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ThermexWELD Exothermic Welding Training Guide

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.

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ThermexWELD Exothermic Welding Training Guide

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  1. ThermexWELDExothermic WeldingTraining Guide BASIC EARTHING / GROUNDING CONNECTIONS

  2. ThermexWELDExothermic WeldingTraining Guide • How to make the BEST ELECTRICAL CONNECTION available using the ThermexWELD Exothermic Welding System.

  3. ThermexWELDExothermic WeldingTraining Guide • How to use the product. • How to make the best electrical connection. • Safety TIPS.

  4. ThermexWELDExothermic WeldingTraining 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.

  5. ThermexWELDExothermic WeldingTraining 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

  6. ThermexWELDExothermic WeldingTraining 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.

  7. ThermexWELDExothermic WeldingTraining Guide • MOULD TAG • Shows: • ThermexWELD Mould Code • Weld Metal Size • Cable Run • Cable Tap • Gap

  8. ThermexWELDExothermic WeldingTraining Guide • Weld Metal Size on the tag MUST match the Weld Metal Size on the Box.

  9. ThermexWELDExothermic WeldingTraining 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

  10. ThermexWELDExothermic WeldingTraining 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.

  11. ThermexWELDExothermic WeldingTraining Guide • GAP continued, • No gap, the cables MUST be placed in the CENTRE of the TAP HOLE.

  12. ThermexWELDExothermic WeldingTraining Guide • Gap continued, • When a gap is specified, set this in the CENTRE of the TAP HOLE using a ROD of the specified diameter.

  13. ThermexWELDExothermic WeldingTraining Guide • Place the Mould Handle into the Mould making sure that the clamp closes “firmly”.

  14. ThermexWELDExothermic WeldingTraining Guide • If mould does: • not close fully OR • the mould handle pressure is too tight then ---------

  15. ThermexWELDExothermic WeldingTraining Guide • Mould Handle adjustment: • Withdraw the R Clip in the mechanism.

  16. ThermexWELDExothermic WeldingTraining 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.

  17. ThermexWELDExothermic WeldingTraining Guide • Mould Clamp adjustment continued: • After adjustment re-check the handle pressure – a “firm click” to close.

  18. ThermexWELDExothermic WeldingTraining 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.

  19. ThermexWELDExothermic WeldingTraining 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

  20. ThermexWELDExothermic WeldingTraining Guide • Place conductors in mould. • Note mould clamp open. • Once conductors are in the CENTRE of the TAP HOLE close mould handle.

  21. ThermexWELDExothermic WeldingTraining Guide • Conductor Set-up: • Note conductors to be joined are CENTRAL in the TAP HOLE.

  22. ThermexWELDExothermic WeldingTraining Guide • Mould Set-up: • Check mould closure line. • Mould must close neatly.

  23. ThermexWELDExothermic WeldingTraining 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.

  24. ThermexWELDExothermic WeldingTraining Guide • Mould Set-up: • Tip! • Note stray strands of wire in closing line of mould. • Reset the cable such that the mould closes properly.

  25. ThermexWELDExothermic WeldingTraining Guide • ThermexWELD Metal • Each box contains: • 10 weld metals • 2 starter containers • 10 discs • 1 measuring spoon • instructions

  26. ThermexWELDExothermic WeldingTraining 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.

  27. ThermexWELDExothermic WeldingTraining Guide • Weld Metal Starter: • Close container and • Shake the container to FULLY mix the starter ingredients.

  28. ThermexWELDExothermic WeldingTraining Guide • Metal Disc: • Place 1 metal disc to cover the tap hole. • Check: that the pointed side is down.

  29. ThermexWELDExothermic WeldingTraining 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.

  30. ThermexWELDExothermic WeldingTraining 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.

  31. ThermexWELDExothermic WeldingTraining Guide • Starter: • Take 1 HEAPED spoon of the mixed starter material. • Safety: Close starter container and store safely.

  32. ThermexWELDExothermic WeldingTraining Guide • Starter: • ½ of spoon of starter powder placed on top of weld metal.

  33. ThermexWELDExothermic WeldingTraining Guide • Starter: • Place about HALF of the LEVEL spoon of STARTER on weld metal and the remainder in the mould cap cup.

  34. ThermexWELDExothermic WeldingTraining Guide • STARTER: • Starter powder in cover cup.

  35. ThermexWELDExothermic WeldingTraining Guide • STARTING • Use the T-805 Flint Igniter

  36. ThermexWELDExothermic WeldingTraining Guide • STARTING • Use the T-807 Hand Held Spark Igniter

  37. ThermexWELDExothermic WeldingTraining Guide • STARTING • Use the T-807 Hand Held Spark Igniter • Electrodes must contact the start powder (NOT the cap).

  38. ThermexWELDExothermic WeldingTraining 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.

  39. ThermexWELDExothermic WeldingTraining Guide • Exothermic Reaction: • Allow 30 seconds after the reaction. • Open Cover. • Note: Slag in the crucible and tap hole. • Safety: Beware of hot items.

  40. ThermexWELDExothermic WeldingTraining Guide • Mould Opening: • Open the mould to reveal the Connection. • Safety: Beware of hot items.

  41. ThermexWELDExothermic WeldingTraining Guide • ThermexWELD Exothermic Connection. • Note: • Good shape • Clean • Safety: Beware of hot items.

  42. ThermexWELDExothermic WeldingTraining 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.

  43. ThermexWELDExothermic WeldingTraining 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.

  44. ThermexWELDExothermic WeldingTraining Guide • Mould: • Is now ready to be used again. • Properly maintained moulds will last for 75 to 80 connections.

  45. ThermexWELDExothermic WeldingTraining 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.

  46. ThermexWELDExothermic WeldingTraining 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.

  47. ThermexWELDExothermic WeldingTraining Guide • Flat Tape Connection: • ThermexWELD Type FF2

  48. ThermexWELDExothermic WeldingTraining Guide • Flat Tape Connection: • ThermexWELD Type FF3

  49. ThermexWELDExothermic WeldingTraining Guide • Earth Mat • Manufactured from 25mm x 3 mm copper tape with all joints ThermexWELD Exothermically Welded.

  50. ThermexWELDExothermic WeldingTraining Guide • Earth Mat for touch & step potential protection. • Manufactured from 70 sqmm bare copper earth wire using ThermexWELD Type SS2 & SS3 exothermically welded connections.

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