Harger Ultraweld GD User manual

INSTRUCTIONS FOR ULTRAWELD® GROUNDING CONNECTIONS - CABLE TO GROUND ROD
GD
Place end of cable under
the center of the tap hole.
Cable must sit on top of
ground rod. Use locking
pliers or a clamp on the
rod below the mold to
prevent it from slipping
when the mold is fired.
StartingPowder
WeldPowder
SteelDisc
TapHole
WeldCavity
Cable
GroundRod
GO
Place cable in the mold.
Cable must sit on top of
ground rod. Use locking
pliers or a clamp on the rod
below the mold to prevent it
from slipping when the
mold is fired.
GS
Place cable into mold and secure mold to ground rod with handle clamp.
Support mold to keep it from sliding down the ground rod
when welding with locking pliers or clamp below mold.
GF
Place cables in mold. Bottom
run cable must sit on top of the
ground rod. Use a pair of
locking pliers or a clamp below
mold on ground rod to support
the mold and prevent slipping.
GT
Place end of tap cable under
center of tap hole. Run cable
must sit on top of the ground
rod. Use a pair of locking pliers
or a clamp below mold on
ground rod to support the mold
and prevent slipping.
Revised1/3/2014 Visitourwebsiteatwww.harger.com forfurthertipsandvideos.

GENERALSAFETYINSTRUCTIONS
1. Alwayswearproperclothing,safetyglassesandgloveswhen
exothermicwelding.
2. Onlywelditemsthatthemoldisdesignedfor.
3. Donotusewornorbrokenmoldswhichcouldcauseleakage
ofmoltenweldmetal.
4. Alwaysuseproperhandleclampsorframeworkrequiredfor
themoldandmakesureitisadjustedproperlytoclosethe
moldcompletely.
5. Makesurethattheconductorsbeingweldedfitinthemold
properlyandthatthemoldwillclosetightlyaroundthem.
6. Donotaltermoldsoraccessorieswithoutfactory
authorization.
7. Avoidbreathingconcentrationsofsmoke,asitmaybe
hazardoustoyourhealth.
8. Avoidcontactwithhotmaterials.
9. Removeorprotectfirehazardsintheweldingarea.
10. Avoidmoistureandcontaminantsinthemoldandconductors
beingwelded.Contactofmoltenweldmetalwithmoistureor
contaminantsmaycauseweldmetaltospewoutofmold.
11. Whenweldingtopipeorvessels,youshouldconsiderthe
following:
A. theeffectweldingmayhaveonstructuralmembersand
thinwallpipeorvessels.
B. pipeorvesselsthatarepressurizedorcontain(orhave
contained)flammable,explosiveorhazardousmaterials
shouldbeevaluatedinthecaseofameltthroughorhot
moltenweldmetalcomingincontactwithany
flammable,explosiveorhazardousmaterials.
12. Failuretoabidebytheaboveandfollowweldingprocedures
mayresultinimproperwelds,damagetothematerialbeing
weldedorcreatehazardoussituationsfortheindividual.
PREPARATIONOFCABLE
1. Cablemustbebright,cleananddry.
2. Cablethatissaturatedwithoilorgreasemustbecleaned.
Cablemaybecleanedbyburningitoffwithapropaneor
oxy‐acetylenetorch.Afterburningoffoilorgrease,awire
brushshouldbeusedtoremoveresidue.Wetcablemustbe
driedout.Useahandpropanetorch.
3. Corrodedcablemustbecleaned.UsetheCCBRSH2cable
cleaningbrushorCCBRSH1cardclothbrush.Itisimportant
thattheendsoftheindividualstrandsareclean.Thiscan
bestbeaccomplishedbymakingafreshcutontheendof
thecable.
4. Cableshouldbestraightenedbeforeclampingmoldinplace.
Bentoroutofroundcablewillholdmoldopenandcause
leaks.
5. Removeinsulationfrominsulatedcablebeforecuttingwith
hacksaw.Otherwise,endsofstrandswillbecomecoated
withinsulatingmaterialwhichmaycausedefectivewelds.
6. FLEXIBLECABLE:Asleevemustbeusedwhenwelding
flexiblecable.WRPSLVwrapsleevesarerecommendedfor
300MCMandsmallercable orcheckwithfactoryfor
premadesleeves.
PREPARATIONOFGROUNDRODSAND
GROUNDRECEPTACLES
1. Endsthatarethreaded,mushroomedfromdriving,or
drilledandtapped,mustbecutoffbeforeweldingtothe
end.Contactfactoryaboutgroundroddrivingsleeves.
2. Thesiteoftheweldonthegroundrodsandreceptacles
mustbeclean.Useacoarsefiletoremoverustandoxide
beforewelding
3. SlightlyUNDERSIZEDRODMAYBEBUILTUPWITHWRPSLV
WRAPSLEEVES.Thiswillnotworkforlargedifferencesin
size.
WELDINGPROCEDURE
1. Readallinstructionsandsafetywarningsbeforestarting.
2. Checkmoldtagforconductorstobeweldedandproper
weldmetalcartridgesizetouse.
3. Insertproperhandlesintothemoldandlockmoldshutif
applicable.
4. Makesureallsurfacesandconductorsareclean,dryand
arethepropersizesforthemold’sapplicationpermoldtag.
5. Moldscanbedriedbyheatingtoapproximately250°F.
Moldsmaybedriedwithahandoperatedpropanetorchor
byfiringachargeinthemoldbeforemakingthedesired
weld.
6. Positionconductor(s)intothemold.Seefrontofthissheet
forpositioningofconductorsintomold.Lockmoldwith
handleclampsorframe,whicheveristhecase.Checkto
makesuremoldiscompletelyclosed.
7. NuwTube:
A. Insertsteeldiskbeingsureitisdirectlycenteredover
thetaphole.Failuretoinsertdiskintomoldwillcreate
improperweldsandspewingofweldmetal.
B. Pourcartridgeorcartridgesintothecruciblebeing
carefulnottoupsetthesteeldisk.
C. RemoveOrangebottomlidinNuwTube toremove
startingpowder.Closelidandpourstartingpowder
intocupinthetopofthelid,allowingsometofallthru
theignitionholeinthelid.
D. Ignitestartingpowderwithflintgun.Pullflintgun
awayquicklytopreventfoulingflint.
8. UltraShot
A. InsertUltrashotcupintomoldcruciblealigningmetal
igniterwiththesmallgroveinthetopofthemold.
Closelid.
B. Insertmetaligniterintobatteryignitioncord.
C. Pressbothignitionbuttonsonbatterypackwhile
standingclearofexhaustportonmold.Moldshould
firerightaway.
9. Waitapproximately30secondsbeforeopeningmoldto
permitmetaltosolidify.
10. Tocleanthemold,useaMCBRSH1naturalbristlebrush,
softclothornewspaperbeforemakingnextweld.Do NOT
usewireorplasticbrushestocleanthemold!
11. Onhorizontallysplitmolds,useendofmoldcleaningspade,
asmalldiameterrod,orscrewdrivertoremoveslagfrom
taphole.Cautionshouldbeusedwhencleaningmoldsto
avoidburnsfromcontactwithhotmold.
NOTE:
1.Afouledflintgunmaybecleanedbysoakinginhouseholdammonia.
2.Properweldmetalcartridgesizeismarkedonmoldtagandshownonthecapofthecartridgetube.
3.Cartridgesizeistheapproximateweightofthepowderingrams.Whenthecartridgesizespecifiedisnotavailable,twoormore
smallercartridgesorpartofalargercartridgemaybeused.
4.HandleClampadjustmentsmaybemadebyremovingadjustingscrewandturningeyebolt180° clockwisetotightenor180° counter
clockwisetoloosen.