ThermexWELD
Exothermic Welding
Training Guide
BASIC EARTHING / GROUNDING
CONNECTIONS
ThermexWELD
Exothermic Welding
Training Guide
• How to make the
BEST ELECTRICAL
CONNECTION
available using the
ThermexWELD
Exothermic Welding
System.
ThermexWELD
Exothermic Welding
Training Guide
• How to use the
product.
• How to make the
best electrical
connection.
• Safety TIPS.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
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
ThermexWELD
Exothermic Welding
Training Guide
• 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.
ThermexWELD
Exothermic Welding
Training Guide
• MOULD TAG
• Shows:
– ThermexWELD
Mould Code
– Weld Metal Size
– Cable Run
– Cable Tap
– Gap
ThermexWELD
Exothermic Welding
Training Guide
• Weld Metal Size on
the tag MUST match
the Weld Metal Size
on the Box.
ThermexWELD
Exothermic Welding
Training Guide
• Conductor Sizes:
– Run
– Tap
are shown on the mould
tag.
e.g. Run:70 sq mm
Tap: 25 x 3 mm
OR
Run: 1/0
Tap: 5/8” Earth Rod
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• GAP continued,
– No gap, the cables
MUST be placed in
the CENTRE of the
TAP HOLE.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• Place the Mould
Handle into the
Mould making sure
that the clamp
closes “firmly”.
ThermexWELD
Exothermic Welding
Training Guide
• If mould does:
– not close fully
OR
– the mould handle
pressure is too tight
then ---------
ThermexWELD
Exothermic Welding
Training Guide
• Mould Handle
adjustment:
– Withdraw the R Clip
in the mechanism.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• Mould Clamp
adjustment
continued:
– After adjustment recheck the handle
pressure – a “firm
click” to close.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
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
ThermexWELD
Exothermic Welding
Training Guide
• Place conductors in
mould.
– Note mould clamp
open.
– Once conductors are
in the CENTRE of
the TAP HOLE close
mould handle.
ThermexWELD
Exothermic Welding
Training Guide
• Conductor Set-up:
– Note conductors to
be joined are
CENTRAL in the
TAP HOLE.
ThermexWELD
Exothermic Welding
Training Guide
• Mould Set-up:
– Check mould closure
line.
– Mould must close
neatly.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• ThermexWELD
Metal
– Each box contains:
•
•
•
•
•
10 weld metals
2 starter containers
10 discs
1 measuring spoon
instructions
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• Weld Metal Starter:
– Close container and
– Shake the container
to FULLY mix the
starter ingredients.
ThermexWELD
Exothermic Welding
Training Guide
• Metal Disc:
– Place 1 metal disc to
cover the tap hole.
• Check: that the
pointed side is down.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• Starter:
– Take 1 HEAPED
spoon of the mixed
starter material.
• Safety: Close starter
container and store
safely.
ThermexWELD
Exothermic Welding
Training Guide
• Starter:
– ½ of spoon of starter
powder placed on
top of weld metal.
ThermexWELD
Exothermic Welding
Training Guide
• Starter:
– Place about HALF
of the LEVEL spoon
of STARTER on
weld metal and the
remainder in the
mould cap cup.
ThermexWELD
Exothermic Welding
Training Guide
• STARTER:
– Starter powder in
cover cup.
ThermexWELD
Exothermic Welding
Training Guide
• STARTING
– Use the T-805 Flint
Igniter
ThermexWELD
Exothermic Welding
Training Guide
• STARTING
– Use the T-807 Hand
Held Spark Igniter
ThermexWELD
Exothermic Welding
Training Guide
• STARTING
– Use the T-807 Hand
Held Spark Igniter
– Electrodes must
contact the start
powder (NOT the
cap).
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• Mould Opening:
– Open the mould to
reveal the
Connection.
• Safety: Beware of hot
items.
ThermexWELD
Exothermic Welding
Training Guide
• ThermexWELD
Exothermic
Connection.
– Note:
• Good shape
• Clean
• Safety: Beware of hot
items.
ThermexWELD
Exothermic Welding
Training Guide
Mould Crucible:
– Clean slag from crucible
with Crucible Scraper
from Tool Kit.
– Use Soft Brush to finally
clean Crucible.
– Clean the mould after
EVERY weld.
• Safety: Beware of hot
items.
ThermexWELD
Exothermic Welding
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.
• Safety: Beware of hot
items.
ThermexWELD
Exothermic Welding
Training Guide
• Mould:
– Is now ready to be
used again.
– Properly maintained
moulds will last for
75 to 80
connections.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• Flat Tape
Connection:
– ThermexWELD Type
FF2
ThermexWELD
Exothermic Welding
Training Guide
• Flat Tape
Connection:
– ThermexWELD Type
FF3
ThermexWELD
Exothermic Welding
Training Guide
• Earth Mat
– Manufactured from
25mm x 3 mm
copper tape with all
joints
ThermexWELD
Exothermically
Welded.
ThermexWELD
Exothermic Welding
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.
ThermexWELD
Exothermic Welding
Training Guide
• ThermexWELD
Connection:
– Type FE2
– 70 mm x 1 mm
copper tape to 5/8”
earth rod.
ThermexWELD
Exothermic Welding
Training Guide
• ThermexWELD
Connection:
– Type SS4
– 1/0 solid to 1/0 solid
copper conductors.
ThermexWELD
Exothermic Welding
Training Guide
• ThermexWELD
Connection:
– Type SF3
– 1/0 solid to 70 mm x
1 mm flat copper
tape.
ThermexWELD
Exothermic Welding
Training Guide
• ThermexWELD
Connection:
– Type SE2
– 2/0 stranded cable to
5/8” UNC earth rod.
ThermexWELD
Exothermic Welding
Training Guide
• Qualified:
– You have qualified to
make the BEST
electrical connection.
– Follow these
instructions step by
step.
ThermexWELD
Exothermic Welding
Training Guide
• ThermexWELD
Exothermically
Welded Joints:
–
–
–
–
Can be used on:
Copper to Copper
Copper to Steel
Copper to Copper
Jacket Earth Rods
– Copper to Pipes
– Etc
ThermexWELD
Exothermic Welding
Training Guide
• For “USER & INSPECTORS GUIDE”
ask to see ThermexWELD presentation.
• See website www.lectrotech.co.za for a
full catalogue.