4m).

5-Port Thermocouple Block HCS1358

The HCS1358 is a type “J”, 5 port thermocouple block receptacle.

This block provides a continuous temperature rating to 400°F (200°C)

and 500°F (260°C) intermittent.

Thermocouple Round Single Port Block HCS1365

The HCS1365 is a type “J”, round single thermocouple block that

provides a continuous temperature rating to 400°F (200°C).

Equipment Accessory Assortment continued




Applications:The HCS2042 Temperature Indicator provides technicians with a way to monitor up to 10 thermocouples. This unit is most benefi cial when the temperature controller or composite repair system being used does not have sufficient thermocouple capabilities. Other uses include monitoring secondary areas that are away from the cure but may be damaged by excess heat, extra large repairs or special Quality Assurance (Q.A.) requirements.

This Temperature Indicator is highly recommended for users of the HCS6500 Econo Bonder. The HCS6500 only has one controlling thermocouple which, due to the nature of heat blankets, is often not enough to monitor certain processes with confidence. The temperature indicator has receptacles for ten type “J” thermocouples which can be monitored one at a time by rotating the dial manually.

HCS2042

Specifi cations:120V (HCS2042-01)240V (HCS2042-02)J Type Thermocouples10 ChannelsDial Selector°F or °CLED Read-OutNo Print Out

Temperature Indicator

Front View

Rear View




Applications:Our lightweight, rugged and portable vacuum generator is designed to provide regulable vacuum pressure for a wide range of applications. The HCS2025 can achieve up to 28 in/Hg or 933.33mb vacuum pressure. It can be used in conjunction with our composite repair systems for large area repairs or as a stand alone unit for wet lay-up repairs.

This unit features a vacuum gauge for precise readings and a brass regulator for exact control. Vacuum can be measured Inches/Hg or Millibars. Positive Air Pressure of 80-100psi is needed to operate this device.

Both single vacuum source or dual confi gurations are available (see part number variations above image). The dual unit can be used to provide vacuum to two separate repairs or to provide vacuum to a double bag lay-up for use with our HCS2046-02 Phosphoric Acid Anodizing Kit.

Single Vacuum ModelsHCS2025-01 Single, in/HgHCS2025-02 Single, mb

Dual Vacuum ModelsHCS2025-03 Dual, in/HgHCS2025-04 Dual, mb

HCS2025


Dimensions - 10.25in x 6in x 5in m (26.04cm x 15.24cm x 12.7cm)

Vacuum Generator




Applications:Portable two-stage Electric Vacuum Pump for small to medium sized composite repairs. Unit has two modes of operation, maximum fl ow and maximum level. Maximum fl ow is 0.75 cubic ft/min (354 cm3/sec) and used for initial bag pull-down and seal. Maximum level is 28+ in/Hg (0.967kgs/cm2) and used for fi nal cure vacuum.

This unit includes universal power input for operation anywhere in the world (47-63Hz, 100-250VAC). The removable accessory case lid holds a vacuum hose assembly. There is also an internal power cord storage area (shown). Vacuum hose included with vacuum pump.

Applications:This Accessory Case with Electrical Vacuum Pump is capable of delivering 28+ in/Hg (0.967kg/cm2) at 1 cubic ft/min (472cm3/sec) per and is equipped with power switch, fuse and built-in vacuum gauge. The lid of the case has a large storage compartment with hinged divider and push button latches. The lower section of the case has additional storage room for hoses and cords. An “F” adapter (HCS2016-06) and interface hose w/sniffer are also included.

HCS2055

Specifi cations:Weight - 29lbs (13kg)

Dimensions - 24in x 15in x 9in v (60.96cm x 38.1cm x 22.86cm)


Dimensions - 13.75in x 12.25in x 7.5in m (34.93cm x 31.12cm x 19.05cm)

HCS2055-02 120V VersionHCS2055-04 220V Version

Electric Vacuum Pumps

HCS2055-06100-250V




Applications:The HCS2018 Vacuum Leak Checker can help prevent one of the most common problems associated with composite fabrication and repair - loss of vacuum pressure during the cure process. This device allows you to check the integrity of your vacuum seal before you cure your composite lay-up.

The vacuum leak checker can be used in conjunction with autoclaves, ovens and composite repair systems (hot bonders). This simple yet effective system can detect the presence of hidden leaks before they ruin a valuable part.

Applications:The HCS2015-05 Vacuum Hose/Sniffer Assembly is designed to eliminate problems such as vacuum leaks and collapsed vacuum lines. It is intended for use with both composite repair systems and curing ovens.

HCS2018

HCS2015-05Specifi cations:Vacuum - 0-30 in/HgUsed with HCS2015-06 Vacuum Sniffer

Specifi cations:10ft (3m) Long AssemblyCollapse-proof, high temperature Tefl on® hoseStainless steel braided protective wrap to prevent crushing and abrasionQuick release fi tting for ease of operation and vacuum integrity250°F (121°C)

High temperature machined aluminum vacuum snifferOther lengths available

Vacuum Leak Checker

Vacuum Hose/Sniffer Assembly




Vacuum

Vacuum Accessory AssormentDescription1 Image Part Number Details Size

Vacuum Hose - Tefl on® with stainless

steel overbraid 250°F (121°C)

HCS1404

This collapse-proof hose with stainless steel over-braid offers excellent abrasion

and puncture protection. Each end includes 0.25in (6.4mm) NPT male

threads. This vacuum hose is offered in various lengths, including custom

lengths.

4ft (1.21m)

HCS1405 5ft (1.52m)

HCS1406 6ft (1.82m)

HCS1403 10 ft (3.04m)

HCS1407 20ft (6.09m)

Vacuum Sniffer HCS1418

Made of machined aluminum with maximum temperature 500°F (260°C).

Simple 1/4 turn installation, and breathable base design. Wrench fl ats for easy change of fi ttings. Very rugged and

easy to seal.

Vacuum SnifferAssembly HCS2015-06 Same as above, with the addition of the

HCS1402 male Quick-Disconnect.

Vacuum “F” Adapter HCS2016-06Allows composite repair system to monitor and record vacuum from

an external source.

Air Filter/TrapAssembly HCS2021-01

Inline fi lter/trap, bulb style. Easy to clean and view contaminates. Installs directly to machine’s plant air connection and has quick disconnect on plant air side.

Can be used on other Composite Repair units. Please consult factory.

Element, Replacement Filter HCS2021-01-001 Replacement Filter Element for

Air Filter/Trap Assembly

Integrated VacuumPump & Sniffer HCS2026-01

Attach to plant air and apply vacuum direct to repair. Use 80 to 100psi, at 2.0 SCFM for 27in - 28in/Hg at sea level.

5-Port Vacuum Manifold

HCS2016-02Primarily designed for schools or

training situations when curing multiple projects simultaneously. Allows vacuum

to multiple bags.4-Port Vacuum Manifold HCS2016-03

1Replacement Accessories for HCS9000/9200 Series Composite Repair Systems.

Vacuum Accessory Assortment




Vacuum

Vacuum Accessory AssortmentDescription1 Image Part Number Details

Quick Disconnect Coupler - Male HCS1428-002 Male version with 0.25in (6.35mm) NPT female threads. Also

used on HCS2015-05 Vacuum Hose/Sniffer Assembly.

Quick Disconnect Coupler -Female

HCS1015-002 Female version with 0.25in (6.35mm) NPT male threads. Mates with HCS1428-002.

Quick Disconnect

HCS1414

Plant air hose fi tting that mates with the composite repair equipment air input connection. For equipment that uses

plant air. 0.25in (6.35mm) NPT female threads.Used on HCS2021-01 fi lter assembly

Quick Disconnect -Female

HCS1401

Vacuum hose fi tting that mates with HEATCON® Composite Systems vacuum sniffers. Allows for rapid, leak-proof

vacuum connections. This parts 0.25in (6.35mm) NPT female threads mate with vacuum hoses or HCS1402 with 0.25in

(6.35mm) NPT male fi ttings.

Quick Disconnect -Male

HCS1402

Vacuum hose fi tting that mates with HEATCON® Composite Systems vacuum sniffers. Allows for rapid, leakproof

vacuum connections. Attaches to HCS1418 vacuum sniffer with 0.25in (6.35mm) NPT male fi ttings or the HCS1401

Vacuum Gauge

HCS2051-01-002(gauge only)

Precision 0-30 in/Hg gauge with 3in (7.6cm) dial. 0.25in (6.35mm) NPT Stainless Steel fi tting provides 0.5% accuracy.

Available with certifi cation documents for calibration purposes. Also used as a replacement gauge for the HCS2051 Calibration Kit. Not available in millibars.

HCS2051-01-005 Vacuum Gauge Assembly -- Shown

Vacuum Gauge with Sniffer HCS2027-01

Inexpensive means of monitoring the vacuum of a composite repair bag. Available with certifi cation documents

as an option.

Also available: HCS2027-04 Vacuum Gauge with HCS1401 quick disconnect, without sniffer.

Vacuum Gauge with

Quick DisconnectHCS2027-03

Precision 0-30 in/Hg and 0-100 Kilopascals (KPS) gauge and HCS1401 Quick Disconnect used to monitor vacuum

of a composite repair bag. Available with certifi cation documents as an option.

Used with HCS2015-06 Vacuum Sniffer.

1Replacement Accessories for HCS9000/9200 Series Composite Repair Systems.

Vacuum Accessory Assortment continued




Features:• Direct reading scale for instantaneous reading of

Good, Fair, Poor and Unacceptable radome moisture levels.• Spring-loaded contact points allow nondestructive testing of

irregular radome surfaces.• Separate electrode gun permits testing in remote areas.• Rechargeable Ni-Cad batteries• Available with 115V or 230V battery charger

Kit Includes:• Metering unit• Electrode gun• Separate charger

HCS2049-01 115VHCS2049-02 230V

HCS2049

Applications:The HCS2049 Radome Moisture Meter indicates moisture levels in aircraft radomes. A patented dielectric radio frequency power loss absorption method is used to determine moisture levels.

Radome Moisture Meter




Specifi cationsModel Number Pan Size Capacity Accuracy Weighing Modes Power Incl. / (Optional)

HCS2038-03-002 5.75x5.25in(14.61cm x 13.34cm) 2000g ±1g g, lb/oz 115 VAC

(3 AA Alkaline Batteries)

HCS2038-03-003 5.5x5.5in(13.97cm x 13.97cm) 620g ±0.01g g, ct, lb/oz

115 VAC(230 VAC, EUROPEAN

STYLE, HCS2038-03-009)

HCS2038-03-005 7.5x7.5in(19.05cm x 19.05cm) 6200g ±0.1g g, ct, lb/oz

115 VAC(230 VAC, EUROPEAN

STYLE, HCS2038-03-009)

HCS2038-03-006 6.5x5.5in(16.51cm x 13.97cm) 6000g ±0.1g kg/g, lb/oz 115 VAC






Model Number Description Voltage Style

HCS2038-03-009 ADAPTER, SCALE 6VDC/230VAC EUROPEAN STYLE, (FOR HCS2038-03-003, 005)

HCS2038-03 SeriesPortable Electronic Scales

Applications: Typically used for weighing fi llers, adhesives, and resins during composite layup applications, the HCS2038-03 Series electronic scales allows for accurate weight measurements up to 6200g.

HCS2038-03-002 HCS2038-03-003 / 005 HCS2038-03-006 / 007 / 008




HCS2038-02

Applications:The HCS2038-02 Ultrasonic Leak Detector is ideal for detecting and locating sources of vacuum leaks through the use of sophisticated electronic circuitry. The Ultrasonic Leak Detector incorporates an internal noise control that eliminates interference from audible noise and detects only high frequency sounds caused by vacuum leaks.

Multiple Uses:• Vacuum Bag Leaks • Leaks in Compressed Air Systems• Diagnosing Solenoid Operations • Detecting Electric Arcing

Specifi cations:Weight with battery - 9oz (255g)

Operating Temp - 32° to 140°F (0° to 50°C)

Power - 9VDC (Battery)Includes - 9V Battery, Rubber Probe Extension, Headphones, Storage Case

Ultrasonic Leak Detector

Applications:The HCS2038-11x Magnehelic® is the industry standard to monitor and measure positive pressure in clean rooms, fan and blower pressures, and fi lter resistance.

Stocked ModelsModel Number Range in W.C. Range Pa or kPaHCS2038-11A 0 - 0.5 0 - 125PaHCS2038-11B 0 - 1.0 0 - 250Pa

HCS2038-11C 0 - 2.0 0 - 500PaNote: Indicate Positive, Negative or Differential Accurate within 2%

Specifi cations:Service - Air and non-combustible, compatible gases.

Housing - Die cast aluminum case and bezel with acrylic cover. Exterior fi nish is coated gray to withstand 168 hour salt spray corrosion test.

Accuracy - ±2% of full scale (±3% on -0, -100PA, -125PA, -10mm and ±4% on -00, -60PA, -6mm ranges), throughout range at 70°F (21.1°C).

Pressure Limits - -20 in/Hg to 15psig† (-0.677 bar to 1.034 bar); MP option; 35psig (2.41 bar), HP option; 80psig (5.52 bar).

Overpressure - Relief plug opens at approximately 25psig (1.72kPa), standard gauges only.

Temperature Limits - 20 to 140°F (-6.67 to 60°C).

Size - 4in (101.6mm) Diameter dial face.

Mounting Orientation - Diaphragm in vertical position. Consult factory for other position orientations.

Process Connections - 1/8in (3.175mm) female NPT duplicate high and low pressure taps - one pair side and one pair back.

Weight - 1lb 2oz (510g), MP & HP 2lb 2oz (963g).

Note: Magnehelic® is a registered trademark of Dwyer Instruments

Magnehelic® Pressure Gauges® Pressure Gauges®

• Detecting Gas Leaks• Locating Worn Bearings




Protective Case Included!

Be sure to check out the Heat Blanket section of

our catalog!

Applications:This “easy-to-use” Heat Blanket Tester will identify possible hidden damage to the blanket with a simple “Pass/Fail” feature. This will help to ensure uniform heating of the application by elimination of cold spots associated with blanket failure.With prompting by on-screen menus the repair technician connects the blanket to the tester, enters the voltage and wattage and views the results. The tester can identify open, shorted and intermittent circuits or power leads.

IT’S AS SIMPLE AS “PASS” OR “FAIL”

HCS2047-01

Specifi cations:Weight - Only 2.5lbs (1.1kg)


Power - 100-240VAC (47-63Hz), 0.1AConstruction - Aircraft Quality Aluminum Enclosure, Sealed Keypad, Backlit LCD DisplayIncludes - Carrying Case, Test Leads

Heat Blanket Tester




Applications:Our silicone rubber heat blankets are specifi cally designed or the repair of composite structures using vacuum bagging techniques. The unique construction of our heat blankets allows you to apply uniform heat exactly where you want it. Our design employs a grid of wound resistance wire vulcanized between two layers of fi berglass reinforced silicone rubber. This design features strength, fl exibility, durability and even heat distribution.

Standard

Specifi cations:Maximum Width - 42in (91.4cm) UnsplicedMaximum Length - 136in (345.44cm) UnsplicedMaximum Temperature - 500°F (232°C)

Watt Density - 5 W/in2 (0.8 W/cm2)

Standard Material - Textured Silicone RubberStandard Leads - Tefl on® insulated 600V/400°F (204°C)

Standard Lead Length - 5ft (1.52m)

Standard Input Power - 120V or 220/240V (others available)Double Buss Bar Construction - to Maximize Strain ReliefExternal Tabs - Increase Heating Area

Featured Options:Heat Mapping - to test for thermal uniformitySupervisory Circuits - for Hazardous EnvironmentsMultiple Zones - for Large RepairsCustom Sizes/Shapes/ContoursPlugs - for Various Applications and Power SourcesCE Conformity - must be specifi ed at time of order.

Heat Blankets

The Solution to Uneven Heat

Distribution is Quality!

STRONGFLEXIBLEDURABLE

UNIFORM HEATINGUNIQUE

CONSTRUCTION




← Length → ←

Width →

To ensure traceability, each heat blanket is identifi ed with: 1) serial number, 2) voltage and 3) watts.

SerialNumber

Volts

In Stock 120V Rectangular Heat Blanket Assortment - plug not included

Available OptionsDescription Part Number Watts Stock Bonder Kit1 Supervisory Heat Mapping

4in x 10in (10.6cm x 25.4cm) HC040100E51 200W √ √ √6in x 6in (15.2cm x 15.2cm) HC060060E51 180W √ √ √ √6in x 8in (15.2cm x 20.3cm) HC060080E51 240W √ √ √

6in x 10in (15.2cm x 25.4cm) HC060100E51 300W √ √ √6in x 12in (15.2cm x 30.5cm) HC060120E51 360W √ √ √6in x 20in (15.2cm x 50.8cm) HC060200E51 600W √ √ √6in x 24in (15.2cm x 61.0cm) HC060240E51 720W √ √ √6in x 36in (15.2cm x 91.4cm) HC060360E51 1080W √ √ √6in x 40in (15.2cm x 101.6cm) HC060400E51 1200W √ √ √6in x 72in (15.2cm x 182.9cm) HC060720E51 2160W √ √ √8in x 8in (20.3cm x 20.3cm) HC080080E51 320W √ √ √9in x 12in (22.8cm x 30.4cm) HC090120E51 540W √ √ √

10in x 10in (25.4cm x 25.4cm) HC100100E51 500W √ √ √ √12in x 12in (30.5cm x 30.5cm) HC120120E51 720W √ √ √ √12in x 18in (30.5cm x 45.7cm) HC120180E51 1080W √ √ √12in x 24in (30.5cm x 61.0cm) HC120240E51 1440W √ √ √15in x 15in (38.1cm x 38.1cm) HC150150E51 1125W √ √ √ √15in x 18in (38.1cm x 45.7cm) HC150180E51 1350W √ √ √18in x 18in (45.7cm x 45.7cm) HC180180E51 1620W √ √ √18in x 24in (45.7cm x 61.0cm) HC180240E51 2160W √ √ √24in x 24in (61.0cm x 61.0cm) HC240240E51 2880W √ √ √

In Stock 120V Round Heat Blanket Assortment - plug not included

6in (15.2cm) HC060060E51R 141W √ √ √8in (20.3cm) HC080080E51R 250W √ √ √10in (25.4cm) HC100100E51R 393W √ √ √12in (30.5cm) HC120120E51R 565W √ √ √15in (38.1cm) HC150150E51R 884W √ √ √18in (45.7cm) HC180180E51R 1272W √ √ √

1Standard Sizes to be included with Hot Bonder Purchase. Please specify requirement - 120V or 220VCE Conformity - must be specifi ed at time of order

Watts




( )V NEW V RATED

Useful Formulas

3 Phase Amperes =

W NEW = W RATED

Total WattsVolts x 1.732

²

Ohm’s Law

Heat Output Due to Voltage Change

In Stock 220/240V Rectangular Heat Blanket Assortment - plug not included

Available Options

Description Part Number Watts Stock Bonder Kit1 Supervisory Heat Mapping

4in x 10in (10.6cm x 25.4cm) HC040100E52 200W √ √ √6in x 6in (15.2cm x 15.2cm) HC060060E52 180W √ √ √ √6in x 8in (15.2cm x 20.3cm) HC060080E52 240W √ √ √6in x 10in (15.2cm x 25.4cm) HC060100E52 300W √ √ √6in x 12in (15.2cm x 30.5cm) HC060120E52 360W √ √ √6in x 20in (15.2cm x 50.8cm) HC060200E52 600W √ √ √6in x 24in (15.2cm x 61.0cm) HC060240E52 720W √ √ √6in x 36in (15.2cm x 91.4cm) HC060360E52 1080W √ √ √6in x 40in (15.2cm x 101.6cm) HC060400E52 1200W √ √ √6in x 72in (15.2cm x 182.9cm) HC060720E52 2160W √ √ √8in x 8in (20.3cm x 20.3cm) HC080080E52 320W √ √ √

9in x 12in (22.8cm x 30.4cm) HC090120E52 540W √ √ √10in x 10in (25.4cm x 25.4cm) HC100100E52 500W √ √ √ √12in x 12in (30.5cm x 30.5cm) HC120120E52 720W √ √ √ √12in x 18in (30.5cm x 45.7cm) HC120180E52 1080W √ √ √12in x 24in (30.5cm x 61.0cm) HC120240E52 1440W √ √ √15in x 15in (38.1cm x 38.1cm) HC150150E52 1125W √ √ √ √15in x 18in (38.1cm x 45.7cm) HC150180E52 1350W √ √ √18in 18in (45.7cm x 45.7cm) HC180180E52 1620W √ √ √18in 24in (45.7cm x 61.0cm) HC180240E52 2160W √ √ √

24in x 24in (61.0cm x 61.0cm) HC240240E52 2880W √ √ √In Stock 220/240V Round Heat Blanket Assortment - plug not included

6in (15.2cm) HC060060E52R 141W √ √ √8in (20.3cm) HC080080E52R 250W √ √ √10in (25.4cm) HC100100E52R 393W √ √ √12in (30.5cm) HC120120E52R 565W √ √ √15in (38.1cm) HC150150E52R 884W √ √ √18in (45.7cm) HC180180E52R 1272W √ √ √

1Standard Sizes to be included with Hot Bonder Purchase. Please specify requirement - 120V or 220V




Applications:Our stretchable silicone rubber heat blankets are specifically designed for the repair of complex 3-dimensional composite shapes or contoured surfaces. The unique construction of our stretchable heat blankets allows you to apply uniform heat exactly where you want it. Our design employs a grid of wound resistance wire vulcanized between durable unsupported sil icone rubber. This design features strength, fl exibility, durability and even-heat distribution.

STRONGFLEXIBLEDURABLE

UNIFORM HEATINGUNIQUE CONSTRUCTION

Specifi cations:Maximum Width - 20in (50.8cm) UnsplicedMaximum Length - 20in (50.8cm) UnsplicedMaximum Temperature - 500°F (232°C) Watt Density - 5 W/in2 (0.8 W/cm2)

Standard Material - Unsupported Silicone RubberStandard Leads - Tefl on® insulated 600V/ 400°F (204°C)

Standard Lead Length - 5ft (1.52m)

Standard Input Power - 120V or 220/240V (others available)External Tabs - Increase Heating Area

Featured Options:Plugs - for Various Applications and Power Sources

StretchableHeat Blankets

Complex Problem

Innovative Solution




Applications:The quality of the repair can, in many cases, be traced back to the quality of the cure. A heat blanket that provides temperature uniformity over the entire surface is the key step in the repair process.

Thermal mapping is becoming the quality standard for many maintenance facilities. The Commercial Aircraft Composite Repair Committee (CACRC) refers to SAE Document ARP 5144 Section 7, which states specifi c recommendations for the handling, maintenance and thermal testing of heat blankets.

Our testing follows the recommendations of SAE Document ARP 5144 and meets many of the manufacturers’ requirements.This additional quality process can be specifi ed for all of your Silicone Rubber Heat Blankets at a nominal charge. Please contact us for your quote.

Standard Stretchable Stock Sizes 120Vplug not included Available Options

Description Part Number Watts Stock Heat Mapping6in x 6in

(15.2cm x 15.2cm) HC060060E51E 180W √ √

8in x 8in (20.3cm x 20.3cm) HC080080E51E 320W √ √






Standard Stretchable Stock Sizes 220/240V plug not included Available Options

Description Part Number Watts Stock Heat Mapping6in x 6in

(15.2cm x 15.2cm) HC060060E52E 180W √ √







StretchableHeat Blankets

Heat Blanket Services

Thermal Uniformity




Applications:Supervisory Heat Blankets are used when performing a composite repair in a hazardous or fl ightline environment. These blankets have a very unique construction and includes four layers of protection. Three layers combine to effectively reduce hazardous situations in a vapor volatile environment.

The Supervisory Heat Blankets are designed to be used with our HCS9000/9200FL (Flightline) Series Composite Repair Systems. If the blanket sensor detects a high cure temperature the controller will disable power output to the blanket. The circuit will then reset itself when the temperature falls below the critical level. An indicator and alarm on the HEATCON® Flightline Repair System will alert the operator to the condition.

Tab Cover

Typical Strain Relief Confi guration

Black Wire

White Wire

Green Wire

White Wire

Supervisory Circuit

Uncured/Fiber/Uncured .020 Thick Silicone Rubber

Standard Textured Silicone Rubber

Heater Circuit

Uncured/Fiber/Uncured .029in Thick Silicone Rubber

Ground Grid

Standard Textured Silicone Rubber

Black Wire

White Wire

Green Wire

White WireTypical Strain

Relief Confi gurationBlack Wire

Standard - 120V - plug not includedHC080080M51R-X 8in (15.2cm) Diameter

HC100100M51R-X 10in (25.4cm) Diameter

HC120120M51X 12in x 12in (30.5cm x 30.5cm)

HC080180M51X 8in x 18in (15.2cm x 45.7cm)

HC060060M51X 6in x 6in (15.2cm x 15.2cm)

HC100100M51X 10in x 10in (25.4cm x 25.4cm)

HC150150M51X 15in x 15in (38.1cm x 38.1cm)

Standard - 240V - plug not included HC080080M52RX 8in (15.2cm) Diameter

HC100100M52RX 10in (25.4cm) Diameter

HC120120M52X 12in x 12in (30.5cm x 30.5cm)

HC080180M52X 8in x 18in (15.2cm x 45.7cm)

HC060060M52X 6in x 6in (15.2cm x 15.2cm)

HC100100M52X 10in x 10in (25.4cm x 25.4cm)

HC150150M52X 15in x 15in (38.1cm x 38.1cm)

SupervisoryCustom Heat Blankets

Black Wire




Standard - 220 Volt - Two Zone Radome Stock

Aircraft Model Part Number Height (inches)

Watt Density

Wattage Zone 1

WattageZone 2

B707/727/737 HC737130G42Z2 13in (33.02cm) 4 1936W 2720W

B747 HC747130G42Z2 13in (33.02cm) 4 2500W 5493W

B757 HC757130G42Z2 13in (33.02cm) 4 1936W 2596W

B767/777 HC777130G42Z2 13in (33.02cm) 4 2500W 5493W

A300/310/330/340 HCA30130G42Z2 13in (33.02cm) 4 1936W 3568W

A318/319/320/321 HCA32130G42Z2 13in (33.02cm) 4 1936W 5492W

DC9/MD80/MD90 HCM80100G42Z2 10in (25.4cm) 4 1936W 2944W

RJ200 HCRJ2220GX2Z2H 22in (55.88cm) 5 / 4 2446W 2545W

Note: plug not included

Capabilities:• Standard Confi guration for Boeing,

Airbus, McDonnell-Douglas• Custom Radome heat blankets available for any aircraft• Repair side is made of one piece silicone, to eliminate

mark-off from seams, giving you an exact fi t• Storage fi xture available• Single Zone• Multiple Zones• Uniform Heat

2 ZONE CONFIGURATION

HEIGHT

RadomeHeat Blankets

2 ZONE CONFIGURATION2 ZONE CONFIGURATION




Seal Replacement

Capabilities:• Standard Confi gurations for • RB211 • V2500 • CFM56• Custom Package Available Upon

Request• Single or Multiple Zone Heat

Blankets• Bagging Materials

You Know the Problem!

We Know the Solution!

Abradable/Fan Track

Applications:HEATCON® Composite Systems has the knowledge and expertise to help with all your Abradable/Fan Track seal replacement problems. With our “State-of-the-Art” hot bonders and custom designed fan track heat blankets, your seal replacement is done right the fi rst time, every time. HEATCON® Composite Systems has a proven track record on the following engine series: RB211, V2500, CFM56.

LET US DESIGN A CUSTOM PACKAGE FOR YOU!




Capabilities:The need for custom shaped, fl exible heat blankets in composite repair has increased dramatically in recent years with all of the emerging applications being performed. HEATCON® Composite Systems has both the experience and dedication to meet all of your custom heat blanket requirements from design to delivery.

Our Design Capabilities Include:• Flat Geometrics/Die-Cuts • 3D - An excellent example for a 3-D heat blanket application is a radome repair. The nose cone, or radome, of an airplane is a highly sensitive and odd shape which requires a heat blanket designed for very specifi c form.Radome Capabilities: • Confi gurations for Boeing, AirBus, M-D • Other confi gurations available • Single Zone • Mutliple Zones • Storage Fixture Available

Contours:Some application examples for contoured heat blankets include: leading edge, trailing edge, propeller, rotor, fl ap, fan-track and fan-cowl repairs.

Simply supply us with the details listed below, and we’ll begin design the blankets to suit your specifi c needs. • Width • Length • Lead Length • Input Voltage • Watt Density • Dimensional Drawings

Contoured:Leading Edge & Angled (V-Shaped) Blankets

Flat Geometrics/Die-Cuts:

Various Shapes & Cut Out Blankets

3-D: Radome Heat Blanket

Custom FormedHeat Blankets




Supply us with your partor with a tooling “splash”

Custom tool to fabricateHeat Blanket

Your PartHEATCON® Composite Systems can manufacture custom Heat Blankets to fi t your specifi c needs. From your part we produce a fi nished Heat Blanket using our unique fabrication processes.

A high temperature tool is produced. This is used during the Heat Blanket manufacturing and curing process.

The fi nished Heat Blanket is an exact fi t to your supplied part or tooling “splash”.

Custom FormedOur Process

Custom Tooling

Finished Heat Blanket




A Quality Difference:Non-uniform heating by a heat blanket is generally caused by one of two factors, poor quality construction or improper handling. HEATCON® Composite Systems has the solution to both situations. The most effective means to evenly distribute heat is by placing the heater wires closer together. Poorly designed heat blankets have circuit spacing of often 0.5in (12.7mm) or more, whereas our blankets have a circuit spacing of 0.15in (3.81mm) average. We have also addressed the improper handling factor by incorporating a strain relief in the power lead entry tab, using special eyelet crimping techniques and utilizing double buss bars which minimize open circuits at the buss bar connection. Computer-generated circuitry optimizes circuit design to create even heat distribution. Our standard leads are Tefl on® insulated for easy removal, from the tacky tape, after a repair.

Competitor “A” Heat Blanket

HEATCON® Composite Systems’ Heat Blanket

Textured or Smooth Silicone

Rubber

Double Buss Bars:to increase strength at

circuit connection

Tefl on® Insulted Leads:for easier removal from the tacky tape

External Lead Entry Tabs:to maximize heating area

Strain Relief:to minimize

wire breakage

Circuit Spacing:at 0.25in (6.35mm) or less for more even

heat distribution

QualityHeat Blanket Construction

HEATCON® Composite Systems’Standard Quality Features

Heat Blanket Circuit Spacing & Quality Comparisons




Heat Blanket AccessoriesDescription Image Part

Number Application Volts Amps NEMA Max.Wattage

Straight Blade Plugs

HCS1201 For standard use 125V 15A L5-15 1800W

HCS1202

For standard use with higher voltage

250V 15A L6-15 3600W

Straight Blade

Receptacles -Female

HCS1213Used to ExtendCables

125V 15A L5-15 1800W

HCS1219Used to ExtendCables

250V 15A L6-15R 3600W

Twist Lock Plugs

HCS1204

Used primarily in school

applications to prevent burnout of blankets

125V 15A L5-15P 1800W

HCS1205Used with

Large Heat Blankets

125V 30A L5-30P 3600W

Note: Other Plugs and Receptacles also available.

Plugs and ReceptaclesHeat Blanket




Heat Blanket AccessoriesDescription Image Part

Number Application Volts Amps NEMA Max.Wattage

Twist Lock Plugs

HCS1207 250V 15A L6-15P 3600W

HCS1209 Used when High Amps Are Required 250V 30A L6-30P 7200W

Twist Lock Receptacles

-Female

HCS1208 Used to Extend Cables 250V 30A L6-30R

5-Pin Connector -

A-Model Repair Part

HCS1212

Connects directly to composite Repair

Units or used as a HCS9000

/9200A-Model output cable repair part.

120/ 240V 30A

3-Pin Connector -

B-Model Repair Part

HCS1223 CA3108-E2019PB

Connects directly to composite Repair Units or used as a

HCS9000B /9200B-Model output

cable repair part.

120/ 240V 30A

3-Pin Connector

Supervisory Plug

HCS1211

Connects directly to composite Repair Units (supervisory

blankets only)

120/240V

30A

2-Pin Connector

Supervisory HCS1009-060

Connects directly to composite Repair Units (supervisory

blankets only)

120/ 240V 13A

Cable Clamp HCS1009-061

Note: Other Plugs and Receptacles also available.

Heat BlanketPlugs and Receptacles continued




A.O.G.

Small Quantities

Packaging

Airbus Standard Parts

Capabilities:Prepreg repair materials typically have a six to twelve month shelf life. For many facilities, a full roll of materials would not be used in this time frame and the excess would have to be thrown away. Buying from the manufacturer can take months of waiting for delivery with large minimum order requirements. For these reasons, we provide material in large (full roll) or small (by the yard) quantities. All our materials are inspected and arrive overnight express packed in dry ice with the appropriate quality control paperwork, such as Certifi cate of Conformance, Material Safety Data Sheets and IATA forms.

Capabilities:As an added service to our customers, we offer A.O.G. (aircraft on ground) priority service for composite repair materials. Contact us if you have a grounded aircraft, or a work stoppage due to material requirements. We can have a shipment of the material you require (in the quantity you need) on the way to your facility the same day we receive your purchase order. A.O.G. orders must be received by 11:00am (PST) in order to allow suffi cient processing time for same day shipment. International A.O.G. priority shipments are subject to space availability on the next fl ight out. The use of a Customs Broker is recommended to avoid unnecessary delays. An additional A.O.G. fee may also apply.

Capabilities:In addition, our international frozen materials are packaged in dry ice in a special double walled, high density, sprayed-foam insulated container. Our domestic and international packaging ensures that your material shipment will remain at manufacturer recommended temperatures, avoiding heat and mishandling damage. This service can and will save you time and money, with little or no wasted material.

Capabilities:If you work with Airbus Silicone Adhesive Foam Tapes, Extruded Seals, Wire, Cables, Cable Wraps, Filters and other miscellaneous Airbus materials, please see page 73 or contact your HEATCON® representative today.




HEATCON® Composite Systems offers material recertifi cation testing for Boeing Material Specifi cation (BMS) materials.

This testing will often allow material to be recertifi ed for a time equal to the original shelf life. Test reports are issued directly by Boeing, giving you the assurance that your material has been properly handled. Please contact us with your requirements.

HEATCON® Composite Systems now offers precision cutting and kitting services.

Using a state of the art cutting table, we can cut virtually any shape and size. All we need is your material specifi cation, and a CAD fi le with your patterns. In addition to getting a highly accurate cut, reducing labor in the cutting process, we can minimize your material waste by nesting patterns together. Send us your requirements, and we can help you start saving time and money today!

As seen in HIGH-PERFORMANCE Composites magazine May 2004 -precision cutting can save you time, and reduce material scrap rates.

Material ServicesMaterial Recertifi cation

Material Cutting and Kitting




Applications:Everything needed for temporary and permanent repair of composite structures assembled in one convenient kit. Estimated coverage is nine repairs of 10in (25.4cm) in diameter. Other materials available upon request.Note: Resin not included. Please call for pricing and delivery.

Pre-assembled KitsHCS2510-09/14

1. Nylon Bagging Film(HCS2101)

Vacuum Gauge(HCS2027)

Vacuum Hose/Sniffer Assembly(HCS2015-05)

3. Release Film Non-Perforated(HCS2108-NP)

ORTefl on Coated Fiberglass/Non-

Porous(HCS2103-NP)

Caul Plate (optional)

8. Fiberglass Bleeder Cloth(HCS2410-010)

9. Repair Plies

Thermocouples6. Sealant Tape

(HCS2125)

2. Breather/Bleeder(HCS2102)

Silicone Rubber Heat Blanket(Contact Sales for P/N)

5. Flash Tape(HCS2114)

OR Polyester Discs

(HCS2115)

4. Release Film, Perforated(HCS2108-P)

ORTefl on Coated Fiberglass/Porous

(HCS2103-P)

7. Peel Ply(HCS2112)

Core Splice Adhesive(HCS2405)




Bagging Kit - HCS2510-09Item Number Part Number Description Size Qty

1 HCS2101 Bagging Film, Nylon 60in x .002in(152.4cm x .05mm)

3yds(27m)

2 HCS2102-10 Breather/Bleeder (10oz) 60in x 36in(152.4cm x 91.44cm)

1yd(0.9m)

3 HCS2108-NP Release Film, Non-Perforated 48in x .001in (121.9cm x .025mm)

1yd(0.9m)

4 HCS2108-P Release Film, Perforated 48in x .001in x .045in(121.9cm x .025mm x 0.114cm)

1yd(0.9m)

5 HCS2114 Flash Tape 1in x 72yds x .0025in(2.54cm x 6583.68cm x .228cm) 1 Roll

6 HCS2125 Sealant Tape, Tacky Tape 0.125in x .5in x 25ft(11.43cm x 1.3cm x 762cm) 2 Rolls

7 HCS2112 Peel Ply, Nylon 46in x .005in (116.84cm x .12mm)

1yd(0.9m)

8 HCS2410-010 Fiberglass Bleeder Cloth 38in x .0045in(96.5cm x .11mm)

1yd(0.9m)

Bagging Kit Dimensions: 29in x 10in x 9.5in (73.7 cm x 25.4 cm x 24.1 cm)

Shipping Weight: 7lbs (3.2k)

Repair Plies and Bagging KitItem Letter Part Number1 Material Description Size Qty

a HCS2510-10 BMS9-3 Dry Fiberglass Cloth(Style 7781, MIL-C-9084)

38in x .0089in(96.52cm x .22mm)

1yd(0.9m)

b HCS2510-11 BMS9-8 Dry Graphite Cloth(Style 3K-70-PW TY1, CL2)

42in x .007in(106.68cm x .17mm)

1yd(0.9m)

c HCS2510-12 BMS9-8 Dry Graphite Cloth(Style 3K-135-8H TY1, CL2)

42in x .0135in(1.06cm x .34mm)

1yd(0.9m)

d HCS2510-13 Kevlar™49 Dry Kevlar™ Cloth(STYLE 120)

38in x .0040in(96.52cm x .1mm)

1yd(0.9m)

e HCS2510-14 Kevlar™49 Dry Kevlar™ Cloth(STYLE 285)

38in x .010in(96.52cm x .25mm)

1yd(0.9m)

1Repair Plies listed above include Bagging Kit (Items 1, 2, 3, 4, 5, 6, 7, 8)

HCS2510-09/14Pre-Assembled Kits




Applications:Used on wet lay-up and repair. These are two part epoxy paste adhesive/resin systems for potting, bonding, fairing and repair.

SAVE TIME AND MONEY!

• Practical• No Waste• Mix Only What is Required• No Weighing

Resin Kits - Minimum Order Quantity: 18ea ± 10%Part Number Specifi cation Number

(Manufacturer Part Number)Cure Temp Cure Time Storage Temp Mix

Ratio Size

HCS2407-091 BMS8-3011

(EY 3804)150°F(66°C) 3 Hours Below 40°F

(4°C) 100:66 50g

HCS2407-101 BMS8-3011

(EA 93902)200°F(93°C) 3 - 4 Hour 40°F

(4°C) 100:56 50g

HCS2407-131 EA 934NA

200°F(93°C) 1 Hour

40°F(4°C) 100:33 50g

77°F(25°C) 5 - 7 Days

HCS2407-141 EA 9394

150°F(66°C) 1 Hour

77°F(25°C) 100:17 50g

77°F(25°C) 5 - 7 Days

HCS2407-151 EA 956

200°F(93°C) 1 Hour

40°F(4°C) 100:58 50g

77°F(25°C) 5 - 7 Days

HCS2407-161 EA 9309.3NA

180°F (82°C) 1 Hour

35°F(1°C) 100:22 50g

77°F(25°C) 5 - 7 Days

Please contact us for current price and lead time.EPOCAST® is a registered trademark of Vantico A&T US Inc.

1Also available in Quarts2Stock Item

Resin KitsResin Kits

Typical Coverage

50g40/60 Resin to Fiber Ratio

24in x 24in (60.96cm x 60.96cm)

for style 7781 Fiberglass Cloth6 - 8 repair plies 8in (20.32cm) diameter




Application:The HCS-C60 Tack Rag is used to remove dust from surfaces before coating or painting application. High quality cheesecloth is oil and wax free to resist surface contamination. The Tack Rag meets or exceeds many aerospace specifi cations.

Sized at 30in x 36in (7.62cm x 9.14cm) the HCS-C60 is folded and packaged individually in sealed plastic bags. Available quantities are 50,100, and 400 pieces.

Carton AvailabilityPart Number Carton QuantityHCS-C60-50 50HCS-C60-100 100HCS-C60-400 400

HCS-C60Tack Rags




Fiberglass

Part NumberSpecifi cation (Manufacturer Part

Number)Class

Grade/Style/Form

Nominal Cured

ThicknessRoll Size1 Storage

Life2

Handling/Mechanical

Life2

Cure Temp

CureTime

HCS2401-01XBMS8-79

(F155-5)(MXB7701/120)

Class III

Style 120

.0045in(0.1143mm)

38in x 100yds (96.52cm x 91.44m)

270 DaysBelow 10°F

(-12.2°C) (DOM)

Handling/Mechanical:200 Hours

min @ 75°F ± 5°F

250°F(121°C)

Consult SRM for

Requirements

HCS2401-02XBMS8-79

(F155-5)(MXB7701/1581)

Class III

Style 1581

.0095in(0.2413mm)

38in x 65yds (96.52cm x 59.44m)

270 DaysBelow 10°F

(-12.2°C) (DOM)


min @ 75°F ± 5°F

250°F(121°C)

Consult SRM for

Requirements

HCS2401-03XBMS8-79

(F155-5)(MXB7701/7781)

Class III

Style 7781

.0095in(0.2413mm)

38in x 65yds (96.52cm x 59.44m)

270 DaysBelow 10°F

(-12.2°C) (DOM)


min @ 75°F ± 5°F

250°F(121°C)

Consult SRM for

Requirements

HCS2401-04XBMS8-139

(F161-108)(MXB7668/120)

Class 1

Style 120

.0045in(0.1143mm)

38in x 100yds (96.52cm x 91.44m)

270 DaysBelow 10°F

(-12.2°C) (DOM)

Handling:360 Hours Below 80°F

(26.7°C)Mechanical:720 Hours Below 80°F

(26.7°C)

350°F(177°C)

Consult SRM for

Requirements

HCS2401-05XBMS8-139

(F161-108)(MXB7668/1581)

Class 1

Style 1581

.0095in(0.2413mm)

38in x 60yds(96.52cm x 54.86m)

270 DaysBelow 10°F

(-12.2°C) (DOM)



(26.7°C)

350°F(177°C)

Consult SRM for

Requirements

HCS2401-06XBMS8-139

(F161-108)(MXB7668/7781)

Class 1

and2

Style 7781

.0095in(0.2413mm)

38in x 60yds (96.52cm x 54.86m)

270 DaysBelow 10°F

(-12.2°C) (DOM)



(26.7°C)

350°F(177°C)

Consult SRM for

Requirements

NOTE: All quoted material subject to availabilityPlease call for pricing and delivery. Other specifi cations available upon request.

1Roll Yardages Vary. Five Yard Minimum Order. Confi rmation of approximate yardage supplied at time of order.

2Storage/Handling/Mechanical Recommendations May Vary

PrepregsFiberglass

*Final Part Number is based on Specifi c Customer Request.




Carbon FabricsPart

Number

Specifi cation(Manufacturer Part Number)

Type ClassGrade/Style/Form

Nominal Cured

ThicknessRoll Size1 Storage

Life2

Handling/Mechanical

Life2

Cure Temp

CureTime

HCS2402-01X

BMS8-168(F155-76)

(CYCOM 97714A/PWC T300 3K NT)

Type II&

Type III

Class 2

Style3K-70-

PW

.0086in(0.2184mm)

42in x 75yds(106.68cm x

68.58m)

300 DaysBelow 10°F

(-12.2°C) (DOM)

Handling/Mechanical:200 Hours Below 80°F

(26.7°C)

250°F(121°C)

Consult SRM for

Requirements

HCS2402-02X

BMS8-212(F263-8)

(CYCOM 934/PWC T300 3K NT)

Type IV

Class 2

Style3K-70-

PW

.0083in(0.2108mm)

42in x 75yds (106.68cm x

68.58m)

450 DaysBelow 10°F

(-12.2°C) (DOM)

Handling:240 Hours

(min @ room temp)

Mechanical:720 Hours

(min @ room temp)

350°F(177°C)

Consult SRM for

Requirements

HCS2402-03X

BMS8-212(F263-7)

(CYCOM 934/8HS T300 3K ST)

Type III

Class 2

Style3K-135-

8H

.0141in(0.3581mm)

42in x 75yds(106.68cm x

68.58m)

450 DaysBelow 10°F

(-12.2°C) (DOM)

Handling:240 Hours

(min @ room temp)

Mechanical:720 Hours

(min @ room temp)

350°F(177°C)

Consult SRM for

Requirements

HCS2402-040

BMS8-256(CYCOM 970/PWC

T300 3K UT)

Type IV

Class 2

Style3K-70-

PW

.0085in(0.2159mm)

42in x 80yds(106.68cm x

73.15m)

180 DaysBelow 10°F

(-12.2°C) (DOS)


(26.7°C)

350°F(177°C)

Consult SRM for

Requirements

HCS2402-050

BMS8-297(CYCOM 934/PWC

T300 UT)

Type IV

Class 2

Style3K-70-

PW

.0083in(0.2108mm)

60in x 80yds (152.4cm x

73.15m)

455 DaysBelow 10°F

(-12.2°C) (DOM)


(26.7°C)

350°F(177°C)

Consult SRM for

Requirements

HCS2402-060

BMS8-297-2(CYCOM 924/PX

T300 ST)

TypeIV

Class 2

Style 3K-70-

PX

.0083in(0.2108mm)

60in x 80yds(152.4cm x

73.15m)

455 Days Below 10°F

(-12.2°C)(DOM)


(26.7°C)

350°F(177°C)

Consult SRM for

Requirements

Kevlar™

Part Number*Specifi cation

(Manufacturer Part Number)

Grade/Style/Form

Nominal Cured

ThicknessRoll Size* Storage

Life2

Handling/Mechanical

Life2

Cure Temp

CureTime

HCS2403-01XBMS8-219

(F155-71)(MXM 7714/285 KEV

49)

Style 285 .010in(0.254mm)

38in x 65yds (96.52cm x

59.44m)

270 DaysBelow 10°F

(-12.2°C) (DOM)

Handing/Mechanical:200 Hours Below 80°F

(26.7°C)

250°F(121°C)

Consult SRM for

Requirements

Note: All quoted material subject to availabilityPlease call for pricing and delivery. Other specifi cations available upon request.



PrepregsCarbon Fabrics and Kevlar™

*Final Part Number is based on Specifi c Customer Request.




Film

Part NumberSpecifi cation(Manufacturer Part Number)


Nominal Cured

Thickness/Weight

Roll Size1 Storage Life2

Handling/Mechanical

Life2

Cure Temp

CureTime

HCS2404-010

BMS5-101(AF163-2K)

Type 2

N/A Grade 10

.010in(0.254mm)

36in x 50yds (91.44cm x

45.72m)

12mosBelow

0°F(-17.8°C)

(DOS)


(33.3°C)

250°F(121°C)

Consult SRM for

Requirements.060lb/ft2

(0.293kg/m2)BMS5-129(AF163-2K)

Type4

HCS2404-020 BMS5-101(AF163-2K)

Type 2 N/A Grade

5

.005in(0.1143mm) 36in x 50yds

(91.44cm x 45.72m)

12mosBelow

0°F(-17.8°C)

(DOS)


(33.3°C)

250°F(121°C)

Consult SRM for


(0.146kg/m2)

HCS2404-030BMS5-129(AF-126-2)

(minimum order may apply)

Type 2

Class IIA

Grade 5

.005in(0.1143mm) 36in x 36yds

(91.44cm x 32.92m)

3mosBelow

0°F(-17.8°C)

(DOS)


(32.2°C)

250°F(121°C)

Consult SRM for


(0.146kg/m2)

HCS2404-040 BMS5-129(FM-123-5)

Type 2

Class 2C

Grade 10

.010in(0.254mm) 36in x 55yds

(91.44cm x 50.29m)

6mosBelow

0°F(-17.8°C)

(DOS)


(32.2°C)

250°F(121°C)

Consult SRM for


(0.293kg/m2)

HCS2404-050 BMS5-154(1515-4M)

Type 2

Type3

Class 1&

Class 2

Grade 5

.005in(0.1143mm) 36in x 55yds

(91.44cm x 50.29m)

12mosBelow 10°F

(-12.2°C)


(35°C)

350°F(177°C)

Consult SRM for


(0.244kg/m2)

HCS2404-060 BMS8-145(FM355)

Type 1 N/A N/A

.0125in(0.318mm) 48in x 50yds

(121.92cm x 50.29m)

6mosBelow

0°F(-17.8°C)

(DOS)


(35°C)

350°F(177°C)

Consult SRM for


(0.366kg/m2)

HCS2404-190 BMS5-101(AF163-2OST)

Type 2 N/A Grade

5.030lb/ft2

(5.5mm)

36in x 50yds (91.44cm x

50.29m)

6mosBelow

0°F(-17.8°C)

(DOS)


(35°C)

350°F(177°C)

Consult SRM for

Requirements

Foaming



Nominal Cured

Thickness/Weight

Roll Size*

Storage Life2

Handling/Mechanical

Life2

Cure Temp

CureTime

HCS2405-010 BMS5-90(FM490A)

Type 3

Class 1

Grade 50

.05in(1.143mm) 1in x 25ft

(2.54cm x 7.62m)

12mosBelow 10°F

(-12.2°C)(DOS)


(32.2°C)

250°F/ 350°F(121°C/ 177°C)

Consult SRMfor

Requirements0.395lb/ft2

(6.33kg/m2)

Note: All quoted material subject to availabilityPlease call for pricing and delivery. Other specifi cations available



AdhesivesFilm and Foaming




REFERENCESDAN 1226 Silicone - Elastomeric Foam; Material Standard

DAN 444 Silicon - Elastomeric Foam; Semi-fi nished product and formed parts

TEMPERATURE RANGEOperating Temperature (-55ºC up to 120ºC (-67°F up to 248°F))

Meets Flammability, Smoke Emission, and Toxicity - DAN1226-01 Normative Reference

Contact your local HEATCON®

Composite Systems Representative for all the details.

Silicone Adhesive Foam TapeAirbus Materials

ABS5006 series tapes are manufactured to Airbus standards DAN 1226-01 and DAN 444. The tapes are constructed of a single-sided adhesive and fi re retardant silicone elastomer tape. Available in both 32.81ft (10m) and 49.21ft (15m) rolls.

Silicone Tapes

Part Number Roll Length

Width/Tolerance (in/±1.5)

Thickness/Tolerance (in/±0.76)

Mass

(max. in/ft)

(max. g/m)

ABS5006-2A 49.21ft(15m)

0.35in(9mm)

.08in(2mm) 0.2, 9.8 6, 3

ABS5006-2B 49.21ft(15m)

0.47in(12mm)

.08in(2mm) 0.3, 13.1 8, 4

ABS5006-2C 49.21ft(15m)

0.75in(19mm)

.08in(2mm) 0.5, 9.8 13, 3

ABS5006-2D 49.21ft(15m)

0.98(25mm)

.08in(2mm) 0.6, 16.4 17, 5

ABS5006-2E 49.21ft(15m)

1.18in(30mm)

.08in(2mm) 0.7, 0 21, 0

ABS5006-2F 49.21ft(15m)

1.5in(38mm)

.08in(2mm) 0.9, 0 27, 0

ABS5006-2G 49.21ft(15m)

1.97in(50mm)

.08in(2mm) 1.2, 0 35, 0

ABS5006-4A 32.8ft(10m)

0.35in(9mm)

0.16in(4mm) 0.4, 6.6 11, 2

ABS5006-4B 32.8ft(10m)

0.47in(12mm)

0.16in(4mm) 0.5, 29.5 14, 9

ABS5006-4C 32.8ft(10m)

0.75in(19mm)

0.16in(4mm) 0.8, 19.7 23, 6

ABS5006-4D 32.8ft(10m)

0.98(25mm)

0.16in(4mm) 1.1, 0 31, 0

ABS5006-4E 32.8ft(10m)

1.18in(30mm)

0.16in(4mm) 1.3, 9.8 37, 4

ABS5006-4F 32.8ft(10m)

1.5in(38mm)

0.16in(4mm) 1.6, 3.3 45, 1

ABS5006-4G 32.8ft(10m)

1.97in(50mm)

0.16in(4mm) 2.9, 0 62, 0

ABS5006-6A 32.8ft(10m)

0.35in(9mm)

0.24in (6mm) 0.6, 22.9 16, 7




Aluminum Foil

Part NumberSpecifi cation(Manufacturer Part

Number)Type

Grade/Style/Form

Roll Size1 Storage Life2

Cure Temp

CureTime

HCS2408-010 BMS8-289 Ty 0/250/2/1235/002Ty 0/350/2/1235/002

Grade BForm 1

36in x 60yds(91.44cm x 54.86m)

5yrs at 95°F (35°C) or Below

250°F / 350°F(121°C / 177°C)

Consult SRMfor

Requirements

1Roll Yardages Vary. Five Yard Minimum Order. Confi rmation of approximate yardage supplied at time of order. 2Storage/Handling Mechanical recommendations may vary.

Corrosion Inhibiting Adhesive Primers


Type Grade/Style/Form Unit Size Storage Life2 Cure

TempCureTime

HCS2406-011 BMS5-89(BR127) Type 1

Grade ASprayable/Brushable

1 Gallon Can

(3.785L)

12mos Below 0°F

(-17.8°C)(DOS)

250°F(121°C)

Consult SRMfor Requirements

2Storage/Handling Mechanical recommendations may vary.

AluminumAluminum Foil

PrimersCorrosion Inhibiting

FillersPart Number

(Manufacturer Part Number)Description Unit Size

HCS2201Resin Epoxy Filler/

Fumed Silica1gal

(3.785L)

HCS2202Lightweight Epoxy Filler/

Micro Balloons1gal

(3.785L)

HCS2202-01(BJO-0930) Phenolic Micro Balloons 1gal

(3.785L)

Fillers, Resins, Potting, and Edge




Resins

Part NumberSpecifi cation

(Manufacturer Part Number)

Type Class Unit Size Storage Life2 Cure Temp

CureTime

HCS2407-040BMS8-201

(EPOCAST 50-A1/946)

Type 4 Quart Kit(0.9463L)

12 mosBelow 80°F

(26.7°C)(DOS)

150°F - 100°F(66°C - 93°C)After RT Gel

Consult SRM for Requirements

HCS2407-060BMS8-201

(EPOCAST 50-A1/9816)

Type 3 Quart Kit(0.9463L)

360 daysBelow 80°F

(26.7°C)(DOS)

150°F - 200°F(66°C - 93°C)After RT Gel


HCS2407-090 BMS8-301(EY 3804 A/B) Class 2 Quart Kit

(0.9463L)

A - 6 mosBelow 40°F

(4.44°C)(DOS)

B - 3mosat 40°F - 80°F(4.44°C - 26.7°C)

150°F(66°C)


HCS2407-100 BMS8-301(EA9390) Class 1 Quart Kit

(0.9463L)

12 mosat 40°F(4.44°C)

200°F - 300°F(93°C - 149°C)


Potting Compound and Edge Filling

Part NumberSpecifi cation(ManufacturerPart Number)

Type Class Description Unit Size Storage Life2

HCS2407-010 BMS5-28(CG 1305) Type 7 Class 1

Potting CompoundPourable

Gallon Kit(3.785L)

-(4.44°C - 32.2°C)(DOS)

HCS2407-020 BMS5-28(EC 89537) Type 7 Class 2

Potting CompoundPourable

Gallon Kit(3.785L)

12mos at 40°F - 90°F (4.44°C - 32.2°C)

(DOS)

HCS2407-030BMS5-28

(EPOCAST 1511 A/B)

Type 3 N/A Non Flow Edge Filler Quart Kit(0.9463L)

360 days at 40°F - 90°F (4.44°C - 32.2°C)

(DOS)Note: Minimum Order may apply. 2Storage/Handling/Mechanical recommendations may vary.

Wet Lay-upsFillers, Resins, Potting, and Edge Continued

Fiberglass, Carbon, and Kevlar™Fiberglass, Carbon, and KevlarCarbon Dry Fabric

Part NumberSpecifi cation(Manufacturer Part

Number)Type Class Grade/

Style/Form Thickness Roll Width

HCS2409-010 BMS9-8(584-42) Type I Class

2Grade 3,

Style 3K-135-8H.0135in

(0.3429mm)42in

(106.68cm)

HCS2409-020 BMS9-8(282-42) Type I Class

2Grade 3,

Style 3K-70-PW.007in

(0.1778mm)42in

(106.68cm)




Fiberglass Dry Fabric

Part Number Specifi cation(Manufacturer Part Number)

Type Class Grade/Style/Form

Thickness Laminate 50% VF

Roll Width1

HCS2410-010 BMS9-3(120-38) Type D Class 7 Style 120 3.3mils

(.08mm)38in

(96.52cm)

HCS2410-020 BMS9-3(1581-38) Type H-2 Class 7 Style 1581 9.1mils

(0.23mm)38in

(96.52cm)

HCS2410-030 BMS9-3(7781-38) Type H-3 Class 7 Style 7781 9.1mils

(0.23mm)38in

(96.52cm)

Kevlar™ Dry FabricPart Number Specifi cation

(Manufacturer Part Number)Style/Weave Thickness Dry Nominal Roll Width1

HCS2411-010 Kevlar™49(120-38) Style 350/Plain 3.3mils

(.08mm)38in

(96.52cm)

HCS2411-020 Kevlar™49(181-38) Style 348/8H Satin 9.0mils

(0.23mm)38in

(96.52cm)


(0.24mm)38in

(96.52cm)


(0.24mm)50in

(127cm)

HCS2411-040 Kevlar™49(352-38) Style 352/Plain 10mils

(0.254mm)38in

(96.52cm)1Roll Yardages Vary. Five Yard Minimum Order. Confi rmation of approximate yardage supplied at time of order.Note: All quoted material subject to availability.Please call for pricing and delivery. Other specifi cations available upon request.

Wet Lay-upsFiberglass, Carbon, and Kevlar™Fiberglass, Carbon, and Kevlar

Applications:The HCS2112 Series Nylon Release Peel Ply is a heatset and scoured smooth weave nylon fabric used as a release fabric directly against bond lines or laminates where a fi nish for subsequent bonding or painting is needed. This Release Peel Ply is excellent for controlling adhesive squeeze out and works well on all fi ber/epoxy laminates.

Release Peel PlyPart

Number Thickness Weight Roll Size1 Yarn Type

HCS2112 5mil(.005in)

2oz/yd2

(66.5g/sq.m)46in x 300yds

(121.9cm x 274.3m) Nylon


HCS2112Release Peel Ply




Applications:The HCS2101 Series Nylon Bagging Film is a high-grade nylon fi lm which is heat-stabilized for long term cures. The fi lms are soft, pliable and ideal for high temperature composites, metal bonding and any function requiring heat and/or pressure. Nylon Bagging Film is used as the last material to a part that is being repaired to form the vacuum bag.

Nylon Bagging FilmPart Number Nominal Thickness Roll Size1 Maximum Use Temp.

HCS2101-04-5MIL 5mils(0.127mm)

54in x 254yds(137.2cm x 232.3m)

400°F(204°C)

HCS2101-04-30T 30in TUBE 2mils(.0508mm)

30in Tube x 333yds(76.2cm x 304.5m)

400°F(204°C)

HCS2101-04-60V V-FOLD 2mils(.0508mm)

30in (Open 60in) x 333 yds Wide(76.2cm (1.52m) x 304.5m)

400°F(204°C)

HCS2101-04-30TNH 30in TUBE 1 - 1.5mils(.0254mm - .0381mm)

30in Tube x 333yds(76.2cm x 304.5m)

No Heat(Debulking Application)

Bagging Film PropertiesTensile Strength - 10,000psi -16,000psi Fold Endurance - > 250,000 cycles

Elongation - 375-500% Brittleness Temp - < 75°FGraves Tear Strength - 500-600gms Dimensional Stability (300°F, 10min) - < 2.0%Elmerdorf Tear Strength - 20-50gms Flammability Self Extinguishing


HCS2101Nylon Bagging Film

Applications:The HCS2102 Series Breather/Bleeder Cloth is a needlepunch polyester breather system commonly used as a vacuum transfer medium in the vacuum bagging process. It can be used at pressures up to 85psi (5.8 bars). The HCS2102-04 cloth can be used at pressures up to 200psi (13.8 bars). Multidirectional conformability make it a very efficient breather. This cloth does not contain any binders which could seal off air flow. The breather is required for air evacuation and the bleeder system is required to absorb excess resin. Recommended maximum use temperature: 400°F (204°C).

Breather/Bleeder ClothPart Number Weight Roll Size1

HCS2102-04 4oz(113.4g)

60in x 100yds(152.4cm x 91.4m)

HCS2102-10 10oz(283.4g)

60in x 50yds(152.4cm x 45.7m)


HCS2102Breather/Bleeder Cloth




Release Fabric Tefl on® - Non PorousPart Number Thickness Roll Size1 Maximum Use Temp.

HCS2103-NP 3mils(.007in), (0.8mm)

38in x 100yds (96.52cm x 91.4m)

550°F(288°C)


Applications:The HCS2103-P Release Fabric is a porous release Tefl on® coated fi berglass. The porosity is always the same; the release coating does not vary from roll to roll and will release from all commercial resin systems. Tefl on® Coated Fiberglass/Porous Release Fabric is used as a release ply that allows outgassing of volatiles during processing. It is generally used for high temperature 350°F (177°C) applications.

Applications:The HCS2103-NP Release Fabric is a non-porous release Tefl on® coated fi berglass designed for release and resin restriction. This fabric will release from all commercial resin systems without transfer. Non-Porous Tefl on® Coated Fiberglass is commonly used as a parting fi lm. It is generally used for high temperature 350°F (177°C) applications.

Release Fabric Tefl on® - PorousPart Number Thickness Roll Size1 Maximum Use Temp.

HCS2103-P 2mils(.003in), (0.8mm)

38in x 100yds (96.52cm x 91.4m)

550°F(288°C)


HCS2103-PTefl on® Release Fabric - Porous

HCS2103-NPTefl on® Release Fabric - Non-Porous® Release Fabric - Non-Porous®




Applications:The HCS2108-P Release Film is a perforated, high-quality fi lm made for contoured surfaces. This fi lm is strong and has high elongation. Perforated Release Film is used as a porous release ply that allows volatile outgassing during processing.

Applications:T h e H C S 2 1 0 8 -NP Release Fi lm is a n o n - p e r f o r a t e d , fluoropolymer release fi lm for cures to 500°F (260°C). This fi lm is an economical alternative to high-cost FEP release film. It is ideally used for fl at or single contour lay-ups. Non-Perforated Release Film is used as a parting fi lm.

Release Film - PerforatedPart Number Thickness Roll Size1 Resin

Loss Hole Size Mark Off Color

HCS2108-P (P3) 1mil(.001in)

48in x 200yds(121.9cm x 182.88m)

35%

.015in (0.38mm)

Diameter on .25in (0.63cm) Centers

NoneRed - easier to see than typical

clear60in (162.56cm) maximum width

HCS2108-P4 1mil(.001in)

48in x 200yds(121.9cm x 182.88m) .04%

.045in (1.14mm)

Diameter on 2in (5.08cm) Centers


clear

HCS2108-P5 1mil(.001in)

48in x 200yds(121.9cm x 182.88m) .023%

.045in (1.14mm)

Diameter on 3.5in (8.89cm) Centers


clear


Release Film - Non-PerforatedPart Number Thickness Roll Size1 Color

HCS2108-NP 1mil(.001in)

48in x 200yds(121.92cm x 182.88m)

Red - easier to see than typical

clear1Roll Yardages Vary. Five Yard Minimum Order. Confi rmation of approximate yardage supplied at time of order.

HCS2108-PRelease Film - Perforated

HCS2108-NPRelease Film - Non-Perforated

Release Film PropertiesSpecifi c Gravity - 2.12-2.17 sq ft/lb

Elongation @ Break - 300%

Max Use Temp - 400°F (204.44°C) (Cont)

Melt Point - 485-540°F

Yield (1 mil fi lm) - 90 sq ft/lb

Tensile Modulus - 70000psi

Flammability - Self Extinguishing

Water Absorption - <0.01%

Initial Tear Strength - 1mil 0.5lb - 0.6lb

Tensile Strength @ Break - 3500psi




Applications:The HCS2114 Flash Tape is a polyester-backing f i lm with a rubber adhesive. This tape is very tough and ideal for resin or adhesive fl ash removal.

Applications:The HCS2125 Sealant Tape contains aggressive tack to hold vacuum bag to tools. Releases f rom metal or composite tools, hot cold. Ideal for standard 250°F (121°C) and 400°F (204°C) cures. Will operate at pressures exceeding 200psi (14bars).

Polyester DiscsPart Number Size Quantity per roll Maximum Use Temp.

HCS2115-01 1in(2.54cm) 500 Up to 450°F

(232°C)

HCS2115-02 1.25in(3.17cm) 500 Up to 450°F

(232°C)

Flash TapePart Number Case Thickness Roll Size Maximum Use Temp.

HCS2114 36 Rolls 2.5mils(.06mm)

1in x 72yds(2.54cm x 65.8m)

Up to 400°F(204°C)

HCS2114-02 18 Rolls 2.5mils(.06mm)

2in x 72yds(5.08cm x 65.8m)

Up to 400°F(204°C)

Sealant TapePart Number Case Roll Size Maximum

Use Temp. Color

HCS2125 40 Rolls 0.125in x 0.5in x 25ft(3.18mm x 12.7mm x 7.62m)

400°F(204°C) Black

HCS2125-02 40 Rolls 0.125in x 0.5in x 25ft(3.18mm x 12.7mm x 7.62m)

400°F(204°C)

Light Gray

Applications:The HCS2115 is a h igh temperature polyester disc that is ideal for thermocouple isolation on composite repairs.

HCS2114Flash Tape

HCS2115Polyester Discs

HCS2125Sealant Tape




Applications:Pre-formed core are machined to three-dimensional contour from aluminum or non-metallic honeycomb. It can be supplied with or without recesses or splice bonding.

Tabs

FlapsVanes

Slats

Spoilers

Honeycomb - Pre-Formed Core MaterialStyle Available for

Slats 7 2 77 3 7

7 4 77 6 7

VanesD C 8D C 9

D C 1 0

M D 1 1M D 8 0

Spoilers7 0 77 2 77 3 7

7 4 77 5 77 6 7

D C 8D C 9

D C 1 0

M D 1 1M D 8 0L 1 0 1 1

Tabs7 0 77 2 77 3 7

7 4 77 5 7D C 8

D C 9D C 1 0M D 8 0

Flaps7 0 77 2 77 3 7

7 4 77 5 7D C 8

D C 9D C 1 0M D 8 0

Please call for part numbers, pricing and delivery.Note: Among the many confi gurations available, machining is available for the following: Cargo Barrier Doors, Fan Cas-ings, Rotor Blades, Trust Reversers, Cowl Doors and Blocker Doors

HoneycombPre-Formed Core Materials




Tired of Long Lead Times and Buying in Full Sheets?HEATCON® Composite Systems offers Metallic and Non-Metallic

Honeycomb core by the square foot.

Please call for price and stock availability.• HRH10* - Aramid Fiber/Phenolic Resin• HRH10* - Flex-Core• HRP* - Reinforced Plastic Honeycomb• Certifi ed to the Boeing Material Specifi cations* Other types may also be available

Non-Metallic Honeycomb Core

Aluminum Honeycomb Core

HoneycombAluminum and Non-Metallic




HCS2036-05Composite Repair Tool Kit

Applications:Our selection of Tool Kits were designed by Mechanics for Mechanics. We have included a wide variety of only the most necessary tools used for completing either a composite, a metal bond or a fl oor panel repair effi ciently. Included are a wide variety of tools used to get the job done effectively and effi ciently, and our pre-assembled, convenient cases have a place for each tool so you always know where to fi nd them. Best of all, each kit is lightweight and portable for the mechanic on the go.

Features:Weight - Only 23lbs (10.4kg)

Size - Compact 15in x 20in x 9in (38.1cm x 50.8cm x 22.9cm)

Easy to UseEach item has its place within the case - reducing the possibility of lossIndividual items can be ordered seperately - should replacement be neededThe case is made out of a high impact material - shock absorbent if droppedPortability - Ready for any fi eld repairOptional - Vacuum for easy clean-up




HCS2036-05Drill Motor and Grinder Motor

Drill MotorHCS2036-01-002Grinder Motor

HCS2036-01-022

Drill MotorDrill Motor Accessories and Attachments

Descritption Part Number Image Overall Diameter Angle Qty

Hole Saws - Piloted, Diamond Cut

HCS2036-01-089 1in (2.74cm) 1

HCS2036-01-090 1.5in (3.81cm) 1

HCS2036-01-091 2in (5.08cm) 1

Counter Sink Feed - Cage Assembly HCS2036-01-034 0.25in x 4in

(6.4mm x 10.16cm) 1

Counter Sinks - Piloted, Carbide Tip

HCS2036-01-035 0.125in (3.2mm) 100° 1

HCS2036-01-036 0.16in (4.0mm) 100° 1

HCS2036-01-037 0.19in (4.8mm) 100° 1

HCS2036-01-038 0.25in (6.4mm) 100° 1

Grinder MotorGrinder Motor Accessories and Attachments

Description Part Number Image Overall Diameter Qty

Grinder - Barrel Attachment for Sanding Disks

HCS2036-01-025 5 sizes 1

Sanding Pad Holders

HCS2036-01-028 2in (5.08cm) 1

HCS2036-01-029 1in (2.54cm) 1

Diamond Wheel Arbor HCS2036-01-092 0.25in

(4.8mm) 1

-029-028




Router MotorDescription Part Number Image Overall

LengthFlute Length

Cutter Diameter Qty

Router Bit - 40 Mesh Diamond HCS2036-01-014 0.25in x 3in

(6.4mm x 7.62cm)1in

(2.54cm)0.25in (6.4mm) 1

Collets

HCS2036-01-101 0.1875in x 0.19in

(4.8mm x 4.8mm)

0.110in (2.8mm) 1

HCS2036-01-102 0.128in x 0.16in

(3.3mm x 4.0mm)

0.165in (4.2mm) 1

Router Bit - Split Helix HSC2036-01-043 0.25in x 2.5in

(6.4mm x 6.35cm)1in

(2.54cm)0.25in (6.4mm) 1

Split Helix

-101-102

HCS2036-05Router Motor and Orbital Sander

Random Orbital SanderRandom Orbital Sander Accessories and Attachments

Description Part Number Image Overall Length Grit Qty

SandpaperHCS2036-01-084 5in

(12.7cm) 80 10

HCS2036-01-085 5in (12.7cm) 120 10

Random Orbital Sander

HCS2036-01-070

Router Motor Base - Two-Handed

HCS2036-01-013Router Motor

HCS2036-01-012




HCS2036-05Grinder Motor AccessoriesGrinder Motor Continued

Grinder Motor Accessories and AttachmentsDescription Part Number Image Overall Diameter Grit Qty

Sanding Disk HCS2036-01-030 2in (5.08cm) 80 10

Sanding Disk Bayonets

HCS2036-01-031 1in (2.54cm) 80 10

HCS2036-01-040 1in(2.54cm) 120 10

HCS2036-01-041 2in (5.08cm) 120 10

Sanding Barrels

HCS2036-01-026 1in x 1in(2.54cm x 2.54cm) 80 5

HCS2036-01-075 0.5in x 0.5in (1.27cm x 1.27cm) 120 5

HCS2036-01-076 0.75in x 1in (1.91cm x 2.54cm) 120 5

HCS2036-01-077 1in x 1in (2.54cm x 2.54cm) 120 5

HCS2036-01-078 1.5in x 1.5in (3.81cm x 3.81cm) 120 5

HCS2036-01-079 2in x 1.5in (5.08cm x 3.81cm) 120 5

HCS2036-01-080 0.5in x 0.5in (1.27cm x 1.27cm) 80 5

HCS2036-01-081 0.75in x 1in (1.91cm x 2.54cm) 80 5

HCS2036-01-082 1.5in x 1.5in (3.81cm x 3.81cm) 80 5

HCS2036-01-083 2in x 1.5in (5.08cm x 3.81cm) 80 5

Fiberglass Cut-Off Wheel HCS2036-01-087 3in x 3in

(1.27cm x 1.27cm) 80 3

-080

-075-026

-079

-076

-081

-077

-082

-078

-083




HCS2036-05Additional Tools and Accessories

Additional Tools and Accessory PartsAccessories and Attachments

Description Part Number Image Qty

Cutter - Honeycomb Core HCS2036-01-039 1

Retractable Utility Knife HCS2036-01-051 1

Shears - Soft Touch HCS2036-01-053 1

Vacuum Cleaner - Air Driven HCS2036-01-069 1

Resin Applicator HCS2036-01-086 3

Manifold, Air, 3 Way HCS2036-01-088 1




Applications:The HCS2036-05A Composite Repair Tool Kit is designed as a supplement for our HCS2036-05 Composite Repair Tool Kit. This kit includes a popular selection of drills, drill stops, guides, reamers and countersinks. All are supplied in a durable, lightweight, impact resistant carrying case.

HCS2036-05AComposite Repair Tool Kit

Features:LightweightCompact sizeEasy to useItems can be ordered individuallyPortable and ready for any fi eld repair

Itemized List of ContentsDescription Part Number Overall

DiameterSize

Number Qty

Reamer, Tapered Drill

HCS2036-01-006A .09in (2.5mm) 1

HCS2036-01-006B 0.125in (3.2mm) 1

HCS2036-01-006C 0.16in (4.0mm) 1HCS2036-01-006D 0.19in (4.2mm) 1HCS2036-01-006E 0.25in (6.4mm) 1

Router Bit Diamond Cut

HCS2036-01-015A 0.25in(6.4mm) 1

HCS2036-01-015B 0.25in(6.4mm) 1

HCS2036-01-015C 0.187in(4.75mm) 1

HCS2036-01-043A Burr Style 1HCS2036-01-043B End Mill 1HCS2036-01-043C Drill Point 1

HCS2036-01-044A Shear Compression 1

Roller, Steel HCS2036-01-054 2in (5.08cm)wide 1

Drill Bits Key Point

HCS2036-01-059B .09in (2.5mm) 1

HCS2036-01-059C .0125in (3.2mm) 1

HCS2036-01-059D 0.16in (4.0mm) 1HCS2036-01-059E 0.19in (4.8mm) 1HCS2036-01-059F 0.25in (6.4mm) 1

Scribe HCS2036-01-114 10in (25.4cm) Metal 1

Knife, CuttingHCS2036-01-120A #2 1HCS2036-01-120B 1

Blade, Cutting

HCS2036-01-120-18 #18 10HCS2036-01-120-19 #19 10

HCS2036-01-120-24 #24 10

Ruler, Steel HCS2036-06-01212in (30.48cm)Metal, 0.5in

(12.7mm) wide1




Applications:Our Metal Bond Repair Tool Ki t inc ludes a s e l e c t i o n o f t o o l s necessary for performing most metal bond repairs. All items are supplied in a compact, impact-resistant carrying case.

HCS2036-06Metal Bond Tool Kit


Router MotorAccessories and Attachments

Description Part Number Overall Length Flute Length

Cutter Diameter Qty

Router Bits - Taper Pin

HCS2036-01-017 0.128in x 2.25in (3.3mm x 5.72cm)

0.875in (22.2mm)

0.110in (2.8mm) 4

HCS2036-01-018 0.25in x 2.75in (6.4mm x 6.99cm)

1.25in (3.18cm)

0.224in (5.7mm) 4

HCS2036-01-018A 0.1875in x 2.5in (4.8mm x 6.35cm)

1.06in (2.55cm)

0.165in (4.2mm) 4

Cleco® PliersCleco® Plier Accessories and Attachments

Description Part Number Diameter Grip QtyCleco® Pliers HCS2036-01-050 1

Clecos®

Fasteners

HCS2036-01-045A .09in (2.5mm)

0.5in (12.7mm) 10

HCS2036-01-045 0.125in (3.2mm)

0.5in (12.7mm) 10

HCS2036-01-046 0.16in (4.0mm)

0.5in (12.7mm) 10

HCS2036-01-047 0.19in (4.8mm)

0.5in (12.7mm) 10

HCS2036-01-048 0.25in (6.4mm)

0.5in (12.7mm) 10

Clecos® Side Grip Clamp HCS2036-06-009 0.75in x 0.5in

(19.1mm x 12.7mm)0.25in

(16.4mm) 10

Grinder MotorAccessories and Attachments

Description Part Number Overall Diameter Grit Qty

Sanding Pad Holders

HCS2036-01-028 2in (5.08cm) 1

HCS2036-01-029 1in (2.54cm) 1

Sanding Disk HCS2036-01-030 2in

(5.08cm) 80 25

Sanding Disk

Bayonets

HCS2036-01-031 1in (2.54cm) 80 25

HCS2036-01-040 1in (2.54cm) 120 25

HCS2036-01-041 2in (5.08cm) 120 25




HCS2036-06Accessories

Additional Tools and Accessory Parts

Accessories and AttachmentsDescription Part Number QtySteel Rule HCS2036-06-012 1

Scribe, 10in (25.4cm) Metal HCS2036-01-114 2

Center Punch, Auto HCS2036-06-006 1

Replacement Punch HCS2036-06-006A 6

Tap Hammer HCS1104-01 1Motor

Combination Cushion Grip Pliers - 6.5in

(16.51cm)

HCS2036-06-007 1

Aviation Snips - Straight Cut HCS2036-06-001A 1

Aviation Snips - Left Cut HCS2036-06-011B 1

Aviation Snips - Right Cut HCS2036-06-011C 1

Case, Tool Kit HCS1011-021 1Placard, Tool Kit HCS1010-113 1

Clamp, Side Grip HCS2036-06-009 10

Air Input FTG, Male, 0.25in Male NPT

HCS1014-005 1

Drill MotorDrill Accessories and Attachments

Description Part Number Overall Diameter Angle QtyCountersink Feed -

Cage Assembly HCS2036-01-034 0.25in x 4in (6.4mm x 10.16cm) 1

.5in (12.7mm) Countersinks -

Piloted, Carbide Tip

HCS2036-01-035 0.125in pilot (3.175mm) 100° 1

HCS2036-01-036 0.156in pilot(3.96mm) 100° 1

HCS2036-01-037 0.188in pilot(4.76mm) 100° 1

HCS2036-01-038 0.25in pilot(6.35mm) 100° 1

Drill Stops

HCS2036-01-060 #40 1HCS2036-01-06 #30 1

HCS2036-01-062 #21 1HCS2036-01-063 #11 1

HCS2036-01-063A #1/4 1

Drill Bits Carbide Tipped

HCS2036-01-056A .094in (2.38mm) 135° 10

HCS2036-01-057A 0.125in (3.18mm) 135° 10

HCS2036-01-058A 0.156in (3.96mm) 135° 10

HCS2036-01-059G 0.188in (4.76mm) 135° 10

HCS25036-01059H 0.25in (6.4mm) 135° 10

Drill Reamers - Solid Carbide

HCS2036-01-010A .094in (2.38mm) 1

HCS2036-01-010 0.125in (3.2mm) 1

HCS2036-01-009 0.156in (3.96mm) 1

HCS2036-01-008 0.188in (4.76mm) 1

HCS2036-01-007 0.25in (6.4mm)

Drill Guide Housing HCS2036-01-001 1

Drill Guide Brushings

HCS2036-01-001B .094in (2.38mm)

HCS2036-01-001D 0.125in (3.18mm)

HCS2036-01-001F 0.156in (3.96mm)

HCS2036-01-001H 0.188in (4.76mm)

HCS2036-01-001J 0.25in (6.4mm)

Belt SanderAccessories and Attachments

Description Part Number

Overall Diameter Grit Qty

Belt Sander HCS2036-06-001 1

Sanding Belts

HCS2036-06-001-80

0.5in x 12in(12.7mm x 30.48cm)

80 10

HCS2036-06-001-120

0.5in x 12in (12.7mm x 30.48cm)

120 10




Applications:Our Floor Panel Repair Tool Kit includes an assortment of tools needed for common Floor Panel repairs. The Floor Panel Repair Tool Kit is offered in a compact, impact resistant case.

HCS2036-07Floor Panel Repair Tool Kit

Applications:Our Floor Panel Repair Tool Kit includes an assortment of tools needed for common Floor Panel repairs. The Floor Panel Repair Tool Kit is offered in a compact, impact resistant case.

Cutting/Closing ToolsDescription Image Part Number Overall Diameter Qty

Cutter, Rebate HCS2036-07-002A 0.45in(11.4mm) 2

Closing Tool HCS2036-07-003A 1

Drill Motor - Accessories and Attachments

Drill Bits - Kevlar™ HCS2036-07-001 0.19in (4.8mm) 4

Counter Bores

HCS2036-01-066A 0.31in (8.0mm) 2

HCS2036-01-066B 0.44in (11.1mm) 2

HCS2036-01-066C 0.53in(13.5mm) 2

Floor Panel Repair Tool Kit Accessories





HCS2036-09UAV Composite Repair Tool Kit

The HCS2036-09 “UAV” Composite Repair Tool Kit is designed to give you all the necessary tools you need to effi ciently perform a composite repair.Included are a wide variety of tools and accessories used to get the job done effectively the fi rst time, every time. These pre-assembled cases have a convenient place for each tool so you always know where to fi nd them. Best of all, each kit is rugged, lightweight, and portable for those “on-location” fi eld repairs.

Itemized List of ContentsDescription Part Number Qty

FITTING, AIR INPUT, MALE, 1/4” NPT MALE, TYPE-M HCS1014-005 4

HAMMER, TAP INSPECTION, COMPOSITE STRUCTURES,

ALUMINUM CONSTRUCTION WITH LOGO

HCS1104-01 1

VACUUM PUMP AND SNIFFER ASSEMBLY HCS2026-01 1

DRILL GUIDE/HOUSING, FOR BUSHING PART # HCS2036-01-001B

TO 001JHCS2036-01-001 1

DRILL GUIDE/BUSHING 3/32” HCS2036-01-001B 1DRILL GUIDE/BUSHING 1/8” HCS2036-01-001D 1

DRILL GUIDE/BUSHING 5/32” HCS2036-01-001F 1DRILL GUIDE/BUSHING 3/16” HCS2036-01-001H 1DRILL GUIDE/BUSHING 1/4” HCS2036-01-001J 1

DRILL MOTOR, AIR, 5200 RPM, 0-3/8” ID CHUCK HCS2036-01-002 1

ROUTER MOTOR, 208 (1/4”) COLLET STD, 0.9HP MOTOR, AIR DRIVEN, 25,000 RPM, STRAIGHT HANDLE,

ORANGE HOUSINGHCS2036-01-012 1

ROUTER BASE, TWO-HANDED, FOR SERIES, 10-20 GRINDERS HCS2036-01-013 1

ROUTER BIT, 1/4”X 3” OAL, 40 MESH, DIAMOND CUT, 1” CUTTING

SURFACEHCS2036-01-014 1

ROUTER BIT, 1/4”X 2” OAL, END MILL STYLE, DIAMOND CUT, 1/4” SHANK DIA., 2” O.A.L., 3/4” FLUTE LENGTH

HCS2036-01-015 1

ROUTER BIT, 1/4”X 2” OAL, DRILL PT, DIAMOND CUT, 3/4” FLUTE LENGTH,

1/4” SHANK DIA., 2” O.A.L.HCS2036-01-015A 1


ROUTER BIT, 3/16”X 2” OAL, BURR STYLE, DIAMOND CUT, 3/16” SHANK DIA., 2” O.A.L., 3/4” FLUTE LENGTH

HCS2036-01-015C 1

GRINDER, AIR DRIVEN 90 DEG., REAR EXHAUST, 20,000 RPM HCS2036-01-022 1

DRUMS, RUBBER SANDING W/SLEEVE ASSORTMENT, 1/4”DIA SHANK WITH THE FOLLOWING

SIZED BARRELS: 1/2” X 1/2”, (1/8” DIA SHANK), 3/4” X 1”, 1” X 1”, 1-1/2”

X 1-1/2”, 2” X 1-1/2”, INCLUDES:1 SET, 50 GRIT AND 1 SET 120 GRIT

SLEEVES

HCS2036-01-025 1

SANDING BARREL, 1” X 1” X 80 GRIT HCS2036-01-026 1SANDING PAD, 2”, SPEED LOC TS

MOUNT WITH THREADED MANDREL (STD ABRASIVES SOCATT MOUNT)

HCS2036-01-028 1

SANDING PAD, 1”, SPEED LOC TS MOUNT WITH THREADED MANDREL (STD ABRASIVES SOCATT MOUNT)

HCS2036-01-029 1

SANDING DISK, 2” DIA, 80 GRIT,SPD LOC TS, STD. ABR. SOCATT MOUNT,

ALUM OXIDEHCS2036-01-030 10

SANDING DISK, 1” DIA, 80 GRIT SPD LOC TS, STD. ABR. SOCATT MOUNT,


SANDING DISK, 2” DIA, 180 GRIT, SPD LOC TS, STD. ABR. SOCATT

MOUNT, ALUM OXIDEHCS2036-01-032 10

SANDING DISK, 1” DIA, 180 GRIT, SPD LOC TS, STD. ABR. SOCATT

MOUNT, ALUM OXIDEHCS2036-01-033 10

COUNTERSINK FEED (CAGE ASSEMBLY) HCS2036-01-034 1

COUNTERSINK, 1/2” X 100 DEGREE, 1/8” PILOT, CARBIDE TIPPED HCS2036-01-035 1









CUTTER, HONEYCOMB CORE, FLAT KNIFE HCS2036-01-039 1

SANDING DISK, 1” DIA, 120GRIT SPD LOC TS, STD ABR. SOCATT MOUNT,


SANDING DISK, 2” DIA, 120 GRIT SPD LOC TS, STD ABR. SOCATT MOUNT,


ROUTER BIT, 1/4” SPLIT HELIX, FOR CUTTING KEVLAR LAMINATES,

CARBIDE 1/4” DIA 2.5” LONG, SPEED 1600-1900 SFM, **MUST SUPPLY

WITH WARNING NOTICES

HCS2036-01-043 1

ROUTER BIT, 1/4” X 3” OAL, BURR HCS2036-01-043A 1ROUTER BIT, 1/4”X 3” OAL, DRILL

PT, CARBIDE, 3” LONG X 1” FLUTE LENGTH FOR KEVLAR, DIAMOND

CUTHCS2036-01-043B 1

ROUTER BIT, 1/4”X 3” OAL, END MILL CARBIDE, 3” LONG X 1” FLUTE LENGTH, FOR KEVLAR, DIAMOND

CUTHCS2036-01-043C 1

ROUTER BIT, 1/4”X 3” OAL, BI SHEAR, COMPRESSION, FOR

KEVLAR 1” FLUTE LENGTHHCS2036-01-044A 1

KNIFE, RETRACTABLE UTILITY HCS2036-01-051 1SHEARS, FISKAR SOFT TOUCH NOT FOR USE ON KEVLAR MATERIAL, 10-1/2” OAL X 3-5/8” CUTTING LENGTH

HCS2036-01-053 1

SHEARS, FOR KEVLAR, RH, 12” OAL, CARBIDE COATED HCS2036-01-053R 1

SWEEP KIT, 7PC, 1/4”, POLYETHYLENE HCS2036-01-055 1

DRILL BIT, 3/32” SOLID CARBIDE, 118 DEG POINT, JOBBER LENGTH**NOT

RECOMMENDED FOR KEVLAR**HCS2036-01-056A 10

DRILL BIT, 1/8”, CARBIDE TIPPED, 135 DEGREE POINT, JOBBER

LENGTH**NOT RECOMMENDED FOR KEVLAR**

HCS2036-01-057A 10

DRILL BIT, 5/32”, CARBIDE TIPPED, 135 DEGREE POINT, JOBBER

LENGTH**NOT RECOMMENDED FOR KEVLAR**

HCS2036-01-058A 10

DRILL BIT, 3/32”, KEV POINT, FOR KEVLAR HCS2036-01-059B 5

DRILL BIT, 1/8”, KEV POINT, FOR KEVLAR HCS2036-01-059C 5

DRILL BIT, 5/32”, KEV POINT, FOR KEVLAR HCS2036-01-059D 5

DRILL BIT, 3/16”, KEV POINT, FOR KEVLAR HCS2036-01-059E 5


DRILL BIT, 1/4”, KEV POINT, FOR KEVLAR, OAL UNDER 3” HCS2036-01-059F 5

DRILL BIT, 3/16”, CARBIDE TIPPED, 135 DEGREE SPLIT POINT, 2.5”, NOT

RECOMMENDED FOR KEVLARHCS2036-01-059J 10

DRILL BIT, 1/4”, CARBIDE TIPPED, 135 DEGREE SPLIT POINT, 2.5”, NOT

RECOMMENDED FOR KEVLARHCS2036-01-059K 10

MICROSCOPE, MAGNIFER, 30X HCS2036-01-067 1SANDER, RANDOM/ORBITAL, 5” PAD,

12,000 RPM 1/2HP HCS2036-01-070 1SANDING BARREL, 1/2”X1/2”, 120

GRIT HCS2036-01-075 1

SANDING BARREL, 3/4”X1”, 120 GRIT HCS2036-01-076 1SANDING BARREL, 1” X 1”, 120 GRIT HCS2036-01-077 1

SANDING BARREL, 1-1/2”X1-1/2”, 120 GRIT HCS2036-01-078 1

SANDING BARREL, 2”X 1-1/2”, 120GRIT HCS2036-01-079 1

SANDING BARREL, 1/2” X 1/2”, 80 GRIT HCS2036-01-080 1

SANDING BARREL, 3/4” X 1”, 80 GRIT HCS2036-01-081 1SANDING BARREL, 1-1/2” X 1-1/2”X

80 GRIT HCS2036-01-082 1SANDING BARREL, 2”X 1-1/2”, 80

GRIT HCS2036-01-083 1SANDING DISK, 5” DIA, 80 GRIT

ALUMINUM OXIDE, PSA STICK-IT HCS2036-01-084 10SANDING DISK, 5” DIA, 120 GRIT ALUMINUM OXIDE, PSA STICK-IT HCS2036-01-085 10CUT-OFF WHEEL, 3”, FIBERGLASS

REINFORCED 3” X 1/16” X 1/4” ARBOR, MAX SPEED 25,465 RPM

HCS2036-01-087 10

ARBOR, DIAMOND WHEEL 1/4” SHANK HCS2036-01-092 1

COLLET, 5/32”, FOR .110 SMALL END, .128 SHANK, #2 ROUTER BIT, (USE

WITH HCS2036-01-012 ROUTER MOTOR)

HCS2036-01-101 1

BLADE, CUTTING KNIFE, CHISEL, #18, FITS KNIFE HCS2036-01-120, 5

BLADES PER PACKAGEHCS2036-01-120-18 5

BLADE, CUTTING KNIFE, CARVING, #19, FITS KNIFE HCS2036-01-120 5


BLADE, CUTTING KNIFE, ANGLED, #24 FITS KNIFE HCS2036-01-120A 5


KNIFE, CUTTING, #2, REPLACABLE BLADE HCS2036-01-120A 1

KNIFE, CUTTING, HEX METAL HANDLE, REPLACEABLE BLADE HCS2036-01-120B 1





ROLLER, FIBERGLASS, 1/2” X 3”, ALUM HCS2036-01-121 1

SANDING DISK, 5” DIA, 150 GRIT, PSA, ALUMINUM OXIDE ON ‘C’

WEIGHT PAPERHCS2036-01-161 10









SANDING DISK, 5” DIA, 800 GRIT, PSA, ALUMINUM OXIDE ON FILM

BACKHCS2036-01-166 10

SANDING DISK, 5” DIA, 1200 GRIT, PSA, ALUMINUM OXIDE ON FILM

BACKHCS2036-01-168 10

SANDING DISK, 2” DIA, 150 GRIT, SPEED LOK TS, ALUMINUM OXIDE HCS2036-01-172 10SANDING DISK, 2” DIA, 240 GRIT,

SPEED LOK TS, ALUMINUM OXIDE HCS2036-01-174 10SANDING DISK, 2” DIA, 320 GRIT,



SPEED LOK TS, ALUMINUM OXIDE HCS2036-01-180 10


SANDING DISK, 1” DIA, 320 GRIT, SPEED LOK TS, ALUMINUM OXIDE HCS2036-01-181 10

BOX, PLASTIC FLEX-A-TOP HINGED LID, ID 2.64” X 3.60” X 1.5” HCS2036-125 22

BOX, PLASTIC FLEX-A-TOP HINGED LID, ID 4.41” X 7.89” X 1.16” HCS2036-126 4

PETRI DISH, 150mm X 25mm, STYRENE PLASTIC W/ LID HCS2036-127 4

PLACARD, HCS2036-09 TOOL KIT (1 OF 2), 2 X 6”, BLACK W/WHITE

LETTERS, PLASTICHCS1010-182 1

PLACARD, HCS2036-09 CONSUMABLES KIT (2 OF 2), 2 X 6”, BLACK W/WHITE LETTERS, PLASTIC

HCS1010-183 1

CASE, HCS2036-09 TOOL KIT, TOOLS, REMOVABLE LID, DIVIDER

FLAP, CUSTOM FOAMHCS1011-033 1

CASE, TOOL KIT HCS2036-09, COMSUMABLES, 3.0” TOP, 3.0”

BOTTOM, DIVIDER FLAP IN TOP PORTION, TAKE-APART HINGES,

CUSTOM FOAM FILLER

HCS1011-034 1




Durable, secure cabinets are designed to provide years of safe, convenient storage and problem-free operation. Our cabinets: • Provide the highest density storage, reducing the footprint needed for storage by as much as 50% • Provide maximum weight-bearing capacity, organization and access• Feature all the benefi ts of our unique, infi nitely customizable drawer • Offer the fl exibility to adapt to your future requirements• Can be stacked for even greater storage density in the same footprint• Allow keyed-alike cabinet groupings to be created. Our removable core locks can be switched in the fi eld for

both keyed-alike and master key systems.

CabinetsStorage Solutions

Features:Lockable cabinetsErgonomic handlesHinged label holdersDrawer dividers with ability to add labelingPrevenTip® interlock systemExclusive suspension systemOptional wood counters

One-Piece Drawer Face And HandleThe drawer front has an integral handle and is welded to the bottom of the drawer for added stability. No hardware is used to at-tached the drawer front or handle, resulting in superior durability and ergonomic safety.

Suspension SystemOur exclusive suspension system incorporates a guide track, which wraps under the drawer body for additional stability and strength. This unique system features quiet Polyoxy methylene (POM) bearings, combining strength, hardness, dimensional stability, fatigue resistance, low wear and low friction, to give Lista drawers remarkably smooth, quiet operation.

Drawer PerformanceWhen we say our drawers provide unequaled performance, we have the results to back that claim up. To test our drawers, we chose the RAL-RG 614 standard from the German Institute of Quality Assurance and Marking, a globally respected standard. This test required our drawers to pass a series of diffi cult test criteria. In these demanding tests, our cabinets excelled. Our suspensions ex-ceeded the required number of cycles, fully loaded, without diminished performance.




CabinetsStorage Solutions continued

Part Number Width x Depth x Height Number of Drawers Number of CompartmentsCounter Height Cabinets

HCS2038-04-001 28.25in x 28.5in x 41.75in (71.75cm x 72.39cm x 106.04cm) 5 61







Eye-Level Height CabinetsHCS2038-05-001 28.25in x 28.5in x 59.5in (71.75cm x 72.39cm x 151.13cm) 8 88








Mobile CabinetsHCS2038-06-001 22.18in x 28.5in x 35.5in (56.36cm x 72.39cm x 105.41cm) 5 53


HCS2038-06-003 39in x 28.5in x 37.25in (99.06cm x 72.39cm x 94.61cm) 5 57



Lista® and PreventTip® are Registered Trademarks of Lista International Corp.




Drill Motor:The HCS2036-01-002 Drill Motor is ergonomically designed, compact, quiet and powerful. This tool comes with a short body length, ideal for working in tight areas, while the light weight and perfect balance makes it the mechanics favorite drill.

Repair ToolsDrill Motor and Bits

Drill Bits - Carbon Fiber and Kevlar™Drill Motor Accessories and Attachments

Description Image Part Number Overall Diameter Angle Flute

LengthOverall Length

Drill Bits - Carbide Tipped

HCS2036-01-056A(solid carbide)

.09in (2.5mm) 118° 1.125in

(2.86cm)2.25in (5.72cm)

HCS2036-01-057A 0.125in (3.2mm) 135° 1.75in

(4.45cm)2.75in (6.99cm)

HCS2036-01-058A 0.16in (4.0mm) 135° 2in

(5.08cm)3.125in (7.94cm)

HCS2036-01-059G 0.19in (4.8mm) 135° 2.375in

(6.03cm)3.5in

(8.89cm)

HCS2036-01-059H 0.25in (6.4mm) 135° 2.75in

(6.99cm)4in

(10.16cm)

Drill Bits - Key Point

Twist

HCS2036-01-059B .09in (2.5mm)

1in (2.54cm)

2in (5.08cm)

HCS2036-01-059C 0.125in (3.2mm)

1.25in (3.18cm)

2.25in (5.72cm)

HCS2036-01-059D 0.16in (4.0mm)

1.375in (3.49cm)

2.5in (6.3.5cm)

HCS2036-01-059E 0.19in (4.8mm)

1.625in (4.13cm)

2.75in (6.98cm)

HCS2036-01-059F 0.25in (6.4mm)

2in (5.08cm)

3.25in (8.26cm)

HCS2036-01-002 Specifi cations:Weight - 1.5lbs (0.7kg)

Height - 6.3in (15.9cm)

RPM - 5,200Diameter Capacity - .0375in (9.525mm)

Throttle - Two StageExhaust - 360° Rotable




Repair ToolsDrill Motor Accessories and Counter Bores

Drill Motor Accessories and AttachmentsDescription Image Part Number Overall Diameter

Drill Stops

HCS2036-01-060 #40

HCS2036-01-061 #30

HCS2036-01-062 #21

HCS2036-01-063 #11

HCS2036-01-063A #14

Drill Guide Bushings *

* Also available as a kit: HCS2036-01-001K

HCS2036-01-001B .09in (2.5mm)

HCS2036-01-001D 0.125in (3.2mm)

HCS2036-01-001F 0.16in (4.0mm)

HCS2036-01-001H 0.19in (4.8mm)

HCS2036-01-001J 0.25in (6.4mm)

Drill Guide Housing* HCS2036-01-001J Used for drilling straight holes at 90°

-060 -061 -062 -063 -063A

-001B -001D -001F -001H -001J

Counter BoresDescription Image Part Number Overall Diameter

Counter Bores

HCS2036-01-064 0.5in (12.7mm)

HCS2036-01-065 0.75in(19.2mm)

HCS2036-01-066 1in (2.54cm)




ReamersDrill Motor Accessories and Attachments

Description Image Part Number Overall Diameter Flute Length Overall

Length

Reamers - Solid Carbide

HCS2036-01-010A .09in (2.5mm)

1in (2.54cm)

6in (15.24cm)

HCS2036-01-010 0.125in (3.2mm)

1.125in (2.86cm)

6in (15.24cm)

HCS2036-01-009 0.16in (4.0mm)

1.25in (3.18cm)

6in (15.24cm)

HCS2036-01-008 0.19in (4.8mm)

1.5in (3.81cm)

6in (15.24cm)

HCS2036-01-007 0.25in (6.4mm)

1.75in (4.44cm)

6in (15.24cm)

Reamers - Taper Drill

HCS2036-01-006A .09in (2.5mm)

1.5in (3.81cm)

4in (10.16cm)

HCS2036-01-006B 0.125in (3.2mm)

1.5in (3.81cm)

4in (10.16cm)

HCS2036-01-006C 0.16in (4.0mm)

1.5in (3.81cm)

4in (10.16cm)

HCS2036-01-006D 0.19in (4.8mm)

1.5in (3.81cm)

4in (10.16m)

HCS2036-01-006E 0.25in (6.4mm)

1.5in (3.81cm)

4in (10.16cm)

Repair ToolsDrill Motor Accessories and Reamers

Drill Motor Accessories and AttachmentsDescription Image Part Number Overall Diameter Angle Shank Length

Piloted, Diamond Cut Hole Saws

HCS2036-01-089 1in (2.54cm)

0.375in (9.525mm)

HCS2036-01-090 1.5in (3.81cm)

0.375in (9.525mm)

HCS2036-01-091 2in (5.08cm)

0.375in (9.525mm)

Counter Sink Feed - Cage

AssemblyHCS2036-01-034

28 Female Threads:

0.25in (6.4mm)

Shaft Travel: 0.28in (7.1mm)

0.25in x 4in (6.4mm x 10.16cm)

Counter Sinks - with Piloted Carbide Tip

HCS2036-01-035 0.125in (3.2mm) 100°

HCS2036-01-036 0.16in (4.0mm) 100°

HCS2036-01-037 0.19in (4.8mm) 100°

HCS2036-01-038 0.25in (6.4mm) 100°




Router Motor:The HCS2036-01-012 Router Motor is small, comfortable and lightweight, yet can withstand tough treatment. This tool can be used with the HCS2036-01-013 Two-Handed Router Motor Base attached (as shown).

Repair ToolsRouter Motor and Bits

HCS2036-01-012Router Motor

HCS2036-01-013Router Motor Base

Router Bits - Fiberglass and Carbon FiberRouter Motor Accessories and Attachments

Description Image Part Number Overall Length

Shank Diameter

Flute Length

Cutter Diameter

Router Bits - 40 Mesh Diamond

HCS2036-01-014 3in (7.62cm)

0.25in (6.4mm)

1in (2.54cm)

0.25in (6.4mm)

HCS2036-01-014A 3in (7.62cm)

0.25in (6.4mm)

1in (2.54cm)

0.375in (9.5mm)

HCS2036-01-016 3in (7.62cm)

0.25in (6.4mm)

1in (2.54cm)

0.5in (12.7mm)

Router Bits - Diamond Cut

- End MillHCS2036-01-015 2in

(5.08cm)0.25in (6.4mm)

0.75in (19.1mm)

0.25in (6.4mm)

Router Bits - Diamond Cut - Drill Point

HCS2036-01-015A 2in (5.08cm)

0.25in (6.4mm)

0.75in (19.1mm)

0.25in (6.4mm)

Router Bits - Diamond Cut - Burr Style

HCS2036-01-015B 2in (5.08cm)

0.25in (6.4mm)

0.75in (19.1mm)

0.25in (6.4mm)

HCS2036-01-015C 2in (5.08cm)

0.19in (4.8mm)

0.625in (15.9mm)

0.19in (4.8mm)

Drill Point

Bur Style

End MillStyle

DiamondCut

DiamondCut

DiamondCut



Head Height - 2.9in (7.4cm)

RPM - 5,200Exhaust - FrontCollet Size - 0.25in (6.35mm)

Sanding Capacity - 2in (5.08cm)




Repair ToolsRouter Motor Kevlar™ Bits

Router Bits - Kevlar™Router Motor Accessories and Attachments


Shank Diameter

Flute Length

Cutter Diameter

Router Bits - *Split Helix HCS2036-01-043 2.5in

(6.35cm)0.25in (6.4mm)

1in (2.54cm)

0.25in (6.4mm)

Router Bits - Diamond Cut

HCS2036-01-043A 3in (7.62cm)

0.25in (6.4mm)

1in (2.54cm)

0.25in (6.4mm)

HCS2036-01-043B 3in (7.62cm)

0.25in (6.4mm)

1in (2.54cm)

0.25in (6.4mm)

HCS2036-01-043C 3in (7.62cm)

0.25in (6.4mm)

1in (2.54cm)

0.25in (6.4mm)

Router Bits - Honeycomb

PanelHCS2036-01-044A 3in

(7.62cm)0.25in (6.4mm)

1in (2.54cm)

0.25in (6.4mm)

Router Bits - *Bi Shear

CompressionHCS2036-01-044 2.5in

(6.35cm)0.25in (6.4mm)

0.75in (19.1mm)

0.25in (6.4mm)

Burr Style

End MillStyle

Drill Point

Split Helix

Bi Shear




Repair ToolsRouter Motor Bits, Collets, and Templates

Router Bits - AluminumRouter Motor Accessories and Attachments


Shank Diameter

Flute Length

Cutter Diameter

Router Bits - Taper Pin

HCS2036-01-017 2.25in (5.72cm)

0.128in (3.3mm)

0.875in (22.2mm)

0.110in (2.8mm)

HCS2036-01-018A 2.5in (6.35cm)

0.19in (4.8mm)

1.19in (2.55cm)

0.165in (4.2mm)

HCS2036-01-018 2.75in (6.99cm)

0.25in (6.4mm)

1.25in (3.18m)

0.25in (6.4mm)

-101 -102 -103

Router Templates - AluminumRouter Motor Accessories and Attachments

Description Image Part Number Inner Diameter Outer Diameter

Router Templates

HCS2036-01-122A 4.9in(12.5cm)

8.86in (22.5cm)

HCS2036-01-122B 5.9in (15cm)

9.84in (25cm)

HCS2036-01-122C 6.89in (17.5cm)

10.83in (27.5cm)

HCS2036-01-122D 7.87in (20cm)

11.81in (30cm)

HCS2036-01-122E 8.85in (22.5cm)

12.79in (32.5cm)

HCS2036-01-122F 9.84in (25cm)

13.78in (35cm)

Router ColletsRouter Motor Accessories and Attachments


Minimum Capacity

Maximum Capacity

Collets

HCS2036-01-101 0.16in (4.0mm)

0.125in (3.2mm)

0.16in (4.0mm)

HCS2036-01-102 0.19in (4.8mm)

0.156in (4.0mm)

0.1875in (4.8mm)

HCS2036-01-103 0.375in (9.5mm)

0.343in (8.7mm)

0.375in (9.5mm)




Lay-up Cutting Templates - Aluminum and PlasticRouter Motor Accessories and Attachments

Description Image Part Number Overall Diameter

Lay-up Cutting Templates - Metal Kit

(HSC2036-123 consists of all part

number listed on the right)

HCS2036-01-123A 0.98in (25mm)

HCS2036-01-123B 1.96in (5cm)

HCS2036-01-123C 2.95in (7.5cm)

HCS2036-01-123D 3.93in (10cm)

HCS2036-01-123E 4.92in (12.5cm)

HCS2036-01-123F 5.9in (15cm)

HCS2036-01-123G 6.89in (17.5cm)

HCS2036-01-123H 7.87in (20cm)

HCS2036-01-123I 8.85in (22.5cm)

HCS2036-01-123J 9.84in (25cm)

Lay-up Cutting Templates - Plastic

Kit

(HCS2036-124 consists of all part numbers listed on

the right)

HCS2036-01-124A 0.98in (25mm)

HCS2036-01-124B 1.96in (5cm)

HCS2036-01-124C 2.95in (7.5cm)

HCS2036-01-124D 3.93in (10cm)

HCS2036-01-124E 4.92in (12.5cm)

HCS2036-01-124F 5.9in (15cm)

HCS2036-01-124G 6.89in (17.5cm)

HCS2036-01-124H 7.87in (20cm)

HCS2036-01-124I 8.85in (22.5cm)

HCS2036-01-124J 9.84in (25cm)

Repair ToolsRouter Motor Lay-up Cutting Templates




Grinder Motor:The HCS2036-01-022 Grinder Motor is designed to reduce vibration and operate as quiet as possible while providing substantial power. This is accomplished by using precision parts, high-quality bearings and elastomer housings.

Repair ToolsGrinder Motor and Sanding Barrels

Sanding BarrelsGrinder Motor Accessories and Attachments

Description Image Part Number Overall Diameter GritGrinder - Barrel

Attachment for Sanding

Disks

HCS2036-01-025

0.5in x 0.5in (12.7mm x 12.7mm)

0.75in x 1in (19.1mm x 2.54cm)

1in x 1in(25.4mm x 2.54cm)

1.5in x 1.5in(3.81cm x 3.81cm)

2in x 1.5in(5.08cm x 3.81cm)

Sanding Barrels

HCS2036-01-027 1in x 1in (2.54cm x 2.54cm) 180

HCS2036-01-077 1in x 1in (2.54cm x 2.54cm) 120

HCS2036-01-075 0.5in x 0.5in (12.7mm x 12.7mm) 120

HCS2036-01-080 0.5in x 0.5in (12.7mm x 12.7mm) 80

HCS2036-01-076 0.75in x 1in (19.1mm x 2.54cm) 120

HCS2036-01-081 0.75in x 1in (19.1mm x 2.54cm) 80

HCS2036-01-078 1.5in x 1.5in (3.81cm x 3.81cm) 120

HCS2036-01-082 1.5in x 1.5in (3.81cm x 3.81cm) 80

HCS2036-01-079 2in x 1.5in (5.08cm x 3.81cm) 120

HCS2036-01-083 2in x 1.5in (5.08cm x 3.81cm) 80

-078 -082

-076 -081

-075 -080

-079 -083

-027 -077

HCS2036-01-022



RPM - 20,000Exhaust - FrontCollet Size - 0.25in (6.35mm)

Abrasives Capacity - 0.75in (19.1mm) Carbide Bur, 1.5in (38.1mm) Mounted Wheel




Repair ToolsGrinder Motor Sanding Disks / Bayonets

Sanding Disks and Bayonets - Quick Connect LockGrinder Motor Accessories and Attachments

Description Image Part Number Overall Diameter Grit

Sanding Pad Holders Sanding

Disks

HCS2036-01-028 2in (5.08cm)

HCS2036-01-029 1in (2.54cm)


HCS2036-01-030 2in (5.08cm) 80

HCS2036-01-031 1in (2.54cm) 80

HCS2036-01-040 1in (2.54cm) 120

HCS2036-01-041 2in (5.08cm) 120

Sanding Disks

HCS2036-01-032 2in (5.08cm) 180

HCS2036-01-033 1in (2.54cm) 180

Surface Reconditioning Disks (Nylon

Pads)

HCS2036-01-117A 1in (2.54cm) Fine

HCS2036-01-117B 2in (5.08cm) Fine

HCS2036-01-118A 1in (2.54cm) Med

HCS2036-01-118B 2in (5.08cm) Med

HCS2036-01-119A 1in (2.54cm) Coarse

HCS2036-01-119B 2in (5.08cm) Coarse

1”(2.54cm)

2”(5.08cm)




Repair ToolsGrinder Motor Sanding Disks / Bayonets

Sanding Disks and Bayonets - Roloc™1

Grinder Motor Accessories and AttachmentsDescription Image Part Number Overall Diameter Grit

Sanding Pad Holders Sanding

Disks

HCS2036-02-028 2in (5.08cm)

HCS2036-02-029 1in (2.54cm)


HCS2036-02-030 2in (5.08cm) 80

HCS2036-02-031 1in (2.54cm) 80

HCS2036-02-040 1in (2.54cm) 120

HCS2036-02-041 2in (5.08cm) 120

Sanding DisksHCS2036-02-032 2in

(5.08cm) 180

HCS2036-02-033 1in (2.54cm) 180

Surface Reconditioning Disks (Nylon

Pads)

HCS2036-02-117A 1in (2.54cm) Fine

HCS2036-02-117B 2in (5.08cm) Fine

HCS2036-02-118A 1in (2.54cm) Med

HCS2036-02-118B 2in (5.08cm) Med

HCS2036-02-119A 1in (2.54cm) Coarse

HCS2036-02-119B 2in (5.08cm) Coarse

Bristle Reconditioning Disks (Rubber

Pads)

HCS2036-08-250 2in(5.08cm) 50

HCS2036-08-280 2in (5.08cm) 80

HCS2036-08-220 2in (5.08cm) 120

1Roloc™ is a registered trademark of the 3M Corporation.

1”(2.54cm)2”(5.08cm)




Repair ToolsGrinder Motor Accessories

Grinder Motor Accessories and AttachmentsDescription Image Part Number Overall Diameter Grit

Diamond Arbor Wheel HCS2036-01-092 0.25in

(6.4mm)

Fiberglass Cut-Off Wheel HCS2036-01-087 3in

(7.62cm)

Grinder Stone Barrel

Zirconia Alumina Points

HCS2036-01-023 1in x 1.125in (2.54cm x 3.81cm) 30

Grinder Stone Mushroom

Zirconia Alumina Points

HCS2036-01-024 0.75in x 1.125in (19.1mm x 2.86cm) 30




Random Orbital Sander:The HCS2036-01-070 Random Orbital Sander is designed to help the end consumer run a clean operation. This tool, along with the HCS2036-01-022 Grinder Motor, come standard with oiless blades, making it a clean operating tool. Also available with vacuum (HCS2036-01-070-VAC), eliminating inhalation and mess of particles from sanding.

Three Way Air ManifoldThe HCS2036-01-088 Three Way Air Manifold can be used with any of the included air tools. The primary use is to increase a single compressed air outlet to three outlets.• 3 NPT Female Threads - 0.25in (6.35mm)• 1 NPT Female Thread - 0.375in (9.5mm)

Repair ToolsOrbital Sander and Three Way Air Manifold

Random Orbital Sander Accessories and AttachmentsDescription Image Part Number Overall Diameter Grit

Sandpaper

HCS2036-01-084 5in (12.7cm) 80

HCS2036-01-085 5in (12.7cm) 120

HCS2036-01-111 5in (12.7cm) 80

HCS2036-01-112 5in (12.7cm) 120

For use with HCS2036-01-070-VAC

For use with sander shown above

HCS2036-01-070

HCS2036-01-088



Length - 5.3in (13.5cm)

RPM - 10,000Sanding Pad - 5in (12.7cm)

Exhaust - Rear (or vacuum)




Cleco® PliersThe HCS2036-01-050 Cleco® Pliers are constructed out of top quality forged steel and nickel plated to resist wear and abuse. This manual plier makes for ease of operation when installing Cleco® fasteners.

Belt Sander:The HCS2036-06-001 Belt Sander is a right angle sander used for contouring honeycomb when performing a metal bond repair.

Repair ToolsBelt Sander, Accessories, / Cleco®® Pliers® Pliers®

ClecoThe HCS2036-01-050 Cleco

HCS2036-01-050

HCS2036-06-001

Belt Sander Accessories and AttachmentsDescription Image Part Number Overall Diameter Grit

Sanding BeltsHCS2036-06-001-80 0.5in x 12in

(12.7mm x 30.48cm) 80

HCS2036-06-001-120 0.5in x 12in (12.7mm x 30.48cm) 120

Cleco® Pliers Accessories and AttachmentsDescription Image Part Number Overall Diameter Grip Size Number

Clecos

*Also available as a kit. HCS2036-06-008 (kit in-

cludes 10 each)

HCS2036-01-045A .09in (2.5mm)

0.5in (12.7mm) #40

HCS2036-01-045 0.125in (3.2mm)

0.5in (12.7mm) #30

HCS2036-01-046 0.16in (4.0mm)

0.5in (12.7mm) #21

HCS2036-01-047 0.19in (4.8mm)

0.5in (12.7mm) #10

HCS2036-01-048 0.25in (6.4mm)

0.25in (6.4mm) #10

Cleco® Side Clamp Grip HCS2036-06-009 0.75in x 0.5in

(19.1mm x 12.7mm)


Length - 11.3in (13.5cm)

RPM - 20,000Sanding Pad - 0.5in x 12in (12.7mm x 30.48cm)

Exhaust - Front




Repair ToolsAdditional Repair Tools and Accessories

Additional Repair Tools and AccessoriesDescription Image Part Number Details

Soft Touch Shears HCS2036-01-053

Cushion GripLeft/Right Handed Use

Spring ActionAdjustable Rivet

NOT for cutting Kevlar™

Kevlar™ Shears

HCS2036-01-053K 8in - High LeverageSerrated Edge for Kevlar™

HCS2036-01-053RBent Trimmer

Ideal for Cutting Kevlar™

HCS2036-01-053L

Aviation Snips-

Left Cut*

Straight Cut*

Right Cut*

Also available as a kit: HCS2036-06-011

HCS2036-06-011B 0.8 lbs (0.36kg)

HCS2036-06-011A 0.8 lbs (0.36kg)

HCS2036-06-011C 0.8 lbs (0.36kg)

Honeycomb Core Knife HCS2036-01-039Blade: 4in x 1.75in

(10.2cm x 3.2cm)Leather Handle

Retractable Utility Knife HCS2036-01-051Three Blade Positions

Aluminum Diecast Handle - Gray

Step-Ply Cutting Knife

HCS2036-01-120AHandle: Aluminum

Diameter: 0.44in (1.1cm)Length: 4.61in (11.9cm)

HCS2036-01-120BHandle: Plastic

Diameter: 0.75in (1.9cm)Length: 4.375in (11.1cm)

Step-Ply Cutting Knife Blades

Also available as a kit: HCS2036-01-120

HCS2036-01-120-18 Chiseling BladeLength: 1.81in (4.6cm)

HCS2036-01-120-19 Straight Cutting BladeLength: 1.63in (4.1cm)

HCS2036-01-120-24 Detail Cutting BladeLength: 1.56in (4.0cm)






Cushion Grip Peel Pliers HCS2036-06-007Length: 6.5in (16.5 cm)

Jaw: 1in (2.5 cm)Nose Type: Regular

Thermocouple Wire Stripper HCS2036-01-049

One light squeeze strips wire clean up

to 0.875in (2.2 cm)

Magnifi er HCS2036-01-067Used to determine fi ber

alignment during ply removal

Pocket Rule HCS2036-01-132

Stainless Steel6in x 0.5in

(15.24cm x 12.7mm)Metric and English

Air Driven Vacuum Cleaner HCS2036-01-069

Venturi Design with 1in ID12in (30.5 cm) Rigid Tube

0.25in Inlet0.53lbs (0.24kg)

Sweep Kit (7 pieces) HCS2036-01-055

Plastic Polyethylene Squeegee used for apply-ing liquid laminating resin to saturate dry fabric dur-

ing a wet lay-up procedure to smooth and compact prepeg materials during

hand lay-up process. Also used to smooth paste adhesives or fi llers.

Blue Applicator HCS2036-01-086

Used for applying liquid laminating resin during a wet lay-up procedure to

smooth and compact pre-preg materials. Also used

to smooth paste adhesives or fi llers.






Material Roller HCS2036-01-054 2in (5.1cm) Wide Steel Roller

Fiberglass Roller HCS2036-01-121 0.5ft x 3in Aluminum Roller (1.27cm x 7.6cm)

Fiberglass Replacement

Rollers

HCS2036-01-121A 0.5in x 3in Aluminum Roller (1.27cm x 7.6cm)

HCS2036-01-121B 0.5in x 3in Plastic Roller (1.27cm x 7.6cm)

Tap Hammer HCS1104-01

Aluminum Construction Handle: 8in (20.3 cm)Head: 0.5in x 1.5in

(1.3cm x 3.8cm)

Scribe HCS2036-01-114Used to mark metals

for processingLength: 10in (25.4cm)

Auto Center Punch

HCS2036-06-006Fully adjustable heavy

and light markingLength: 5.5in (13.97cm)

Handle Diameter: 0.5in (12.7mm)*Point Diameter: .03in (.794mm)

*HCS2036-06-006A

Insert Closing Tool HCS2036-07-003AUsed on fl oor panel inserts

Diameter: 1in (2.54cm)Pilot Diameter: 0.1875in (4.8mm)

*ReplacementPunch




Our Composite Repair Safety Items provide your maintenance personnel with all the materials necessary for a safe repair.

Repair ToolsComposite Repair Safety Items

HCS2510-06-004A

HCS2510-06-005A

HCS2510-06-004B

HCS2510-06-003AHCS2510-06-002A

HCS2510-06-001A

Composite Repair Safety ItemsDescription Part Number Unit of IssueMask, Dust HCS2510-06-001A Box of 20

Glasses, Safety HCS2510-06-002A EAEar Plugs HCS2510-06-003A Box of 50

Gloves, Lint Free(specify size when ordering) HCS2510-06-004A Box of S, M, L, XL

Gloves, Latex(specify size when ordering) HCS2510-06-004B Box of S, M, L, XL

Coveralls, Tyvek(specify size when ordering) HCS2510-06-005A EA - S, M, L, XL




Technical Services

Composite Repair Training

Consultations/Facility Design/InstallationConsultations/Facility Design/InstallationConsultations/Facility Design/Consultations/Facility Design/

Whether you need help designing a complete repair facility, or simply need help developing a single repair technique, we are available to assist you. Our staff has experience developing technical publications, specialized training curriculum, computer based training courses, and repair procedures. Simply put, if it has anything to do with composite repair, we can help!

Composite repair training is an integral part of our “Composite Repair Solutions” philosophy. Our instructors are among the top in their fi eld and work hard to stay current with the latest skills and techniques in composites. Training courses are hands-on as well as theoretical, supplying students with practical knowledge and techniques to save both time and money. We provide strong technical foundations in the classroom and then go to workshops where students fabricate and repair actual parts. Courses are offered in cooperation with Abaris Training, an industry leader in the fi eld of composite training. In addition to scheduled courses held regularly in Nevada and Georgia, we also offer on-site training worldwide. We can customize our classes to meet your needs and are committed to providing the knowledge and skills needed for your specifi c application. Students can learn with their own equipment, at their own facility, saving travel time, and travel expenses.

For our European, African, and Middle Eastern customers, HEATCON® Composite Systems, Limited (Europe) and Abaris Training have teamed up to form HEATCON® Abaris Training International (Limited) located in the United Kingdom. The United Kingdom provides a convenient training location for international students, but for larger groups, we have the ability to conduct our courses at any worldwide facility. Visit www.heatcon.com for more details.

HEATCON® Composite Training is a one-of-a-kind, state-of-the-art, training facility designed specifi cally for our Asian customers. This new facility offers quality training covering damage assessment and repair techniques for the composite structures being used on the new generation aircraft of today. Courses are offered with a tailored curriculum to suit students of various experience and competency levels. Visit www.heatcon.com for more information.




Advanced Composite StructuresFabrication and Damage Repair - Phase 1

This five-day course is our most popular. It is designed for composite parts fabricators who need to learn a great deal about the fundamentals of advanced composite materials, manufacturing and repair techniques.

This course assumes no pr ior experience with composites. It is an ideal starting point for those interested in developing their advanced composite expertise with a comprehensive fundamental overview.

Hands-on exercises are extensive, and students will work with fi berglass and Kevlar™ cloth, carbon fi ber unidirectional

Key Lecture Elements• Current Status of Composite

Technology: history, recent developments, and terminology

• Characteristics of Advanced Composite Materials

• Material Forms: dry cloth and wet resin vs., prepregs, weave/styles

• Fabrication Methods: wet lay-up, prepreg lay-up, fi lament winding, RTM, press molding, pultrusion Resin/Matrix

• Systems: thermosets vs. thermoplastics, temperature ranges, cold storage requirements/shelf life limits, adhesives

• Fundamentals of Fabrication: prepreg cloth handling and ply orientation, lay-up procedures, vacuum bagging

• Curing Methods: oven/autoclave/hot bonder cures

• Use of Adhesives: co-curing vs. secondary bonding, surface preparation, curing temperatures, cleanliness, pressure, bond line quality

• Inspection Criteria: non-destructive inspection methods, defect detection, galvanic corrosion, documentation, acceptable vs. unacceptable defects, defect prevention

• Principles of Tooling: types of tools, thermal characteristics

• Repair Methods: permanent vs. temporary repairs, scarf vs. stepped vs. mechanical patch repair scenarios, demo of “hot-bonder” fi eld repair units

• Fasteners: use of mechanical fasteners, adhesively bonded fasteners

• Health and Safety Issues: proper handling, personal protection, allergic reactions, waste disposal

Workshop ExercisesComponent lay-up using fi berglass dry cloth and liquid epoxy resin materials, including: fi ber orientation, lay-up, resin mixing procedures, health/safety concerns, controlling fi ber-resin ratios, vacuum bagging

Component lay-up using prepregmaterials, including: sandwich panels in carbon fi ber unidirectional tape, fi berglass and aramid fi ber cloth panels, ply orientation, warp direction, stacking vs. nesting, material cutting and handling, honeycomb and foam core installation

Vacuum bagging: materials and processes, bleeder/breather schedules, bridging, debulking, leak checking, potential problems, use of caul plates, use of thermocouples, use of an ultrasonic leak detector

Curing processes: ramp rates, vacuum schedule, oven cures, potential problems

Repairs: damage removal, scarf preparation, skin repair fabrication, use of wet resins and cloth for repairs,core plug repairs

Prior composite experience and training is not required for this course.

In cooperation with Abaris Training Resources, Inc.

HCS-T101tape, Nomex® honeycomb, and foam core materials. One of the finished parts will be deliberately damaged and repaired using basic repair techniques and “wet” lay-up repair materials and processes. The fi nal repaired part will be cut in half for evaluation of the repair cross section.

For those who desire further training and more difficult repair scenarios, we recommend taking our Advanced Composite Structures: Fabrication and Damage Repair Phase 2 course directly after this course.




Key Lecture Elements• Damage Assessment and

Classifi cation

• Paint Removal Repair Instructions

• Determining Unknown Lay-ups

• Drying Moisture-Contaminated Honeycomb Cores

• Bagging Techniques for On and Off Aircraft Repairs

• Programming and Use of Composite Repair Sets

• Dealing with Contaminated Structures

• Handling Heat Blanket and Thermocouple Problems

• Repair Design Considerations

Workshop Exercises

Damage identifi cation and assessment

Damage removal

Core removal

Unknown lay-up determination; repair procedure determination

Use of manufacturers’ repair instructions

Repair scarfi ng: including curved surfaces

Vacuum bagging (without crushing fragile structures)

Thermocouple welding and repair

Cure programming and monitoring using portable composite repair sets

Inspection of repaired area

This course is designed as a follow-up to the Fabrication and Damage Repair Phase 1. The two courses are best taken in succession, but can be taken separately if necessary. The class assumes the students have the knowledge gained in the fi rst course, and concentrates on more diffi cult

and realistic repair situations. It is designed for those who will actually be performing or inspecting repairs.

Most of this class is devoted to hands-on repair practice, and little time is spent in the classroom. Students will be given a variety of damaged parts and structures to perform repairs.

Determining the extent of the damage, evaluating the ply orientation and lay-up of an unknown structure, and removing internal contamina tion (such as water, fuel, etc.) are fundamental parts of this course. Preparation of both composite and aluminum surfaces for bonding is discussed at length.

Determining the best repair method and actually carrying out the complete repair follow classroom discussions.

This class has a prerequisite, the Fabrication and Damage Repair Phase 1 course, or equivalent practical and theoretical training and experience. HCS-T102


Three different parts will be repaired by each team of participants, with different materials and challenges within each repair scenario.

Programming “hot-bonders” to carry out these repairs is an integral part of this course as well. Our facility has many different types of “hot-bonders” to work with. The advantages of each will become familiar to the students as they have the opportunity to work with several of them individually throughout the week. Vacuum bagging of complex shapes is another challenge presented to students.




Key Lecture Elements

• Characteristics of Advanced Composite Materials

• Material Forms: dry cloth and wet resin vs. prepregs; weave styles

• Resin/Matrix Systems

Workshop Exercises

Multiple Repairs: Damaged area determination, damage removal, core removal, scarfi ng, including on curved surfaces, skin and core repair fabrication, use of wet resins and dry cloth for repairs, use of prepreg and fi lm adhesives for repairs.

Vacuum Bagging: Materials and processes, bleeder/breather schedules, avoiding bridging, leak checking, use of caul plates over repairs, placement and use of thermocouples.

Operation and programming of HEATCON® bonders: Cure cycles, ramp rates, alarm thresholds, times and temperatures, proper handling of alarm conditions during the cures, repair documentation. Use of thermocouples and vacuum ports, vacuum bagging with pleats to prevent crushing and bridging.

This five-day, on-site, course is designed for aircraft repair specialists who need to learn a great deal about the principles of repairing damaged composite aircraft structures. The course presumes the attendees have a strong aircraft sheet metal structural repair background, but perhaps have little experience with advanced composite aircraft structures. Repair techniques are taught in accordance with existing aircraft structural repair manuals, and all practice repairs conform to the practices in those manuals.

Hands on exercises are extensive, and students will work with fi berglass, Kevlar™, and carbon fi ber materials, as well as fi lm and past adhesives, Nomex® honeycomb and foam core materials. Both wet layup and prepreg repairs will be performed by the students, and vacuum bagging and the use of HEATCON® bonders will be an integral part of all workshop exercises.

This course is designed as an on-site combination of the Fabrication and Damage Repair Phase 1 and Phase 2 courses. The class assumes the students have knowledge of aircraft sheet metal

structural repair, and need to concentrate on more diffi cult and realistic Advanced Composite repair situations. It is designed for

those who will actually be performing or inspecting repairs.

HCS-T103

Advanced Composite StructuresFabrication and Damage Repair - Combo

“On-site Course”Phase I / Phase II combined

• Repair Principles

• Use of Adhesives

• Inspection Criteria

• Health and Safety Issues




Workshop Exercises

Damage removal and re-creation of precise surface contour geometry for fabrication of repair tooling

Fabrication of custom-fi tted repair tooling

Repair of damaged edge-band areas on composite panels

Multi-step repair of large-area-damage on a contoured com posite part

Curing repairs with various hot bonders and alternate heat-sources where applicable

Perform post-repair evalua tions of student projects

This course is designed as a follow-up to our Phase 2 fabrication and damage repair training. It is for the repair technician, lead, or supervisor who wants to further his or her education pertaining to repairs of composite structures. This

class presents more challenging damage assessment and repair situ ations than presented in our Phase 2 class which will certainly test the skills of the student. Experimentation with all aspects of composite structural repairs and processing

will be encouraged. Repair tooling is fabricated by the students as an integral part of the course.

• Advanced Damage Determination, Assessment, and Repair Techniques

• Materials and Process Options

• Recreating Surface Geometry Using Custom-Fabricated Repair Tooling

Key Lecture Elements• Repair to Potted Details

and Inserts

• Process Equipment and Applications

• Fastener Removal and Replacement

• Developing and Implementing a Repair Plan

This class is only being offered to students that have previously graduated from our Phase 2 training.

This class is primarily a hands-on composite structural repair workshop that addresses larger and more complex repair scenarios that require multi-step repair processes and repair tooling. The students will be subjected to realistic parts that have sustained damage to large areas or complex features that will require extensive evaluation and repair. Both wet lay up and prepreg materials and process options will be available to the students for use in performing their repairs.

Instruction will include the fabrication of composite repair tools in order to re-create the geometry of damaged contoured surfaces for restoring the critical aerodynamic surface of the part using a custom made caul plate. Other alternative approaches to tooling will be discussed and/or employed during the class to broaden the technician’s overall possibilities.

Repairs to composite edge-bands with fasteners/hole locations will also be addressed in this class. The methods for removal and replacement of fasteners and/or potted details in composite structures will be discussed including using the appropriate tools and techniques.

In addition, students will learn more about processing their repairs utilizing “hot-bonders” with heat blankets, heat lamps, hot-air machines, and other heating devices. The students will learn the capabilities as well as the limitations of the different process equipment available to them within the industry. On-going experimentation with thermocouple placement and different heat-source equipment will be encouraged so that a working knowledge of these systems can be attained.

HCS-T104





Workshop Exercises

Surface preparation of aluminum:Both acceptable and deliberately defi cient surface preparation techniques are applied to a number of aluminum panels

Use of the Boeing-developed and approved “PANTA” and “PACS” processes

Use of the new Boeing-developed“Sol-Gel” process

Aluminum lap joints and skin-to-core bonds will both be performed

Panels are bonded together using a selection of paste and fi lm adhesives and curing techniques

These components are then vacuum-bagged and the adhesives cured

Destructive testing will be performedon a selection of the resulting bonds, including the “wedge” test, and the failure modes will be analyzed

Repairs to damaged aluminum honeycomb sandwich panels with various confi gurations and curvatures will be accomplished as well

Key Lecture Elements

• Fundamentals of Structural Adhesives

• Various Methods for Surface Preparation of Aluminum

and Other Metals

• Bond Line Integrity, Thickness and Contamination Considerations

• Aluminum Honeycomb Core Material Types and Cleaning

• Repair of Damaged Aluminum Sandwich Structures

• Adhesive Cure Cycles

• Vacuum Bagging

• Destructive and Non-Destructive Testing

• Health and Safety Issues

A basic familiarity with sheet metal work and repair techniques is helpful, but not required.

The proper surface preparation of aluminum and aluminum honeycomb for structural adhesive bonding is a complex subject, with many differenttechniques and processes having been developed over the years. Some of these have proven to be defi cient after many years of service. Others have proven their long-term durability, but have signifi cant health and safety issues, as well as hazardous waste disposal problems. Newer techniques are available which mitigate many of these issues, but introduce additional complexities and process control issues of their own.

These processes are discussed extensively in this class, and the students will perform some of these

operations themselves in the process of building numerous test panels during the course of the week. Different surface preparation techniques, adhesives, and curing methods are all tried by the students, including some deliberately poor but commonly used surface preparation methods and deliberate contamination. These panels will be cured and tested to destruction to see the effects of these various items.

Various test methods will be used, and results analyzed and discussed. Most emphasis will be placed on newer techniques which not only give better results, but are in many ways more environmentally friendly, as well as easier to perform.

This course provides a solid foundation in the principles of adhesively bonded repairs in aluminum structures, including both lap joints and

face sheet bonding in sandwich structures with aluminum honeycomb cores. While these subjects are briefl y covered in our Adhesive

Bonding of Composites course, the emphasis in this course is on metallic structures only, and many more aluminum-specifi c surface

preparation and bonding methods are covered in detail here.

HCS-T131

Bonded Aluminum StructuresRepair - 5 days




Advanced Composite Structures: Fabrication and Damage Repair Phase 1The ‘Phase 1’ course is a prerequisite for both our repair and manufacturing course-programs and is highly recommended to anybody seeking a better understanding of advanced composites.

Advanced Composite Structures: Damage Repair - Phase 2The Phase 2 course is designed as a direct follow-on to our Phase 1 course for repair technicians, mechanics, supervisors, and quality assurance personnel directly involved in providing high performance repairs to advanced composite structures.

Advanced Composite Structures: Damage Repair - Phase 3Designed for the repair technician, lead, or supervisor who wants to further his or her education pertaining to repairs of composite structures, this class presents more chal-lenging damage assessment and repair situations than presented in our Phase 2 class, which will certainly test the skills of the student.

Mold Fabrication for Limited Production and RepairsWorking from an existing part or part model, fabricate a mold that allows for replication or short run part production.

Non Destructive Inspection Techniques for Technicians and Inpsectors This fi ve-day course is designed for the repair technician, fabricator, or inspector tasked with identifying and quantifying de-fects in new or damaged composite panels using the latest equipment, methods, and techniques.

Adhesive Bonding of Composites & Metals This fi ve-day course provides a foundation in the principles of producing reliable adhesively bonded joints in advanced composite and metallic structures.

Repair of Bonded Aluminum StructuresThis course provides a solid foundation in the principles of adhesively bonded repairs in aluminum structures, including both lap joints and face sheet bonding in sandwich structures with aluminum honeycomb cores.

Composite Manufacturing PracticesThis f ive-day class is designed for manufacturing engineers, planners, supervisors, technicians, fabricators or anyone who wants to broaden their knowledge of prepreg lay-up techniques and manufacturing methods utilizing oven or autoclave processing.

Advanced Composite Drawing InterpretationInterpreting engineering drawings can be complex when composite materials are used. This three-day course provides instruction in reading and interpreting technical drawings used in manufacturing, production, and repair of advanced composite products.

Resin Infusion TechnologiesResin Infusion is a specialized advanced composite manufacturing technique. This course will examine the building block principles and historical development of vacuum molding processes.

Advanced Composite Structures: Fabrication and Damage Repair “On-Site Only” CourseThis course is an “On-Site Only” combination course of Phases 1 & 2. See descriptions prior.

Rotor Blade Repair SkillsThis five day course will provide the knowledge and teach the skills necessary to effect quality helicopter rotor blade repairs in-house with a high degree of confi dence, and a shorter turn-around time.

ENGINEERING COURSESMechanics of Composite Laminates This course is designed for engineers who need to learn the fundamentals of laminate design and analysis. Students will design, fabricate, and perform structural testing on composite laminates. Results will be compared with predictions.

Aerospace Repair Analysis & SubstantiationThis course is specifi cally aimed at engineers responsible for the design analysis and substantiation of repairs to primary and secondary composite and adhesively bonded structures.

Composite Structural DesignThe Design of Composite Structures course has been developed specifi cally for civil, mechanical, structural and aeronautical engineers. Participants without engineering training in composite laminate design are strongly encouraged to take our Composite Laminate Design and Analysis course as a prerequisite.

Composite Joint AnalysisThis fi ve-day course gives participants an understanding of the unique requirements for mechanically fastening of composite structures, and how to design adhesively bonded joints for full load transfer and longevity.

Understanding Composite Materials and Structures for Technical ManagersThis trhee day course has been developed to provide technical managers with a broad, but comprehensive understanding of composite materials, detailing specifi c issues related to the use of composites in structures and component design, manufacture, and “in-service” operation.

Advanced Stress Analysis Methods for CompositesThis course is designed as the next step for the composite structures engineer that wants to further his or her ability to analyze a composite structure as a whole, without having to rely solely on FEA software.

Structural Engineering for Composite RepairThis fi ve-day course is specifi cally aimed at engineers who are responsible for the design development of both temporary and permanent repairs to primary and secondary composite structures.

Advanced Composite CoursesCourse Descriptions




2011 Course ScheduleComposite Structures: Fabrication and Damage Repair - Phase 1 - 5 Days HCS-T101Reno, Nevada Facility

2011 May 2 - 6 Jun 6 - 10 Jul 11-15 Aug 8 - 12 Sep 26 - 30 Oct 17 - 21Griffi n, Georgia Facility

2011 May 9 - 13 Jun 13 - 17 Jul 18 - 22 Aug 15 - 19 Sep 26 - 30 Oct 31 - Nov 4Oxfordshire - Heatcon Abaris UK Facility

2011 Jul 18 - 22 Sep 26 - 30 Nov 28 - Dec 2

Advanced Composite Structures: Damage Repair - Phase 2 - 5 Days HCS-T102Reno, Nevada Facility

2011 May 9 - 13 Jun 13 - 17 Jul 18 - 22 Aug 15 - 19 Oct 3 - 7 Oct 24 - 28Griffi n, Georgia Facility

2011 May 16 - 20 Jun 20 - 24 Jul 25 - 29 Aug 22 - 26 Oct 3 - 7 Nov 7 - 11Oxfordshire - Heatcon Abaris UK Facility

2011 Jul 25 -29 Oct 3 - 7 Dec 5 - 9

Composite Structures: Fabrication and Damage Repair - Combo - 5 Days HCS-T103“On-Site Only” Contact your HEATCON® Representative for all the details

Advanced Composite Structures: Damage Repair - Phase 3 - 5 Days HCS-T104Reno, Nevada Facility

2011 Jun 20 - 24 Oct 10 - 14 Dec 19 - 23Griffi n, Georgia Facility

2011 Aug 1 - 5 Oct 10 - 14 Dec 19 - 23Oxfordshire - Heatcon Abaris UK Facility

2011 Aug 1 - 5 Oct 10 - 14 Dec 12 - 16

Mold Fabrication for Limited Production and Repairs - 5 Days HCS-T111Reno, Nevada Facility

2011 Aug 22 - 26 Dec 12 - 16

Adhesive Bonding of Composites & Metals - 5 Days HCS-T121Reno, Nevada Facility

2011 Jun 27 - Jul 1

Repair of Bonded Aluminum Structures - 5 Days HCS-T131Reno, Nevada Facility2011 Nov 14 - 18

Griffi n, Georgia Facility2011 Oct 17 - 21

Composite Manufacturing Practices - 5 Days HCS-T141Reno, Nevada Facility

2011 May 16 - 20

Advanced Composite Courses




2011 Course ScheduleAdvanced Composite Drawing Interpretation - 3 Days HCS-T151Reno, Nevada Facility

2011 Jul 6 - 8

Resin Infusion - 5 Days HCS-T171Reno, Nevada Facility

2011 Jul 25 - 29

Non Destructive Inpection Techniques fo Technicians and Inspectors - 5 Days HCS-T162

Reno, Nevada Facility2011 Jul 25 - 29 Oct 31 - Nov 4

Rotor Blade Repair Skills - 5 Days HCS-T182Reno, Nevada Facility

2011 Sep 19 - 23

ENGINEERING COURSESMechanics of Composite Laminates - 5 Days HCS-T201Reno, Nevada Facility

2011 Sep 12 - 16

Aerospace Repair Analysis and Substantiation - 5 Days HCS-T211Reno, Nevada Facility

2011 Aug 15 - 19

Composite Structural Design - 5 Days HCS-T221Reno, Nevada Facility

2011 Sep 19 - 23

Composite Joint Analysis - 5 Days HCS-T222Reno, Nevada Facility

2011 Sep 26 - 30

Advanced Stress Analysis Methods for Composites - 5 Days HCS-T223Reno, Nevada Facility

2011 May 16 - 20 Oct 3 - 7

Understanding Composite Materials and Structures for Technical Managers - 3 Days HCS-T224

Reno, Nevada Facility2011 Jun 21 - 23 Nov 8 - 10

Structural Engineering for Composite Repair - 5 Days HCS-T225Reno, Nevada Facility

2011 Jun 13 - 17 Oct 31 - Nov 4

Advanced Composite Courses




Training MaterialsPart Number Description Unit of Measure

HCS2217 Potting Compound, EY3804 QT

HCS2217-9390 Compound, EA 9390 QT

HCS2217-946 EPOCAST® 50A/946 QT

HCS2217-9816 EPOCAST® 50A/9816 QT

HCS2218-01-GAL Structural Primer, EC 3960 GAL

HONEYCALUM Al Honeycomb 25in x 25in x 0.44in (63.5cm x 63.5cm x 1.11cm) LB

HCS2213-250/350-RL Core Splice Adhesive RL

HCS2214-250 Kevlar™ Prepreg, 250°F (121°C) Cure YD

HCS2214-350 Kevlar™ Prepreg, 350°F (177°C) Cure YD

HCS2212-250-168 Carbon Prepreg, 250°F (121°C) Cure YD

HCS2212-350-212/-256 Carbon Prepreg, 350°F (177°C) Cure YD

HCS2216-250-101/-129 Film Adhesive, 250°F (121°C) Cure YD

HCS2216-350-145/-154 Film Adhesive, 350°F (177°C) Cure YD

HONEYCNMX-2 Nomex® Honeycomb 0.725in (18.41mm) Thick, 0.125in (3.175mm) LB

HONEYCNMX-3 Nomex® Honeycomb 0.930in (23.62mm) Thick, 0.25in (6.35mm) LB

HONEYCNMX-4 Nomex® Honeycomb 0.375in (3.95mm) Thick, 0.125in (3.175mm) SHT

MXB7620/1597 Fiberglass Tooling Prepreg Carbon Tooling Prepreg SHT

MXB7620/2577 Carbon Tooling Prepreg SHT

HCS2210-250-120/-1581/-7781 Fiberglass Prepreg, 250°F (121°C) Cure YD

HCS2210-350-120/-1581/-7781 Fiberglass Prepreg, 350°F (177°C) Cure YD

Technical ServicesAvailable Training Materials




Military and GovernmentNational Stock Numbers

ITEM PART NUMBER /NSN NOMENCLATURE DESCRIPTION U/I1

EA9390

4130-01-471-6414LAMINATING RESIN

Physical FormUnit PackageQuantity in PackageBasic MaterialSeperate CatalystMix Ratio

Pot LifeShelf Life

Spec Ref

LiquidQt Kit1 KitEpoxy Laminating ResinYesComponent A 100PBWComponent B 56PBW 2 Hours12 Months at 40ºF (4.44°C) or below6 Months at 41ºF (5°C) to 77ºF (25°C)BMS8-301

1

2

HCS2520-01

4130-01-471-6416KIT, FIBERGLASS

Kit Contents: 1Dry Fiberglass cloth MIL-C-9084 TY 8B CL1&2Bagging Film, Green 400º FBreather/Bleeder Cloth 4ozVacuum Bag Sealant TapePeel Ply White NylonPorous Tefl on Rel. ClothNonporous Tefl on Rel. ClothFlash Tape, 1in X 72Yds

5 Yards (4.57m)

4 Yards (3.66m)2 Yards (1.83m)5 RL2 Yards (1.83m)2 Yards (1.83m)2 Yards (1.83m)1 RL

3 HCS2010-01

4130-01-471-6417

THERMOCOUPLEASSEMBLY

Thermocouple assembly with plug; 24 GA, Type J, with Kapton® Coated wire

1

4 HCS2026-01

4130-01-471-6421

VACUUM PUMP ASSEMBLY

Integrated vacuum pump assy. w/sniffer. Creates vacuum through shop air source. Used on vacuum bagging applications in conjunction with composite repairs

1

5 HCS1418

4130-01-471-6428VACUUM PROBE

Through bag vacuum probe. Machined aluminum w/ threads for fi tting installation. 1/4 turn installation w/ wrench fl ats

1

6 HCS1402

4130-01-471-6432

MALE DISCONNECT-VACUUM

Used on the through bag connector for vacuum line connection. 1/4 NTP threads

1

7 HCS2015-054130-01-471-6433

VACUUM HOSE W/VACUUM PROBE

ASSEMBLY

10ft (3.05m) long, high-termperature stainless steel braid vacuum hose w/ quick release fi ttings and vacuum probe assembly

1

8 HCS2030

4130-01-471-6434THERMOWELDER

Used to weld thermocouple assemblies available in 120 or 240V, 50/60Hz. Dimensions: 10in x 15in x 6in (25.4cm x 38.1cm x 15.24cm)

1






HCS2055-024130-01-471-6437

HCS2055-044130-01-471-6444

VACUUM PUMP, ELECTRIC, W/ CASE-

PORTABLE

Part description: electric vacuum pump capable of delivering 28+Hg at 1 SCFM volume per minute. power switch, fush, and built in vacuum guage. Case has storage for other vacuum assys. Available in 120 or 240 Volt 50/60 Hg

Dimensions: 24in x 15in x 9in (60.96cm x 38.1cm x 22.86cm)

1

10

HCS9000

4920-01-462-4658

COMPOSITE REPAIR SET

HOT BONDER/ CONTROLLERSINGLE ZONE

Self contained, single zone, composite repair set, automatic management of heat blanket temperature (F or C). Adjustable vacuum level in/Hg or MB. Electroluminescent display screen, 16-Key Keytpad, 10 thermocouple inputs, stores 30 curing programs, audible and visual alarms, with printer

1

11

HCS9200

4920-01-462-4666

HOT BONDER/ CONTROLLER

DUAL ZONE

Self contained, dual zone, composite repair set. Automatic management of heat blanket temperature (F or C). Adjustable vacuum level (in/Hg, MB, KPA). Electroluminescent display screen, 16-Key keypad, 10 thermocouple inputs, stores 30 curing programs, audible and visual alarms, with printer

1

12

HCS9000FL

4920-01-462-4673

HOT BONDER/ CONTROLLERSINGLE ZONE,

FLIGHTLINE

Self contained, single zone, composite repair set for Class 1, Div. 2, Hazardous Environment use. Automatic management of heat blanket temperature (F or C). Adjustable vacuum level (in/Hg, MB, KPA). Electroluminescent display screen, 16-Key keypad, 10 thermocouple inputs, stores 30 curing programs, audible and visual alarms, with printer. Provided with seperate lockable, impact resistant accessory storage case with hinged removable lid and inside compartment divider

1

13

HCS9200FL

4920-01-462-4675

HOT BONDER/ CONTROLLERDUAL ZONE, FLIGHTLINE

Self contained, dual zone, composite repair set for Class 1, Div. 2, Hazardous Environment use. Automatic management of heat blanket temperature (F or C). Adjustable vacuum level (in/Hg, MB, KPA). Electroluminescent display screen, 16-Key keypad, 10 thermocouple inputs, stores 30 curing programs, audible and visual alarms, with printer. Provided with seperate lockable, impact resistant accessory storage case with hinged removable lid and inside compartment divider

1






HCS2000-07

4920-01-462-4701

ACCESSORY KIT, 120 VAC HEAT BLAN-KETS HAZARDOUS

ENVIRONMENT

Assortment of heat blankets for use with hot bonder/controller P/N HCS9000FL and HCS9002FL with 120 VAC Input. Each blanket has hazardous environment supervisory circuitry and arc suppression type connectors.

1

1 EA1 EA1 EA 1 EA

8in (20.32cm) round blanket10in (25.4cm) round blanket12in x 12in (30.48cm x 30.48cm) blanket8in x 18in (20.32cm x 45.72cm) blanket

15

HCS2041-01

4920-01-462-4759

HOT AIR CURING SYSTEM, PORTABLE,

120VAC

Portable hot air generator with internal electrical heating coil, pressure reducer/airfl ow intensifi er and delivery diffuser for use on irregular shpaed composite structures. Utilizes dry, oil-free shop air at 80-100psi, 4-8CFM. Adjustable pressure regulator, internal high limit cutoff switch. Produces temperatures up to 350°F (176.66°C). Use with hot bonder/controller to monitor and control

1

16

HCS2041-02

4920-01-462-4768

HOT AIR CURING SYSTEM, PORTABLE

240VAC

Portable hot air generator with internal electrical heating coil, pressure reducer/airfl ow intensifi er and delivery diffuser for use on irregular shpaed composite structures. Utilizes dry, oil-free shop air at 80-100psi, 4-8CFM. Adjustable pressure regulator, internal high limit cutoff switch. Produces temperatures up to 350°F (176.66°C). Use with hot bonder/controller to monitor and control

1

17

HCS9200M-04

4920-01-588-4308RN


DUAL ZONE

Self contained, dual voltage (120/240), microprocessor controlled and monitored, electrical heating, dual zone composite repair system with ten thermocouple sensor inputs per zone. It contains an internal electrical vacuum pump and venturi pumps in each zone. The controller is certifi ed for Hazardous Environment, Low temperature (14F) and High Temperature (140F) Operations per Mil-Std-810F.

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18 HCS9200B-FLM

4920-01-586-9342


DUAL ZONE

Bonder, Dual Zone, Flightline, 30-Amps per zone, 10 TC per zone, USB Data port, Software confi gured per Military specifi cation, Custom data tags with NSN

1

Documents

HEATCON - Sumincol CATALOGUE.pdfMaterials HEATCON AS9100 and ISO 9001:2008 Certified COMPOSITE SYSTEMS COMPOSITE REPAIR SOLUTIONS ® training equipMent PRODUCT CATALOG accessories