1. ThermexWELD Exothermic Welding Training Guide
BASIC EARTHING / GROUNDING
CONNECTIONS

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

3. ThermexWELD Exothermic Welding Training Guide
How to use the product.
How to make the best electrical connection.
Safety TIPS.

4. 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.

5. 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

6. 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.

7. ThermexWELD Exothermic Welding Training Guide
MOULD TAG
Shows:
ThermexWELD Mould Code
Weld Metal Size
Cable Run
Cable Tap
Gap

8. ThermexWELD Exothermic Welding Training Guide
Weld Metal Size on the tag MUST match the Weld Metal Size on the Box.

9. 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

10. 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.

11. ThermexWELD Exothermic Welding Training Guide
GAP continued,
No gap, the cables MUST be placed in the CENTRE of the TAP HOLE.

12. 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.

13. ThermexWELD Exothermic Welding Training Guide
Place the Mould Handle into the Mould making sure that the clamp closes “firmly”.

14. ThermexWELD Exothermic Welding Training Guide
If mould does:
not close fully OR
the mould handle pressure is too tight then

15. ThermexWELD Exothermic Welding Training Guide
Mould Handle adjustment:
Withdraw the R Clip in the mechanism.

16. 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.

17. ThermexWELD Exothermic Welding Training Guide
Mould Clamp adjustment continued:
After adjustment re-check the handle pressure – a “firm click” to close.

18. 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.

19. 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

20. 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.

21. ThermexWELD Exothermic Welding Training Guide
Conductor Set-up:
Note conductors to be joined are CENTRAL in the TAP HOLE.

22. ThermexWELD Exothermic Welding Training Guide
Mould Set-up:
Check mould closure line.
Mould must close neatly.

23. 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.

24. 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.

25. ThermexWELD Exothermic Welding Training Guide
ThermexWELD Metal
Each box contains:
10 weld metals
2 starter containers
10 discs
1 measuring spoon
instructions

26. 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.

27. ThermexWELD Exothermic Welding Training Guide
Weld Metal Starter:
Close container and
Shake the container to FULLY mix the starter ingredients.

28. ThermexWELD Exothermic Welding Training Guide
Metal Disc:
Place 1 metal disc to cover the tap hole.
Check: that the pointed side is down.

29. 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.

30. 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.

31. ThermexWELD Exothermic Welding Training Guide
Starter:
Take 1 HEAPED spoon of the mixed starter material.
Safety: Close starter container and store safely.

32. ThermexWELD Exothermic Welding Training Guide
Starter:
½ of spoon of starter powder placed on top of weld metal.

33. 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.

34. ThermexWELD Exothermic Welding Training Guide
STARTER:
Starter powder in cover cup.

35. ThermexWELD Exothermic Welding Training Guide
STARTING
Use the T-805 Flint Igniter

36. ThermexWELD Exothermic Welding Training Guide
STARTING
Use the T-807 Hand Held Spark Igniter

37. ThermexWELD Exothermic Welding Training Guide
STARTING
Use the T-807 Hand Held Spark Igniter
Electrodes must contact the start powder (NOT the cap).

38. 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.

39. 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.

40. ThermexWELD Exothermic Welding Training Guide
Mould Opening:
Open the mould to reveal the Connection.
Safety: Beware of hot items.

41. ThermexWELD Exothermic Welding Training Guide
ThermexWELD Exothermic Connection.
Note:
Good shape
Clean
Safety: Beware of hot items.

42. 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.

43. 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.

44. ThermexWELD Exothermic Welding Training Guide
Mould:
Is now ready to be used again.
Properly maintained moulds will last for 75 to 80 connections.

45. 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.

46. 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.

47. ThermexWELD Exothermic Welding Training Guide
Flat Tape Connection:
ThermexWELD Type FF2

48. ThermexWELD Exothermic Welding Training Guide
Flat Tape Connection:
ThermexWELD Type FF3

49. ThermexWELD Exothermic Welding Training Guide
Earth Mat
Manufactured from 25mm x 3 mm copper tape with all joints ThermexWELD Exothermically Welded.

50. 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.

51. ThermexWELD Exothermic Welding Training Guide
ThermexWELD Connection:
Type FE2
70 mm x 1 mm copper tape to 5/8” earth rod.

52. ThermexWELD Exothermic Welding Training Guide
ThermexWELD Connection:
Type SS4
1/0 solid to 1/0 solid copper conductors.

53. ThermexWELD Exothermic Welding Training Guide
ThermexWELD Connection:
Type SF3
1/0 solid to 70 mm x 1 mm flat copper tape.

54. ThermexWELD Exothermic Welding Training Guide
ThermexWELD Connection:
Type SE2
2/0 stranded cable to 5/8” UNC earth rod.

55. ThermexWELD Exothermic Welding Training Guide
Qualified:
You have qualified to make the BEST electrical connection.
Follow these instructions step by step.

56. 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

57. ThermexWELD Exothermic Welding Training Guide
For “USER & INSPECTORS GUIDE” ask to see ThermexWELD presentation.
See website for a full catalogue.