ThermexWELD Exothermic Welding Training Guide BASIC EARTHING / GROUNDING CONNECTIONS.

ThermexWELDExothermic Welding

Training Guide

BASIC EARTHING / GROUNDING

CONNECTIONS


Training Guide

• How to make the BEST ELECTRICAL CONNECTION available using the ThermexWELD Exothermic Welding System.


Training Guide• How to use the

product.

• How to make the best electrical connection.

• Safety TIPS.


Training Guide• SAFETY:

– Observe all local/plant safety regulations.– MSDS (Material Safety Data Sheets) are

available.– The welding process has an open flame and

creates hot materials, caution must be taken.– Follow this training guide.GENERAL:– ThermexWELD Exothermic products are

designed to work as a system and they may not necessarily be compatible with other manufacturer’s products.


Training Guide• Section Through an

“X” connection:– It is metallurgically

fused.– It is electrically

continuous.– It is permanent.– It will carry more

current than the conductors.

– It will not:• Loosen• Corrode• Fuse

• The basic ThermexWELD Exothermic Welding Kit contains tools that can be used with most connection types.

• On bigger conductors a larger mould is needed. A larger mould handle will also be needed.

• Accessories are required with special connection types and these are ordered separately.


Training Guide


Training Guide• MOULD TAG• Shows:

– ThermexWELD Mould Code

– Weld Metal Size– Cable Run– Cable Tap– Gap


Training Guide

• Weld Metal Size on the tag MUST match the Weld Metal Size on the Box.


Training Guide• Conductor Sizes:

– Run – Tapare shown on the mould

tag.

e.g. Run:70 sq mmTap: 25 x 3 mmORRun: 1/0Tap: 5/8” Earth Rod


Training Guide• GAP:

– Small cables usually do not require a gap.

– Larger cables are set with a gap.

• The GAP between the cables will allow the weld metal to melt the faces.


Training Guide• GAP continued,

– No gap, the cables MUST be placed in the CENTRE of the TAP HOLE.


Training Guide• Gap continued,

– When a gap is specified, set this in the CENTRE of the TAP HOLE using a ROD of the specified diameter.


Training Guide• Place the Mould

Handle into the Mould making sure that the clamp closes “firmly”.


Training Guide

• If mould does:– not close fully OR – the mould handle

pressure is too tight then ---------


Training Guide

• Mould Handle adjustment:– Withdraw the R

Clip in the mechanism.


Training Guide• Mould Handle

adjustment continued:– Screw the adjusting

screw out 1 turn to make the closing “firmer”

OR– 1 turn in to make the

closing “softer”

– Re-assemble and check mould closure.


Training Guide• Mould Clamp

adjustment continued:– After adjustment

re-check the handle pressure – a “firm click” to close.


Training Guide• Mould Preparation:

– Heat mould for first use each day.

– Mould must be heated such that ALL moisture will be driven off.

• Safety: Rapid heating of the moisture in the mould or conductors (during welding) can be dangerous.


Training Guide• Conductor

preparation:– Clean conductors with

wire brush provided in Tool Kit.

– Ensure cables are:• Free of OIL - use

solvent to remove• Free of MOISTURE -

use heat to remove– and always clean

with wire brush before placing in mould


Training Guide

• Place conductors in mould.– Note mould clamp

open.– Once conductors

are in the CENTRE of the TAP HOLE close mould handle.


Training Guide

• Conductor Set-up:– Note conductors

to be joined are CENTRAL in the TAP HOLE.


Training Guide• Mould Set-up:

– Check mould closure line.

– Mould must close neatly.


Training Guide• Cable Opening:

– Use DX Seal around the cable to seal if the mould cable opening has worn.

• Note:• DX seal is NOT to

be used inside of the mould.

• DX seal is NOT for making smaller conductor inlets.


Training Guide• Mould Set-up:• Tip!

– Note stray strands of wire in closing line of mould.

– Reset the cable such that the mould closes properly.


Training Guide• ThermexWELD

Metal– Each box

contains:• 10 weld metals• 2 starter

containers• 10 discs• 1 measuring spoon• instructions


Training Guide• Starter:

– Carefully pour the FULL contents of the BLACK container into the RED container.

– Close the RED container.

– Shake the RED container to mix the ingredients.


Training Guide• Weld Metal

Starter:– Close container

and– Shake the

container to FULLY mix the starter ingredients.


Training Guide• Metal Disc:

– Place 1 metal disc to cover the tap hole.

• Check: that the pointed side is down.


Training Guide• Metal Disc:

– Note: metal disc with the pointed side downwards.

– The metal disc retains the weld metal in the crucible.

– It melts at the correct time to allow the molten copper to flow down the tap hole and across the conductors.


Training Guide• Weld Metal:

– Carefully pour the full contents of the weld metal into the crucible.

– NOTE: pour slowly so as not to dislodge the metal disc.



– Take 1 HEAPED spoon of the mixed starter material.

• Safety: Close starter container and store safely.



– ½ of spoon of starter powder placed on top of weld metal.



– Place about HALF of the LEVEL spoon of STARTER on weld metal and the remainder in the mould cap cup.


Training Guide• STARTER:

– Starter powder in cover cup.


Training Guide• STARTING

– Use the T-805 Flint Igniter



– Use the T-807 Hand Held Spark Igniter



– Use the T-807 Hand Held Spark Igniter

– Electrodes must contact the start powder (NOT the cap).


Training Guide• Weld Metal Reaction:

– The weld metal is ignited by the Starter Powder.

– The flame is retained by the Cover.

– The EXOTHERMIC reaction takes place making molten copper.

– The copper burns the metal disc.

– The copper flows down the tap hole.

– The conductors are fused together.


Training Guide• Exothermic

Reaction:– Allow 30 seconds

after the reaction.– Open Cover.

• Note: Slag in the crucible and tap hole.

• Safety: Beware of hot items.


Training Guide• Mould Opening:

– Open the mould to reveal the Connection.



Training Guide

• ThermexWELD Exothermic Connection.– Note:

• Good shape• Clean• Safety: Beware of

hot items.


Training GuideMould Crucible:

– Clean slag from crucible with Crucible Scraper from Tool Kit.

– Use Soft Brush to finally clean Crucible.

– Clean the mould after EVERY weld.



Training Guide• Mould:

– Clean the mould weld cavity with a SOFT BRUSH ONLY from the KIT.

– Clean the mould after EVERY weld.

– Do NOT use sharp articles to clean the internals of the mould.



Training Guide

• Mould:– Is now ready to be

used again.– Properly

maintained moulds will last for 75 to 80 connections.


Training Guide• Earth Rod

Connection:– Use the T-241

clamp supplied in the Kit on ALL Earth Rod connections.

– This clamps holds the mould in place during the welding/exothermic reaction.


Training Guide• T-421 Earth Rod

Clamp:– Fasten the T-421

clamp onto the earth rod below the mould such that the mould RESTS on the clamp.

– This clamps holds the mould in place during the welding/exothermic reaction.

– Proceed with welding as already instructed.


Training Guide

• Flat Tape Connection:– ThermexWELD

Type FF2


Training Guide

• Flat Tape Connection:– ThermexWELD

Type FF3


Training Guide

• Earth Mat– Manufactured

from 25mm x 3 mm copper tape with all joints ThermexWELD Exothermically Welded.


Training Guide• Earth Mat for touch

& step potential protection.– Manufactured from

70 sqmm bare copper earth wire using ThermexWELD Type SS2 & SS3 exothermically welded connections.



Connection:– Type FE2– 70 mm x 1 mm

copper tape to 5/8” earth rod.


Training Guide

• ThermexWELD Connection:– Type SS4– 1/0 solid to 1/0

solid copper conductors.


Training Guide

• ThermexWELD Connection:– Type SF3– 1/0 solid to 70 mm

x 1 mm flat copper tape.



Connection:– Type SE2– 2/0 stranded cable

to 5/8” UNC earth rod.


Training Guide• Qualified:

– You have qualified to make the BEST electrical connection.

– Follow these instructions step by step.



Exothermically Welded Joints:– Can be used on:– Copper to Copper– Copper to Steel– Copper to Copper

Jacket Earth Rods– Copper to Pipes– Etc


Training Guide• For “USER & INSPECTORS GUIDE”

ask to see ThermexWELD presentation.

• See website www.lectrotech.co.za for a full catalogue.

ThermexWELD Exothermic Welding Training Guide BASIC EARTHING / GROUNDING CONNECTIONS.

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Transcript of ThermexWELD Exothermic Welding Training Guide BASIC EARTHING / GROUNDING CONNECTIONS.