ALLTEC TerraWeld Exothermic Welding System Manual
The TerraWeld® Exothermic Welding System is a simple, cost-effective and permanent welded connection that uses a high-temperature exothermic reaction and does not require an external heat or power source to create a molecular bond. It's a superior connection method for making permanently copper-to-copper and copper-to-steel electrical connections.
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TerraWeld
®
Exothermic Welding System
Welding Process, Inspection & Field Quality Control Manual
2
Preface
This Manual is designed to assist technicians in the proper welding process and inspection of TerraWeld ® exothermic welds. The recommended practices in this guide are based on testing, evaluation, and years of comprehensive experience.
Please use the contact information below with any possible questions:
TerraWeld
®
ALLTEC, LLC
64 Catalyst Drive
Canton, North Carolina
28716 USA www.alltecglobal.com
+1 828 646 9290 Tel
+1 828 646 9527 Fax
+1 800 203 2658 US & Canada Toll Free
Safety precautions
R ead this information before operating.
• Wear eye protection and gloves. Failure to do so may result in serious injury.
Stand clear.
• Avoid breathing smoke or fumes as these may cause irritation to respiratory system.
• Avoid looking directly at the light of the weld process as this may irritate your eyes.
• Avoid contact with hot molten metals or molds. Use the handle. Contact will cause burns.
• Avoid contact of hot molten metals with water, oil, grease, etc., excessive spatter and burns may result.
• Do not use in areas where flammable vapors or dust are present as fire or explosion could result.
Content
Introduction .......................................................................................................................... 4
Parts Identification ................................................................................................................ 5
TerraWeld
®
Exothermic Welded Connectors ........................................................................ 6
Electrical Connector Requirements ...................................................................................... 6
Making a TerraWeld
®
Connection ......................................................................................... 8
TerraWeld
®
Mold Inspection ............................................................................................... 10
TerraWeld
®
Exothermic Weld Checklist .............................................................................. 11
Inspection of TerraWeld ® Connections ............................................................................... 12
TerraWeld
®
Guide to Troubleshooting ................................................................................ 13
Disclaimer ........................................................................................................................... 17
3
4
Introduction
About TerraWeld
®
TerraWeld
®
is a simple, cost-effective and permanent welded connection that uses a high-temperature exothermic reaction and does not require an external heat or power source to create a molecular bond. TerraWeld
® provides a simply superior connection and is the universally preferred method for making permanently copper-to-copper and copper-to-steel electrical connections.
Its performance is superior to all existing surface-to-surface connectors.
TerraWeld
®
works when others won’t!
ALLTEC’s hermetically sealed metallized TerraWeld
®
pouch is unique to the industry and provides the product with an extensive shelf life. Each mold is precision engineered for optimal results. TerraWeld
®
is UL listed, and exothermic welding is recommended by IEEE and IEC.
Features
• Permanent molecular bond
• Corrosion resistant
• Low impedance connection
• Highly conductive
• Simple and cost effective
• Portable and easy to use
• Requires no external heat source or equipment
Parts Identification
TerraWeld
®
Mold
Starter Material
Weld Metal
Metal Disk
Conductor A
Mold Cavity
Tools and Accessories
Mold Cover
Crucible
Mold
Tap Hole
Conductor B
Eye Protection
Torch
Gloves
Flint Ignitor
Tool Kit
Exothermic Welding System www.alltecglobal.com
TerraWeld ® Pouch
Metal Disk Mold (Typical)
Card Cloth Brush Mold Cleaning Brush Slag Removal Tool
Handles
(CL-3 shown)
5
6
TerraWeld
®
Exothermic Welded Connectors
Quality Standards
The TerraWeld ® exothermic welding system provides a simply superior connection. The process of exothermic welding, in which no outside source of heat or power is required, is the universally preferred method of making electrical connections of copper-to-copper or copper-to-steel. Lightning protection and grounding systems require connections that maintain current carrying capacity exceeding that of the conductors used in the system.
TerraWeld
®
connections provide higher fusing capacity than the conductors to which they are bonded. System resistance and impedance relate directly to functionality, safety, and regulatory compliance. TerraWeld
®
meets these challenges and delivers assurance.
Meets or exceeds:
• UL 467 listed
• IEEE 80, 837, and 1100
• NFC 15-100
• NEC Article 250
• National Electrical Safety Code (NESC)
• BS 6651
Electrical Connector Requirements
Improper connections between conductors are often the reason for electrical malfunctions. A proper connection should have the following characteristics:
• Capacity to withstand overload conditions without melting, burning or failing.
• Sustain electrical continuity and contact reliability.
• Connector temperature should remain lower than that of the conductor when conducting electrical current.
• Extensive service life. Will not deteriorate, corrode or decay over time, above or below-grade.
Only exothermic welded connections meet or exceed all of the above criteria.
Exothermic welding is recommended by IEEE and IEC. It has been shown to be the best choice where safety, reliability, longevity and current carrying capacity are critical. TerraWeld ® specifically supersedes its competition with its hermetically sealed metallized pouch which provides the product with an extensive shelf life and easy portability. TerraWeld
®
is UL listed and is the preferred method for making copper-to-copper and copper-to-steel electrical connections.
TerraWeld ® weld metal
Molecular bond of cables to weld metal.
Cables supported by weld metal.
7
8
Making a TerraWeld
®
Connection
TerraWeld
®
Instructions - Electrical Connections
STEP
1
TASK
First, make sure to start with a dry mold. This can be done by heating the mold with a torch.
Make sure that all parts, including the crucible, tap and wire cavities are also dried.
2 Dry the conductors.
3
Clean the dried conductor ends with a brush to remove any dirt and oxides. Remove any adhesive, dirt, or other contaminants.
4
When welding to a steel surface, a clean bright metal surface is ideal. Use a rasp or grinding wheel to remove any rust, paint or scale from the area. Acetone may be used to remove grease and oil from the plates.
5
Arrange the mold over the conductors with the conductor ends under the center of the tap hole. Lock the mold handles.
6
Place the round metal disk; each package contains a bag of disks, in the bottom of the crucible ensuring that it covers the tap hole.
7
Remove the small round tube of the starter material from TerraWeld
®
pouch. Pour the weld metal from the foil package into the crucible.
Open the starting material in the tube, and sprinkle on the mold lip as well as over the weld metal.
STEP TASK
8
Shut the mold cover. Light the starting material by using a flint igniter. DO NOT use a torch or matches.
9
Wait about 10-15 seconds following the weld process. Release the mold and remove the finished connection. Mold will become extremely HOT. DO
NOT TOUCH.
10
Being careful not to touch the
HOT mold. Remove any residual slag and dust with a clean rag or mold cleaning tool. Sweep off any lingering residue with a stiff brush. Use ONLY natural bristle brushes. DO
NOT use a wire brush or it will damage the mold!
11
Properly dispose of the mold when excessive seepage occurs around the mold openings or if the mold disk seat is worn or chipped. Molds are not permanent equipment; they will wear out over time.
Areas where leakage can occur
TerraWeld
®
Special Instructions
-
Welding to Steel
STEP TASK
1
2
3
Preheating the steel with a torch usually achieves the best results. This can be done in 1 or 2 minutes.
When welding to galvanized steel, it is important to make sure that ALL galvanized coatings are removed from the area to be welded. Failure to do so will result in excessive gas pores in the connection, thus affecting the quality of the connection.
Welding to Rebar: The rebar needs to be cleaned down to bright shiny metal. Sealing material (putty) must be used around the cavities between the rebar and the mold to prevent any leaking of molten metal.
Sealing Material
9
TerraWeld
®
Mold Inspection
TerraWeld ® molds are made from superior quality graphite and can be expected to endure about
50 or more connections with correct usage and care. Please note that the mold will eventually wear out due to the extreme heat cycling and abrasion. The diagram below shows the difference between a mold that is in good condition and one that needs to be replaced.
Good condition
Smooth clean surfaces.
Top hole is smooth & clear.
Needs replacement
Heavily pitted and chipped surfaces.
Bottom of crucible is damaged. Preventing the disk from sealing properly.
10
Snug fitting cable openings.
Visible structural cracking of mold.
Weld cavity is clearly defined and complete.
Cable/wire opening is excessively worn leading to leakage.
Weld cavity is excessively worn.
Corners and edges are no longer well defined.
NOTE: Inspect the mold regularly to determine if a mold should be replaced.
INSPECT FOR
Cable opening
Weld cavity
Tap hole
Disk seat
Mold parting face
CONDITION
The conductor should fit securely without movement. A loose fit will cause leakage.
The opening should not be chipped or worn.
The cavity should be well defined.
There should be no chips or gouges.
The tap hole should be well defined.
The seat should not be worn or chipped; the disk must seat seal properly.
The parting face should not be chipped.
The parting face should always be cleaned properly. Use a clean shop towel or newspaper and wipe clean. DO NOT USE A WIRE BRUSH for mold cleaning.
TerraWeld
®
Exothermic Weld Checklist
7
8
9
10
5
6
STEP
1
2
3
4
11
12
TASK
Dry and clean the mold with a torch (crucible & all cavities).
Dry and clean the conductors* with a torch to completely remove all oil coating. Any oil residue will show itself via smoke or discolored flame.
Clean the conductors* with a wire brush to remove all dirt, ash & oxides.
When welding to a steel surface:
• Use a rasp or grinding wheel
• Remove rust-proofing, paint, rust or scale
• Weld surface should be bright clean metal
Position a mold over the conductors (center) and lock the mold handle.
Place the metal disk in bottom of crucible with curved side down (cover tap hole).
Pour the weld metal into crucible and sprinkle the starter material (tube) on the mold lip and over the weld metal.
Close the mold cover — Ignite the starter material with flint igniter.
Wait for weld process to complete, then open the mold.
Remove any slag from the welded connection.
Clean the mold with a mold cleaning (natural bristle) brush.
• Remove any remaining slag, dust, or weld residue.
• Do Not use any wire brush or metal object to clean mold.
Discard the mold when leakage occurs or the disk seat is worn/chipped.
CHECK
*NOTES/TIPS on Drying & Cleaning Conductors
• Weld surface MUST be clean of all dirt, grime, and oil residue
(oil is occasionally a residual of the manufacturing process and
MUST BE REMOVED).
• When cleaning conductor with a torch, a red/orange/green flame or smoke indicates that oil is being burned off the conductor.
Wait for the torch flame to turn BLUE to assure all oil is burned off the conductor surface.
11
Inspection of TerraWeld
®
Connections
Visual Inspection
Color
Surface Finish
Porosity
The TerraWeld ® connection can be seen most clearly by brushing the connection lightly with a wire brush. This should produce a connection gold or bronze in color, and occasionally there may be a silver tint on top; the silver indicates “tin sweat,” which is normal.
A TerraWeld
®
connection to cast iron or galvanized surfaces is often silver in color due to alloying with the metals.
The goal of the surface finish is to be reasonably smooth & free from major slag deposits. If slag covers more than 20% of the connection surface. Cut the cable and try to reapply weld.
The connection should be free from porosity, which it is normally the result of contaminants (water, oil, dirt, etc.) in the mold and/or conductor. A few small pinholes may be present on the surface of the riser. Please note: the depth of a pinhole must never extend beyond the center of the conductor. A paper clip or a 1/32” wire can be used to check the depth. Reject the connection if the depth of the pinhole extends beyond the center of the conductor.
Connection Ratings
12
GOOD
A GOOD connection is a normal weld with only slight exterior blemishes.
ACCEPTABLE
REJECT
An ACCEPTABLE connection is a less than normal weld, but still it is a fine performing weld. Imperfections indicate that either:
• A new mold is required
• A change in procedure is necessary
• The proper mold conductor and/or weld metal should be used.
A REJECT connection shows inadequate fill or an extra high riser due to either:
• Use of incorrect equipment and/or equipment worn beyond its useful life
• Use of an incorrect procedure or use of incorrect material.
TerraWeld
®
Guide to Troubleshooting
#
1
2
PROBLEM
The handles lock, but the mold doesn’t close tightly.
The connection is porous.
CAUSE
Handle clamps are not properly adjusted.
Use of improper cable size
Bent or out-of-round cable
Dirt or slag stuck in mold parting line
Presence of moisture in conductor or mold
Not enough heating of the mold or heating temperature is low.
SOLUTION
Adjust the handles, especially when they are new.
Use the correct cable size. A too large cable will hold the mold open.
Make sure that the cables are not curved or bent.
Check the mold parting line. Make sure there is no dirt, slag or foreign objects.
Dry the conductor by wiping and then heating.
Heat mold with torch (to above 212 °F) or by igniting weld materials in mold without any conductors. Be careful to prevent burns from the hot material seeping out of the mold. NOTE: Do not use this method of heating if the mold has wear-plates.
Presence of contaminants (oil, insulation, etc.) in conductors
Use a safety solvent to wash the conductor, and then dry it. If insulation is present between strands, remove it.
Conductors are not properly cleaned.
Remove oxides using the wire brush.
If heavily oxidized, create a fresh-cut conductor end and use TerraWeld
®
Heavy Duty molds.
Conductors are not properly dried.
Dry conductor with a torch.-
3
The conductors do not weld.
Improper gap or butting
Check for proper gap or butting as required (see mold tag and read the instructions packaged with the mold).
Conductors are not properly positioned in the mold.
Check to be sure gap is centered under tap hole.
NOTE: In some cases, the run (thru) conductor must be cut and gapped.
Follow instructions packaged with the mold or use TerraWeld
®
Heavy Duty molds.
13
14
#
4
5
6
7
8
9
PROBLEM
The connection is covered with unnecessary slag
NOTE: A small amount of slag on the surface is usual.
Molten metal seeps out of the crucible when creating a connection (See the
Problem #4.)
The weld metal leaks around the conductor.
The connection has
“fins” — metal is lost.
The cables pull out of mold during welding.
Insufficient fill material to cover conductors.
10 The riser is too high.
CAUSE
Disk was not put in.
SOLUTION
Create a new weld while carefully observing the procedure steps.
Disk movement
Use care when pouring the weld material.
Disk not correctly seated.
Place the disk correctly.
Chipped graphite at tap hole
Presence of moisture in conductor or mold
Lack of mold packing material in weld cavity of mold
Lack of mold packing material
Replace the mold.
Mold material in weld cavity of mold.
Always apply mold packing material to conductor after mold is closed.
Use packing material around the conductor after the mold is closed
Excessively worn mold
Excessive use
Use of improper mold
Replace with a new mold.
Use molds with wear-plates
(which also act as chill-plates).
Use a proper mold. Mold must be the correct size for the cable being welded.
Mold not being completely closed.
Mold worn beyond useful life and needs replacement.
See the Problem #1.
Replace the mold.
Conductor movement
Use a clamp or other means to prevent movement of conductors during welding.
Either twisted or tensioned conductors
Use of improper weld material size
Cut out the twisted conductor.
Resulting from leaking weld metal caused by worn mold
Conductor Movement
Too large a gap between conductors
Mold Leak
Moisture in mold or conductor (see Problem
#4).
Determine use of proper weld material size (see the mold tag).
Replace mold, or if only worn around conductor opening, use duct seal (or putty) around conductor. Do not get duct seal into mold cavity.
Determine use of proper weld material size (see the mold tag).
See the positioning instructions
(Page 5 & Page 6).
See the Problems #6, 7, & 8.
Determine use of proper weld material size (see the mold tag).
#
11
12
13
PROBLEM
The mold wears out quickly.
NOTE: Molds should last an average of
60-80 connections.
See TerraWeld
®
Mold
Inspection page 7.
When welding to steel, the weld does not stick to the steel.
When welding to ductile iron or cast iron, the weld does not stick to the surface.
CAUSE
Mold has not been cleaned at all or has been cleaned improperly.
Use of improper tools
Rough handling of molds
The steel is cleaned improperly.
Galvanized surfaces are not clean enough to be welded.
The steel surface or the conductors are moist or contaminated.
The conductors are not in proper position.
Excessive coatings present.
Contaminated surface
Using a wrong powder.
SOLUTION
Use a cable clamp for harddrawn copper or DSA Copper weld wire.
Clean the mold with a soft brush (preferably natural bristle), clean cloth, or newspaper. DO NOT USE A
WIRE BRUSH, it will cause erosion and quickly destroy the mold.
Use care when removing the mold from a finished connection to prevent chipping of the mold.
Clean the steel with a rasp or grinder to bright metal. All mill scale, paint, and/or other coating must be removed with a safety solvent before cleaning.
Clean galvanized surfaces with a wire brush or emery cloth. However, extra heavy galvanized steel must be cleaned with a rasp.
Heat the surface to be welded with a torch (from back-side if possible). Any carbon deposit
(visible as dark ash) must be removed from the surface to be welded.
Check the instruction sheet.
Remove all coatings before cleaning.
Clean surface with rasp or grinder to bright metal, and wipe with a safety solvent.
Use TerraWeld
®
alloy metal material.
15
ALLTEC offers a TerraWeld
®
Training course. Contact us to discuss your needs.
16
TerraWeld®
Welder Qualification Card
The bearer of this card has successfully completed the classroom and field training for proper
TerraWeld ® welding procedures and practices and has therefore earned this WELDER QUALIFICATION CARD.
Qualification is valid for a three (3) year period.
TerraWeld®
Welder Qualification Card
Bearer Name:_______________________________
Authorized Trainer:__________________________
Date:_____________ Expiration:_____________
Disclaimer
Warranty
ALLTEC’s exothermic welding products are guaranteed to be defect-free in material and construction at the time of shipment. Claims should be made in writing within 5 days of the buyer’s reception of the products. All claims under the warranty provided herein must be made within ninety (90) days from the date of discovery of the defect. Failure to notify ALLTEC of a warranted defect within ninety (90) days of its discovery voids ALLTEC’s obligations hereunder.
Products maintained to be faulty or defective must be returned to ALLTEC for inspection without delay. Warranty void if claims not made within the applicable time period or if regulations not followed exactly as stated above. ALLTEC is not responsible for products that have not been stored or used in agreement with ALLTEC’s recommended specifications and practices. ALLTEC will either repair or replace the defective products or return the purchase price to the buyer, at its discretion.
Limitation of Liability
ALLTEC shall not be liable for any loss, cost, damage, or expense of any kind arising out of a breach of warranty. ALLTEC excludes all liability except that which is directly attributed to willful or gross negligence of ALLTEC’s employees. In the event that ALLTEC claims liability it should in not exceed the total purchase price of a defective product. ALLTEC shall in no event be liable for any incidental, consequential, exemplary, special, or punitive damages, nor for any loss of revenue, profit or use, arising out of a breach of this warranty or in connection with the sale, maintenance, use, operation or repair of any ALLTEC product.
Trademarks
TerraWeld is a registered trademark of ALLTEC, LLC.
IEEE is a registered trademark of The Institute of Electrical and Electronics Engineers, Inc.
NEC is a registered trademark of National Fire Protection Association, Inc.
UL is a registered trademark of Underwriters Laboratories, Inc.
IEC is a registered trademark of the International Electrotechnical Commission.
NFC is an acronym Near field communication.
NESC is a registered trademark of the IEE, Inc.
BS is a registered trademark of the British Standards.
Copyright ©2013 ALLTEC. All rights reserved. ALLTEC is an ISO 9001:2008 Registered Company.
17
SOLUTION PROVIDERS FOR AN ENERGIZED WORLD™
WORLD HEADQUARTERS
64 Catalyst Drive, Canton, North Carolina 28716 USA
TEL: +1.828.646.9290 | FAX: +1.828.646.9527
EMAIL: [email protected]
ALLTEC has offices located across the world.
Go to www.alltecglobal.com/contact to connect with your regional office.
www.alltecglobal.com
© 2016 ALLTEC | 440-003 | 03/24/2016

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Key features
- Permanent molecular bond
- Corrosion resistant
- Low impedance connection
- Highly conductive
- Simple and cost effective
- Portable and easy to use
- Requires no external heat source or equipment