Product57_file1_0_product Pages - Harger_.pdf

Safety and Protection Exothermic Process The Exothermic Process is an effective and safe method of welding copper to copper or copper to steel for the purpose of producing permanent electrical connections. Exothermically welded connections are produced from the energy and molten copper metal liberated from an exothermic reaction between powdered copper oxide and aluminum. The exothermic reaction takes place at a theoretical temperature of 4600°F and as a result, molten copper alloy is created and used to melt the conductors and cast the finished connection. The exothermic reaction takes place in a semi-permanent graphite mold that will last 50 or more welds if properly cared for. The process is simple and easy to implement providing an on-site means to make welded electrical connections without requiring external power, equipment or the special training usually required for brazing and welding. The process will provide a finished connection that will never corrode, loosen or increase in resistance. The finished connection also provides an ampacity that exceeds that of the conductors being joined.

Application – Connections • Cable to cable • Cable to ground rod • Ground rod to ground rod • Cable to steel surface / pipe • Cable to lug • Cable to busbar • Busbar to busbar • Busbar to ground rod • Busbar to steel surface • Cable to rebar • Cable to rail • Equipment ground plate • Aircraft ground receptacle

UltraWeld Pour & Shoot Process

UltraShot Drop-In Process

Step 1: • Clean and dry conductors and mold • Insert conductors into mold

Step 1 • Clean and dry conductors and mold • Insert conductors into mold

Step 2: • Close handle clamp and lock mold • Insert disk into mold

Step 2 • Close handle clamp and lock mold • Insert UltraShot™ drop-in into mold

Step 3: • Pour weld metal into mold

Step 3 • Attach cord to UltraShot™ igniter

Step 4:

Step 4 • Push and hold both igniter buttons at the same time

• Sprinkle starting material over the weld metal and close lid • Sprinkle remaining starting material in the ignition pocket on the top of the TOP-LIGHT lid Step 5: • Ignite using the FLTIG flint igniter

Step 5

Step 6:

A completed UltraShot™ connection

• Reaction is made • Open mold and remove connection • Remove slag before next connection

• After reaction is complete, open the mold and remove the connection • Remove slag from the mold before making the next connection

A complete Ultraweld connection

Materials, Tools & Accessories UltraShot Controller • Patented copper drop-in cartridge consumed during the reaction process. • Rugged long lasting 12-volt rechargeable battery control unit ignites hundreds of connections on a single charge. • Cartridge is consumed leaving no waste such as plastic or metal containers on the job site. • Long lasting Ultra-reliable ignition process allows for little to no downtime on the job site.

UltraShot® (Drop-In) Weld Metal Size

US25 US32 US45 US65 US90 US115 US150

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Qty. / Ctn 20 20 20 20 10 10 10

Size

US200 US250 US300 US400 US500 US600 US750

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Qty. / Ctn 10 10 10 5 5 5 5

UltraShot Weld Metal • The weld metal, a mixture of copper oxide and aluminum, is packaged in individual, moisture resistant copper drop-ins. • The copper drop-in is consumed during the reaction process. • Each drop-in is marked with the size.

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Safety and Protection Ultraweld® (Pour & Shoot) Weld Metal Size

Qty. / Ctn

UWM15 UWM25 UWM32 UWM45 UWM65 UWM90

Size

20 20 20 20 20 10

UWM115 UWM150 UWM200 UWM250 UWM500

Open Mold

Qty. / Ctn 10 10 10 10 5

UltraWeld Weld Metal • The weld metal, a mixture of copper oxide and aluminum, is packaged in individual, moisture resistant plastic cartridges. • Each cartridge is marked with the size. • Each box also contains instructions and metal disks. • One metal disk is used for each connection. • The plastic box is shrink-wrapped to provide additional moisture protection.

Closed Mold

Molds • Depending on the care and treatment of the mold, it will average 50 or more welds. Substantially more with the UltraShot process. • The Ultraweld smokeless process uses an integrated filter system on the mold and electric ignition of the weld metal to produce a finished connection with minimal smoke emission. Ideal for indoor and confined space working conditions. • For Ultraweld smokeless process, ignition is accomplished with the use of a USCONTROLLER. • Mold Handle not included.

Smokeless Mold Open Mold

Closed Mold

USCONTROLLER

Smokeless Mold

Mold Accessories

Flint Igniter USCONTROLLER

• When making an Ultraweld connection, Flint Igniters are used to ignite the starting material. • Flint Igniters comes with MH1 and MH2 handle clamps. • Torches are required to remove moisture from the mold and conductors before making the Ultraweld connections.

36" Extension Torch Head

Cable & Work Surface Preparation

Card Cloth Brush

Cable Cleaning Brush

• Card Cloth Brush has short, stiff, metal bristles which are generally preferred for cleaning concentric conductors and busbars, that are not heavily oxidized. • Cable Cleaning Brush is ideal for cleaning concentric stranded cable, especially very dirty or oxidized conductors. • Rasp is ideal for removing mill scale and rust from steel surfaces.

MCBRSH2

MCBRSH1

Rasp

Mold Cleaning Spades

Mold Care & Use

Patented

MCBRSH2

MCBRSH1

• Slag can be removed from molds by using a Mold Cleaning Brush. • Slag can be cleaned from the molds by using a Mold Cleaning Spade. • The cleaning spades are specifically designed to fit the mold crucible for a given range of weld metal sizes.

Disks • The disk rests on the bottom of the crucible and holds the weld metal powder in place until the reaction occurs. • A new disk is required each time a weld is made. • Disks are included with the Weld Metal. Chain Support Handle Clamps

Magnetic Support Handle Clamps

Patented

Patented MH1, MH2 MH3

MH4

Patented

Mold Fastening & Mounting • Mold Handle Clamps are required for all molds. • Some molds are used with specialized frames. • Chain Support Handle Clamps are used to securely hold the mold to either a vertical or horizontal pipe. • Magnetic Support Handle Clamp allows mold to be securely held in place to steel surfaces.

Mold Blanket • Extends mold life by protecting against shock impact caused by rough handling. • Protects exothermic welders from coming into contact with hot molds; Used as a protection blanket against weld splatter. Patented

Toolkit

Safety & Protection

Patented

• Toolkit Includes: TOOLBOX: 22” x 9.5” x 9.75” plastic toolbox with tray; 9” Cable Cutters; Lineman’s Pliers; 6” Screwdriver; 10” Vise-Grips; Flint Igniter; Card Cloth Brush; Mold Cleaning Brush; Disk Kit Patented

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ented

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Safety and Protection Exothermic Connections

BS

DPRT

RT

DX1C

XX

DPRDT

Cable to Cable

CS

XO

PRPT

PD

PHD

PV

PB

RATD

DX

Cable to Ground Rod

GCU

GV

GU

GD

GSC

GO

GOT

GOXX

GF

GT

Ground Rod to Ground Rod

GG

GRH90B

GRT

GRXO

GRHT

GRS

GROT

Cable to Steel Surface / Pipe

HB

HD

VH

VA

HU

HT

HRT

HTCP

VU

VD

VR

VT

BE

BV

Cable to Lug

LE

LBJ

Cable to Busbar

BCE

BC

BCF

BCX

BU

BD

BL

BTE

BH

BCB

* Please refer to Harger manual for full range of exothermic connections

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Safety and Protection Busbar to Busbar

BB

BHEBVTT

BT

BA

BBC

BHEBHT

BHFBHX

BMB

GVSP

GHSD

Busbar to Ground Rod

GVSD

GVSO

GVSS

GSSD

GVSAS

GLV

GHSO

Busbar to Steel Surface

BBDVS

BBHTVS

Cable to Rebar

RCB

RE

RO

RB

RS

RP

HRCT

Cable to Rail

RMFPL

RMFT

RMVL

RMVH

Equipment Ground Plate

EGPCB

EGPCT

EGPCVD

EGPBS

EGPGRT

EGPHB

EGPID

EGPIO

FGRGD

FGRGO

FGRBS

FGRIGD

Safety & Protection

Aircraft Ground Receptacle

FGRIGO

* Please refer to Harger manual for full range of exothermic connections

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