CAT 7 - AXIWELD EXOTHERMIC

CONTENTS

1. INTRODUCTION 2 2. BASIC INSTALLATION 3-4 3. EXOTHERMIC PROCESS 5-6 4. POWDER AVAILABLE 7 5. SPECIALIZATION 8

6. WELDING JOINTS CABLE TO CABLE 9-14 CABLE TO ROD 15-20 CABLE TO STEEL 21-26 BUSBAR TO TAP 27-31 TAP TO CABLE 32-36

7. SELECT CHART 37-40 8. GRAPHITE MOULD 41 9. ACCESSORIES 42-43 10. TROUBLE SHOOTING TIPS 44

AXI-WELD / EXOTHERMIC WELDING

INTRODUCTION

Axi-weld / Exothermic welding is simple, cost efficient, self contained process of forming high quality connections. This process requires no external power or heat source making it completely portable. It uses high temperature reaction of powdered copper oxide and aluminium, within a mould, to form permanent connections.

In this process connections are made by pouring superheated molten copper alloy on and around the conductors to be joined.The reaction takes place very rapidly, therefore the total amount of heat applied to the conductors or surfaces is considerably less than that of brazing or soldering. This is important to remember when welding to insulated cable or thin wall pipe.

The process use aluminium particles as reducing agent with copper oxide to produce the chemical composition. Exothermic welding is a bonding of high conductivity high copper content alloy and high corrosion resistance.

BASIC INSTALLTION

The majority of connections have at least twice the cross sectional area of the conductors being joined and equivalent or greater current carrying capacity because the connection is a fusion of high conductivity high copper content alloy it will withstand repeated fault current and will not loosen in the way that mechanical connectors can corrosion resistance too, is exceptional, due to the alloy very high copper content.

The moulds are designed to complete +/- 30 connections depending on the care given to the mould during usage, transport and storage.

The exothermic welding process has been used to weld materials other than copper for electrical purposes.Materials welded include:

Stainless Steel, Columbium, Brass, Copper, Plain Steel, Bronze, Nichrome-V, Everdur, Niobium, Galvanized Steel, Kama, Chromax, Silicon Bronze, Steel Rail, Cast Iron, Copper Clad Steel, Cor-Ten, Monel

When welding to galvanized steel it is recommended to resurface exposedbare steel.

Exothermic Process

1. Conductors must be clean & dry when placed in the mould.

2. Close & lock the mould handle clamp.

3. Place the steel retaining disc in the mould cup over the tap hole.

4. Pour weld metal powder into the mould cup.

5. Pour some starting powder on mould lip.

6. Close the lid of mould & from the side ignite the starting powder with the flint gun.

Use Recommended Powder forRecommended Joint. Powders Are Available In Different Gramage For Different Joint.

Avail.Gram.

GivenCode

1 15 gram AWP152 25 gram AWP253 32 gram AWP324 45 gram AWP455 65 gram AWP656 90 gram AWP907 115 gram AWP1158 150 gram AWP150

9 200 gram AWP200

How we are Specialised.

Specialization :

Manufacturing of the Exothermic welding copper powder can be distributed to the user all around the world and satisfied the quality of our products and service.

Our factory has been grown up with the best quality on the complete cycle of theGrounding & Lightning protection system including the survey, designs, materialsupplies, installation, trial maintenance, consultation and problem solving.

All this leads to our high quality products at reasonable prices, which answersour slogan " We will give the best to our customers" which we will cherishforever.

Cable To Cable

Horizontal End To End

Powder Mould Clamp Amm2 ( g ) Type Type

10 25 ACC1-C-10 AHCC16 32 ACC1-C-16 AHCC25 32 ACC1-C-25 AHCC35 32 ACC1-C-35 AHCC50 45 ACC1-C-50 AHCC70 65 ACC1-C-70 AHCC95 90 ACC1-C-95 AHCC120 115 ACC1-C-120 AHCC150 115 ACC1-C-150 AHCC185 150 ACC1-C-185 AHCC240 200 ACC1-D-240 AHCD300 250 ACC1-D-300 AHCD500 200 x 2 ACC1-E-500 AHCD

Cable To Cable

Horizontal To Horizontal Cable Cross

A B Powder Mould Clamp A B Powder Mould Clamp

mm2 mm2 ( g ) Type Type mm2 mm2 ( g ) Type Type

10 10 32 ACC4-C-1010 AHCC 150 95 200 ACC4-D-15095 AHCD

16 16 45 ACC4-C-1616 AHCC 150 70 150 ACC4-C-15070 AHCC




50 50 90 ACC4-C-5050 AHCC 185 185 150 x 2 ACC4-E-185185 AHCD








95 70 150 ACC4-C-9570 AHCC 240 240 250x2 ACC4-D-240240 AHCD



95 25 115 ACC4-C-9525 AHCC 240 120 150X2 ACC4-D-240120 AHCD

120 120 200 ACC4-D-120120 AHCD 240 95 150X2 ACC4-D-24095 AHCD

120 95 200 ACC4-D-12095 AHCD 240 70 250 ACC4-C-24070 AHCC





150 150 250 ACC4-D-150150 AHCC 300 150 250x2 ACC4-D-300150 AHCD

150 120 250 ACC4-D-150120 AHCD 300 120 200x2 ACC4-D-300120 AHCD

300 95 200x2 ACC4-D-30095 AHCD

Cable To Cable

Horizontal Parallel Cable Cross

A B Powder Mould Clampmm2 mm2 ( g ) Type Type10 10 45 ACC6-C-1010 AHCC16 16 45 ACC6-C-1616 AHCC25 25 45 ACC6-C-2525 AHCC35 35 65 ACC6-C-3535 AHCC50 50 90 ACC6-C-5050 AHCC50 35 65 ACC6-C-5035 AHCC50 25 65 ACC6-C-5025 AHCC70 70 115 ACC6-C-7070 AHCC70 50 115 ACC6-C-7050 AHCC70 35 90 ACC6-C-7035 AHCC70 25 90 ACC6-C-7025 AHCC95 95 150 ACC6-C-9595 AHCC95 70 115 ACC6-C-9570 AHCC95 50 115 ACC6-C-9550 AHCC95 35 115 ACC6-C-9535 AHCC

120 120 200 ACC6-C-120120 AHCC120 95 200 ACC6-C-12095 AHCC120 70 150 ACC6-C-12070 AHCC120 50 115 ACC6-C-12050 AHCC

Cable To Cable

orizontal Cable Tap To Horizontal Cable RunH

Mould Clamp A BA B Powder Powder Mould Clamp

mm2 mm2 ( g ) Type ) Type

10 10 25 ACC2-C-1010 AHCC ACC2-C-15025 AHCC150 25 90









70 50 90 ACC2-C-7050 AHCC 240 240 150 2x ACC2-E-240240 AHCD














150 150 200 ACC2-D-150150 AHCD 300 95 150 ACC2-C-30095 AHCC






mm2 mm2 ( g

Cable To Cable

orizontal Parallel Through Cables. H

A B Powder Mould Clamp

mm2 mm2 ( g ) Type Type

10 10 32 ACC7-C-1010 AHCC

16 16 32 ACC7-C-1616 AHCC

25 25 45 ACC7-C-2525 AHCC

35 35 65 ACC7-C-3535 AHCC

35 25 65 ACC7-C-3525 AHCC

50 50 90 ACC7-C-5050 AHCC

50 35 90 ACC7-C-5035 AHCC

50 25 65 ACC7-C-5025 AHCC

70 70 115 ACC7-C-7070 AHCC

70 50 115 ACC7-C-7050 AHCC

70 35 90 ACC7-C-7035 AHCC

70 25 90 ACC7-C-7025 AHCC

95 95 150 ACC7-C-9595 AHCC

95 70 150 ACC7-C-9570 AHCC

95 50 115 ACC7-C-9550 AHCC

95 35 115 ACC7-C-9535 AHCC

AHCC

120 95 200 ACC7-C-12095 AHCC

120 70 150 ACC7-C-12070 AHCC

120 50 150 ACC7-C-12050 AHCC

150 150 150x2 ACC7-D-150150 AHCD

150 120 250 ACC7-C-150120 AHCC

150 95 200 ACC7-C-15095 AHCC

150 70 150 ACC7-C-15070 AHCC

185 185 150x2 ACC7-D-185185 AHCD

185 150 150x2 ACC7-D-185150 AHCD

185 120 250 ACC7-C-185120 AHCC

185 95 200 ACC7-C-18595 AHCC

240 240 200x2 ACC7-D-240240 AHCD

240 185 150x2 ACC7-D-240185 AHCD

240 150 150x2 ACC7-D-240150 AHCD

240 120 250 ACC7-C-240120 AHCC

300 300 250x2 ACC7-D-300300 AHCD

300 240 250x2 ACC7-D-300240 AHCD

300 185 200x2 ACC7-D-300185 AHCD

300 150 150x2 ACC7-D-300150 AHCD

120 120 200 ACC7-C-120120

Cable To Cable

orizontal Parallel Through Cables. H

A B Powder Mould Clamp

mm2 m2 ( g ) Type Type

25 25 65 ACC 52511-M-2 AHCD

35 35 90 ACC11-M-3535 AHCD

50 50 150 ACC11-M-5050 AHCD

70 70 200 CC11-M-7070 AHCD

70 50 200 ACC11-M-7050 AHCD

70 35 150 ACC11-M-7035 AHCD

95 95 250 ACC11-M-9595 AHCD

95 70 250 ACC11-M-9570 AHCD

95 50 200 ACC11-M-9550 AHCD

95 35 200 ACC11-M-9535 AHCD

120 120 150x2 ACC11-M-120120 AHCD

120 95 150x2 ACC11-M-12095 AHCD

120 70 250 ACC11-M-12070 AHCD

120 50 250 ACC11-M-12050 AHCD

120 35 200 ACC11-M-12035 AHCD

150 150 200x2 ACC11-V-150150 AHCD

150 120 200x2 ACC11-V-150120 AHCD

150 95 150x2 ACC11-M-15095 AHCD

150 70 150x2 ACC11-M-15070 AHCD

150 50 250 ACC11-M-15050 AHCD

150 35 250 ACC11-M-15035 AHCD

185 185 250x2 ACC11-V-185185 AHCD

185 150 250x2 ACC11-V-185150 AHCD

185 120 250x2 ACC11-V-185120 AHCD

185 95 200x2 ACC11-V-18595 AHCD

185 70 150x2 ACC11-M-18570 AHCD

185 50 150x2 ACC11-M-18550 AHCD

185 35 150x2 ACC11-M-18535 AHCD

240 240 200x3 ACC11-V-240240 AHCD

240 185 200x3 ACC11-V-240185 AHCD

240 150 200x3 ACC11-V-240150 AHCD

240 120 200x3 ACC11-V-240120 AHCD

240 95 250x2 ACC11-V-24095 AHCD

240 70 250x2 ACC11-V-24070 AHCD

240 50 200x2 ACC11-V-24050 AHCD

m

Cable To Ground Rod

orizontal Cable Terminal To Ground RodH

A B Powder Mould Clampmm mm2 ( g ) Type Type

10 65 ACR1-C-12710 AHCC16 65 ACR1-C-12716 AHCC25 65 ACR1-C-12725 AHCC

65 ACR1-C-12735 AHCC50 65 ACR1-C-12750 AHCC70 90 ACR1-C-12770 AHCC95 90 ACR1-C-12795 AHCC

120 90 ACR1-C-127120 AHCC10 65 ACR1-C-14210 AHCC16 65 ACR1-C-14216 AHCC25 65 ACR1-C-14225 AHCC35 90 ACR1-C-14235 AHCC50 90 ACR1-C-14250 AHCC

90 ACR1-C-14270 AHCC95 90 ACR1-C-14295 AHCC

120 90 ACR1-C-142120 AHCC150 115 ACR1-C-142150 AHCC185 150 ACR1-C-142185 AHCC240 150 ACR1-C-142240 AHCC10 65 ACR1-C-17210 AHCC16 65 ACR1-C-17216 AHCC25 65 ACR1-C-17225 AHCC35 65 ACR1-C-17235 AHCC50 90 ACR1-C-17250 AHCC70 90 ACR1-C-17270 AHCC


12.7 35

14.2 70

17.2 95

Cable To Ground Rod

orizontal Cable Terminal To Ground Rod Continued….

150 115 ACR1-C-172150 AHCC

H

17.2 185 150 ACR1-C-172185 AHCC240 150 ACR1-C-172240 AHCC300 200 ACR1-C-172300 AHCC

Cable To Ground Rod

orizontal Through To Ground Rod H

B Powder MouldA Clampmm mm2 ( g ) Type Type


90 ACR2-C-12735 AHCC50 90 CR2-C-12750 AHCC70 90 ACR2-C-12770 AHCC95 115 ACR2-C-12795 AHCC

120 150 ACR2-C-127120 AHCC10 65 ACR2-C-14210 AHCC16 65 ACR2-C-14216 AHCC25 90 ACR2-C-14225 AHCC35 90 ACR2-C-14235 AHCC50 90 ACR2-C-14250 AHCC


120 150 ACR2-C-142120 AHCC150 200 ACR2-C-142150 AHCC185 200 ACR2-C-142185 AHCC240 250 ACR2-C-142240 AHCC10 65 ACR2-C-17210 AHCC16 65 ACR2-C-17216 AHCC25 90 ACR2-C-17225 AHCC35 90 ACR2-C-17235 AHCC50 115 ACR2-C-17250 AHCC70 115 ACR2-C-17270 AHCC

115 ACR2-C-17295 AHCC120 150 ACR2-C-172120 AHCC150 200 ACR2-C-172150 AHCC185 200 ACR2-C-172185 AHCC240 250 ACR2-C-172240 AHCC300 150x2 ACR2-D-172300 AHCD

12.7 35

14.2 70

17.2 95

able To Ground Rode To Ground Rod

CHorizontal Run & Tap Cabl

B Powder MouldA Clampmm mm2 ( g ) Type Type



120 200 ACR17-C-127120 AHCC25 90 ACR17-C-14225 AHCC35 115 ACR17-C-14235 AHCC50 150 ACR17-C-14250 AHCC


120 150x2 ACR17-D-142120 AHCD150 200x2 ACR17-D-142150 AHCD25 90 ACR17-C-17225 AHCC35 115 ACR17-C-17235 AHCC50 150 ACR17-C-17250 AHCC70 200 ACR17-C-17270 AHCC

250 ACR17-C-17295 AHCC120 150x2 ACR17-D-172120 AHCD150 200x2 ACR17-D-172150 AHCD185 200x2 ACR17-D-172185 AHCD240 200x3 ACR17-D-172240 AHCD25 115 ACR17-C-23125 AHCC35 150 ACR17-C-23135 AHCC50 200 ACR17-C-23150 AHCC70 250 ACR17-C-23170 AHCC

50x2 ACR17-D-23195 AHCD120 200x2 ACR17-D-231120 AHCD150 250x2 ACR17-D-231150 AHCD185 250x2 ACR17-D-231185 AHCD240 250x3 ACR17-D-231240 AHCD

12.7 70

14.2 70

17.2 95

23.1 95 1

Cable To Ground Rodle To Ground RodHorizontal Parallel Run Cab

m2 ( g ) TypeB Powder MouldA Clamp

mm m Type25 115 ACR24-C-12725 AHCC35 115 ACR24-C-12735 AHCC

150 ACR24-C-12750 AHCC70 200 ACR24-C-12770 AHCC95 250 ACR24-C-12795 AHCC

120 ACR24-D-127120 AHCD25 115 ACR24-C-14225 AHCC35 150 ACR24-C-14235 AHCC50 200 ACR24-C-14250 AHCC

250 ACR24-C-14270 AHCC95 150x2 ACR24-D-14295 AHCD

120 200x2 ACR24-D-142120 AHCD150 250x2 ACR24-D-142150 AHCD185 250x2 ACR24-D-142185 AHCD240 250x3 ACR24-D-142240 AHCD25 115 ACR24-C-17225 AHCC35 150 ACR24-C-17235 AHCC50 200 ACR24-C-17250 AHCC70 250 ACR24-C-17270 AHCC

50x2 ACR24-D-17295 AHCD120 200x2 ACR24-D-172120 AHCD150 250x2 ACR24-D-172150 AHCD185 250x2 ACR24-D-172185 AHCD240 250x3 ACR24-D-172240 AHCD25 150 ACR24-C-23125 AHCC35 200 ACR24-C-23135 AHCC50 250 ACR24-C-23150 AHCC70 150x2 ACR24-D-23170 AHCD

200x2 ACR24-D-23195 AHCD120 250x2 ACR24-D-231120 AHCD150 200x3 ACR24-D-231150 AHCD185 200x3 ACR24-D-231185 AHCD

12.7 50

150x2

14.2 70

17.2 95 1

23.1 95

Cable To Ground Rodo Side of Ground RodHorizontal Through Cable t

A B Powder Mould Clampmm mm2 ( g ) Type Type

10 90 ACR3-E-12710 AHCD16 90 ACR3-E-12716 AHCD25 90 ACR3-E-12725 AHCD

90 ACR3-E-12735 AHCD50 115 ACR3-E-12750 AHCD70 115 ACR3-E-12770 AHCD95 115 ACR3-E-12795 AHCD120 150 ACR3-E-127120 AHCD10 90 ACR3-E-14210 AHCD16 90 ACR3-E-14216 AHCD25 90 ACR3-E-14225 AHCD35 90 ACR3-E-14235 AHCD50 115 ACR3-E-14250 AHCD

115 ACR3-E-14270 AHCD95 115 ACR3-E-14295 AHCD120 150 ACR3-E-142120 AHCD150 200 ACR3-E-142150 AHCD185 250 ACR3-E-142185 AHCD240 200x2 ACR3-J-142240 AHCD10 90 ACR3-E-17210 AHCC16 90 ACR3-E-17216 AHCC25 90 ACR3-E-17225 AHCC35 90 ACR3-E-17235 AHCC50 115 ACR3-E-17250 AHCC70 150 ACR3-E-17270 AHCC

150 ACR3-E-17295 AHCC120 200 ACR3-E-172120 AHCC150 250 ACR3-E-172150 AHCC185 200x2 ACR3-J-172185 AHCC240 200x2 ACR3-J-172240 AHCC300 200x3 ACR3-J-172300 AHCD

12.7 35

14.2 70

17.2 95

Cable To Steel Surface

Horizontal Cable to Horizontal Steel Surface

A Powder Mould Clampmm2 ( g ) Type Type10 45 ACS1-A-10 AHCA16 45 ACS1-A-16 AHCA25 45 ACS1-A-25 AHCA35 45 ACS1-A-35 AHCA50 90 ACS1-C-50 AHCC70 90 ACS1-C-70 AHCC95 115 ACS1-C-95 AHCC120 115 ACS1-C-120 AHCC150 150 ACS1-C-150 AHCC185 200 ACS1-C-185 AHCC240 200 ACS1-C-240 AHCC300 250 ACS1-C-300 AHCC


Horizontal Through Cable To Horizontal Steel Surface

A Powder Mould Clampmm2 ( g ) Type Type10 45 ACS2-A-10 AHCA16 45 ACS2-A-16 AHCA25 45 ACS2-A-25 AHCA35 45 ACS2-A-35 AHCA50 90 ACS1-C-50 AHCC70 115 ACS1-C-70 AHCC95 115 ACS1-C-95 AHCC120 150 ACS1-C-120 AHCC150 200 ACS1-C-150 AHCC185 250 ACS1-C-185 AHCC240 150x2 ACS1-D-240 AHCD300 200x2 ACS1-D-300 AHCD


Angular Cable to vertical Steel Surface

ACS–3 Type mold are used to join the end of a copper cable at a 45° angle to a vertical steel surface

A Powder Mould Clampmm2 ( g ) Type Type10 45 AC 0S3-A-1 AHCA16 45 ACS3-A-16 AHCA25 45 ACS3-A-25 AHCA35 45 ACS3-A-35 AHCA50 90 ACS3-C-50 AHCC70 90 ACS3-C-70 AHCC95 115 ACS3-C-95 AHCC

120 115 ACS3-C-120 AHCC150 150 ACS3-C-150 AHCC185 200 ACS3-C-185 AHCC240 200 ACS3-C-240 AHCC300 250 ACS3-C-300 AHCC


Vertical Through cable To Vertical Steel Surface

ACS-4 Type mould are used to join a vertical through copper cable

A Powder Mould Clampmm2 ( g ) Type Type25 90 ACS4-Y-25 AHCC35 115 ACS4-Y-35 AHCC50 200 ACS4-Y-50 AHCC70 200 ACS4-Y-70 AHCC95 250 ACS4-Y-95 AHCC120 250 ACS4-Y-120 AHCC150 250 ACS4-Y-150 AHCC


ACS-7 Overhead Vertical Tap Cable to vertical Steel Surface

ACS-7 Type Mould are used to join an overhead vertical copper surface. conductor drop tap to a vertical steel surface.Note that the cable is

on the Surface

A Powder Mould Clampmm2 ( g ) Type Type10 65 AC 0S7-C-1 AHCC16 65 ACS7-C-16 AHCC25 65 ACS7-C-25 AHCC35 65 ACS7-C-35 AHCC50 150 ACS7-C-50 AHCC70 150 ACS7-C-70 AHCC95 200 ACS7-D-95 AHCD120 200 ACS7-D-120 AHCD150 250 ACS7-D-150 AHCD185 150x2 ACS7-D-185 AHCD240 200x2 ACS7-D-240 AHCD300 200x2 ACS7-D-300 AHCD


in the end of a copper cable at a 45° angle toa vertical steel surfaceACS-3 Type Mould used to jo

A PIPE Powder Mould Clampmm2 SIZE ( g ) Type Type10 45 ACS3.1-C-10 AHCC16 1 1/4" to 4" ACS 1645 3.1-C- AHCC25 4" to 6" 90 ACS3.1-C-25 AHCC35 6" to 10" 90 ACS3.1-C-35 AHCC50 12" 7 up 115 ACS3.1-C-50 AHCC70 115 ACS3.1-C-70 AHCC

BusBar To Tape , Cable and other Steel SurfaceABS-1 Type Mould are used to connect a vertical copper bus bar tap to a

e.vertical steel surface. Bus flat side is parallel to surfac

Powder MouldA Clampmmxmm ( g ) Type Type

2 A0x2 65 BS1-C-202 AHCC

20x3 65 AB 2S1-C-20 AHCC

25x2 90 ABS1-C-252 AHCC

25x3 90 ABS1-C-253 AHCC

25x4 90 ABS1-C-254 AHCC

25x6 150 ABS1-C-256 AHCC

30x2 90 ABS1-C-302 AHCC

30x3 90 ABS1-C-303 AHCC

30x4 115 ABS1-C-304 AHCC

30x5 150 ABS1-C-305 AHCC

31x3 90 ABS1-C-313 AHCC

31x6 200 ABS1-C-316 AHCC

38x3 150 ABS1-C-383 AHCC

38x5 200 ABS1-C-385 AHCC

38x6 250 ABS1-C-386 AHCC

40x3 150 ABS1-C-403 AHCC

40x4 200 ABS1-C-404 AHCC

40x5 200 ABS1-C-405 AHCC

40x6 250 ABS1-C-406 AHCC

50x3 200 ABS1-C-503 AHCC

50x4 250 ABS1-C-504 AHCC

50x5 250 ABS1-C-505 AHCC

BusBar To Tape , Cable and other Steel Surface ABS-1 Type Mould are used to connect a vertical copper bus bar tap to a

e.

50x6 150x2 ABS1-D-506 AHCD

vertical steel surface. Bus flat side is parallel to surfac

Continued…

50x8 200x2 ABS1-D-508 AHCD

60x6 200x2 ABS1-D-606 AHCD

60x8 250x2 ABS1-D-608 AHCD

60x10 200x3 ABS1-D-6010 AHCD

80x6 250x2 ABS1-D-806 AHCD

80x8 200x3 ABS1-D-808 AHCD

80x10 250x3 ABS1-D-8010 AHCD

ABS-2 Horizontal Tap to Horizontal Steel SurfaceABS-2 Type Mould are used to connect a horizontal copper bus bar

to surface. tap to a horizontal steel surface. Bus flat side is parallel

A Powder Mould Clampmmxmm ( g ) Type Type

20x2 65 ABS2-C-202 AHCC

20x3 90 AB 3S2-C-20 AHCC

25x2 90 ABS2-C-252 AHCC

25x3 90 ABS2-C-253 AHCC

25x4 90 ABS2-C-254 AHCC

25x6 150 ABS2-C-256 AHCC

30x2 115 ABS2-C-302 AHCC

30x3 115 ABS2-C-303 AHCC

ABS-2 Horizontal Tap to Horizontal Steel Surface

per bus bartap to a horizontal steel surface. Bus flat side is parallel to surface.

150 ABS2-C-304 AHCC

ABS-2 Type Mould are used to connect a horizontal cop

Continued………

30x4

30x5 200 ABS2-C-305 AHCC

31x3 115 ABS2-C-313 AHCC

31x6 200 ABS2-C-316 AHCC

38x3 150 ABS2-C-383 AHCC

38x5 200 ABS2-C-385 AHCC

38x6 200 ABS2-C-386 AHCC

40x3 115 ABS2-C-403 AHCC

40x4 200 ABS2-C-404 AHCC

40x5 200 ABS2-C-405 AHCC

40x6 250 ABS2-C-406 AHCC

50x3 200 ABS2-C-503 AHCC

50x4 150x2 ABS2-D-504 AHCD

50x5 150 ABS2-D-505 AHCD

50x6 150x2 ABS2-D-506 AHCD

50x8 200x2 ABS2-D-508 AHCD

BusBar To Tape , Cable and other Steel Surface

ABB-2 Horizontal to Vertical at Right Angle

ABB-2 Type Mould are used to join horizontal copper bus bar at rightbus bar. Flat sides of

both are vertical and parallel. angles a vertical steel surface to the top of vertical

Powder MouldA Clampmmxmm ( g ) Type Type

25x3 65 ABB2-C-253 AHCC25x5 90 AB 5B2-C-25 AHCC25x6 115 AB 6B2-C-25 AHCC25x8 150 AB 58B2-C-2 AHCC

25x12 250 ABB2-C-2512 AHCC31x6 150 ABB2-C-316 AHCC38x3 115 ABB2-C-383 AHCC38x6 200 ABB2-C-386 AHCC38x8 250 ABB2-C-388 AHCC50x3 90 ABB2-C-503 AHCC50x4 115 ABB2-C-504 AHCC50x5 200 ABB2-C-505 AHCC50x6 250 ABB2-C-506 AHCC50x8 150x2 ABB2-D-508 AHCD

BusBar To Tape , Cable and other Steel Surface

ABS-4 Horizontal or Vertical Thru Bar to Horizontal Steel Surface

ABS-4 Type Mould are used to join a horizontal through copper bus bar to a vertical steel surface. Bus flat side is parallel to surface.

Powder Mould( g ) Type

20x2 90 ABS4-C-202

A Clampmmxmm Type

AHCC20x3 90 AB 3S4-C-20 AHCC25x2 115 AB 2S4-C-25 AHCC25x3 115 AB 53S4-C-2 AHCC25x4 150 ABS4-C-254 AHCC25x6 150 ABS4-C-256 AHCC30x2 115 ABS4-C-302 AHCC30x3 115 ABS4-C-303 AHCC30x4 200 ABS4-C-304 AHCC30x5 200 ABS4-C-305 AHCC31x3 150 ABS4-C-313 AHCC31x6 200 ABS4-C-316 AHCC38x3 150 ABS4-C-383 AHCC38x5 200 ABS4-C-385 AHCC38x6 250 ABS4-C-386 AHCC40x3 150 ABS4-C-403 AHCC40x4 200 ABS4-C-404 AHCC40x5 200 ABS4-C-405 AHCC40x6 250 ABS4-C-406 AHCC50x3 200 ABS4-C-503 AHCC50x4 250 ABS4-C-504 AHCC50x8 200x2 ABS4-D-508 AHCD60x6 200x2 ABS4-D-606 AHCD60x8 250x2 ABS4-D-608 AHCD60x10 250x3 ABS4-D-6010 AHCD

Tape To Cable

ACB-1 Horizontal Cable Tap to Horizontal Lug or Busould are used to connect a copper conductor

to a copper lug or bus bar. ACB-1 Type M

Powder MouldA Clampmm2 ( g ) Type Type10 32 ACB1-C-10202 AHCC16 32 ACB1-C-16202 AHCC16 32 ACB1-C-16203 AHCC16 45 ACB1-C-16253 AHCC25 32 ACB1-C-25202 AHCC25 45 AACB1-C-25203 AHCC25 45 ACB1-C-25253 AHCC35 32 ACB1-C-35202 HCC35 45 ACB1-C-35203 AHCC35 45 ACB1-C-35253 AHCC50 45 ACB1-C-50202 AHCC50 45 ACB1-C-50203 AHCC50 65 ACB1-C-50253 AHCC70 65 ACB1-C-70253 AHCC70 90 ACB1-C-70254 AHCC70 90 ACB1-C-70256 AHCC95 90 ACB1-C-95253 AHCC95 90 ACB1-C-95254 AHCC95 90 ACB1-C-95255 AHCC95 90 ACB1-C-95256 AHCC120 90 ACB1-C-120253 AHCC120 90 ACB1-C-120254 AHCC120 115 ACB1-C-120255 AHCC120 115 ACB1-C-120256 AHCC120 115 ACB1-C-120305 AHCC120 115 ACB1-C-120503 AHCC120 150 ACB1-C-120506 AHCC

Tape To Cable

tal Cable Tap to Horizontal Lug or Busould are used to connect a copper conductor

ACB1-C-150256 AHCC

ACB-1 HorizonACB-1 Type Mto a copper lug or bus bar.

Continued…….

150 115 150 115 ACB1-C-150305 AHCC150 150 ACB1-C-150405 AHCC150 115 ACB1-C-150503 AHCC150 115 ACB1-C-150504 AHCC185 150 ACB1-C-185305 AHCC185 150 ACB1-C-185316 AHCC185 150 ACB1-C-185386 AHCC185 150 ACB1-C-185405 AHCC185 150 ACB1-D-185504 AHCD185 200 ACB1-D-185505 AHCD185 200 ACB1-D-185506 AHCD240 200 ACB1-D-240503 AHCD240 200 ACB1-D-240504 AHCD240 200 ACB1-D-240505 AHCD240 150x2 ACB1-D-240506 AHCD300 150x2 ACB1-D-300506 AHCD300 200x2 ACB1-D-300508 AHCD

Tape To Cable

ACB-4 Horizontal Cable Tap to Horizontal Bus

ACB-4 Type Mould are used to connect horizontal copper cable tap horizontal to a horizontal copper bus bar with the flat side

B Powder Mouldmmxmm ( g ) Type

10 20x2 25 ACB4-C-10202

A Clampmm2 Type

AHCC16 2 ACB4-C-162020x2 32 AHCC16 20x3 32 ACB4-C-16203 AHCC16 25x3 32 ACB4-C-16253 AHCC25 20x2 25 ACB4-C-25202 AHCC25 20x3 32 ACB4-C-25203 AHCC25 25x3 32 ACB4-C-25253 AHCC35 20x2 32 ACB4-C-35202 AHCC35 20x3 45 ACB4-C-35203 AHCC35 25x3 45 ACB4-C-35253 AHCC50 20x3 45 ACB4-C-50203 AHCC50 25x2 45 ACB4-C-50252 AHCC50 25x3 45 ACB4-C-50523 AHCC50 25x4 65 ACB4-C-50254 AHCC50 25x6 65 ACB4-C-50256 AHCC70 25x3 65 ACB4-C-70253 AHCC70 25x4 65 ACB4-C-70254 AHCC70 25x6 90 ACB4-C-70256 AHCC95 25x3 90 ACB4-C-95253 AHCC95 25x4 90 ACB4-C-95254 AHCC95 25x5 90 ACB4-C-95255 AHCC95 25x6 115 ACB4-C-95256 AHCC120 25x3 90 ACB4-C-120253 AHCC120 25x5 90 ACB4-C-120254 AHCC120 25x6 115 ACB4-C-120255 AHCC120 30x5 115 ACB4-C-120256 AHCC150 25x6 115 ACB4-C-150256 AHCC150 30x5 115 ACB4-C-150305 AHCC

Tape To CableACB-4 Horizontal Cable Tap to Horizontal Bus ACB-4 Type Mould are used to connect horizontal copper cable tap

opper bus bar with the flat side horizontal to a horizontal c

Continued……..

150 40x5 150 ACB4-C-150405 AHCC185 25x3 150 ACB4-C-185305 AHCC185 30x5 150 ACB4-C-185316 AHCC185 40x5 150 ACB4-C-185386 AHCC185 50x5 150 ACB4-C-185405 AHCC185 50x6 150 ACB4-C-185504 AHCC240 50x5 200 ACB4-C-240505 AHCC240 50x6 250 ACB4-C-240506 AHCC300 50x6 150x2 ACB4-D-300506 AHCD300 50x8 200x2 ACB4-D-300508 AHCD

Tape To CableACB-5 Type Mould are used to connect horizontal copper bus bar, flat side horizontal, to a horizontal through run cable.

B Powder Mouldmmxmm ( g ) Type

10 20x2 45 ACB5-C-102

A Clampmm2 Type

02 AHCC16 2 ACB5-C-162020x2 45 AHCC16 20x3 45 ACB5-C-16203 AHCC16 25x3 65 ACB5-C-16253 AHCC25 20x2 45 ACB5-C-25202 AHCC25 20x3 45 ACB5-C-25203 AHCC25 25x3 65 ACB5-C-25253 AHCC35 20x2 45 ACB5-C-35202 AHCC35 20x3 45 ACB5-C-35203 AHCC35 25x3 65 ACB5-C-35253 AHCC50 20x3 65 ACB5-C-50203 AHCC50 25x2 65 ACB5-C-50252 AHCC50 25x3 65 ACB5-C-50523 AHCC70 25x3 90 ACB5-C-70253 AHCC70 25x4 115 ACB5-C-70254 AHCC70 25x6 115 ACB5-C-70256 AHCC95 25x4 150 ACB5-C-95254 AHCC95 25x5 150 ACB5-C-95255 AHCC95 25x6 150 ACB5-C-95256 AHCC120 25x5 150 ACB5-C-120254 AHCC120 25x6 150 ACB5-C-120255 AHCC120 30x5 200 ACB5-C-120256 AHCC150 25x6 200 ACB5-C-150256 AHCC150 30x5 200 ACB5-C-150305 AHCC150 40x5 250 ACB5-C-150405 AHCC185 30x5 250 ACB5-C-185305 AHCC185 40x5 250 ACB5-C-185405 AHCC185 50x5 150x2 ACB5-D-185505 AHCD240 30x5 250 ACB5-C-240305 AHCC240 50x6 200x2 ACB5-D-240506 AHCD300 50x6 250x2 ACB5-D-300506 AHCD300 50x8 250x2 ACB5-D-300508 AHCD

elect chartS

ACC-6 ACC-7 ACC-11 ACC-13 ACC-14




ACC-33 ACC-34 ACC-35 ACC-36 ACR-1

ACR-2 ACR-4 ACR-3 ACR-5 ACR-6

ACR-7 AACR-9 ACR-12 ACR-13 ACR-14


ARR-1 ARR-2ARS-1

(STL SURFACE) (STL SURFACE) (STL SURFACE)ARS-2 ARS-3

ACS-1SURFAC(STL E) (STL CE)

ACS-2SURFA

ACS-3(STL SURFACE)

ACS-4(STL SURFACE)

ACS-5(STL SURFACE)



SURFAC SURFA SURFA SURFAC L SURFAC

ACS-22(STL SURFACE)

ACS-23(STL SURFACE)

ACS-27(STL SURFACE)

ACS-28(STL SURFACE)

ACS-43(STL SURFACE)

ACS-6(STL SURFACE)

ACS-7(STL SURFACE)

ACS-8(STL SURFACE)

ACS-9(STL SURFACE)

ACS-11(STL SURFACE)

ACS-12(STL E)

ACS-13(STL CE)

ACS-14(STL CE)

ACS-15(STL E)

ACS-18(ST E)

ACS-46(STL SURFACE)

ARS-3(STL SURFACE)

ACRS-1(STL SURFACE)

ACRS-2(STL SURFACE) ARE-1

ACB-9ARE-2 ACB-1 ACB-2 ACB-3

ACB-5 ACB-6 ACB-7 ACB-8 ACB-4




ACB-38 ABB-1 ABB-2 ABB-3 ABB-4

ABB-5 ABB-6 ABB-7 ABB-12 ABB-14

ABB-17 ABB-20 ABB-21 ABB-22 ABB-27

RFAC RFAC RFAC RFAC

SURFAC SURFA

ABB-41ABS-1

(STL SURFA E)ABS-2

(STL SURFAC )ABS-3

(STL SURFACABS-4

(STL SURFACE)C E E)

E)ABS-5

(STL SURFACE)ABS-6

(STL SURFACE)ABS-7

(STL SURFACE)ABS-8

(STL SURFACE)ABS-13

(STL SURFAC

ABS-14ABS-15

(STL SU E)ABS-16

(STL SU E)ABS-17

(STL SU E)ABS-18

(STL SU E)

ABS-19(STL E)

ABS-20(STL CE)

ACRE-1 ACRE-2 ACRE-3

ACRE-4 ACRE-5 ACRE-6 ACRE-7 ACRE-8



ACRE-20 ACRE-21 AAC-1 AAC-2 AAR-1

GRAPHIT LD E ERM ELDI OCES

A. Axi-weld Mould is made from graphite which makes it fragile and would crack or break if not handled with care.

B. Designed to withstand high temperatu oduced fr e exothermic welding. C. Requires pre-heating with a butane torch to ensure the mould is totally dry before

every first joint regardless new or used mould. Otherwise, the moulbreak or a bad joint produced or cuts down the life span of the mould.

D. Always ensure that the conductors fits snugly and sections of moulds are clampedtightly with the handle clamp to avoid leakage of weldmetal. Leakage will produced a bad

E. After every joint produced, always remove the slag with a recommended mould

F. ther hard object and brush that would damage the mould. e, the

Do nota spar ed or cuts downthe

E MOU XOTH IC W NG PR S

res pr om th

d may crack or

joint and cuts down the life span of the mould.

scrapper, then brush off the smaller particles with a proper mould cleaning brush. Caution : Do not use any o

G. Always keep the mould away from water or damn areas while it is hot. Otherwismould may crack or break.

over-heat the mould the throughout too many joints. Always either allow to rest or use e mould. Otherwise, the mould may crack or break or a bad joint produc

life span of the mould.

(1) (2) (3) (4)

Accessories

AXT-005 Flint Ignitor

This ignitor is used to ignite the strating powder for making the exothermicwelding joint. Each mold with a frame has a flint ignitor included.

AXT-001 Cable Cleaning Brush

The Cable Cleaning Brush is recommended for cleaning heavily oxidized cables. The V-shaped brushes permit their use orver a wide range of cable sizes. Brush assembly consists of a handle with two stiff wire bristle brushes that are Rotatable, for longer life and are replaceable.AXT-002 Bus Bar Cleaning Brush

The Bus Bar cleaning brush is used to clean large conductors and bus bars. It has short stiff bristles. These brushes should not be used to clean molds.AXT-003 Mold Cleaning Brush

The Mold Cleaning brush is used to clean the molds without damaging the molds.AXT-004 Mold Cleaners

The Mold Cleaners are used to clean the slag from molds that are not split through the crucible.

HandlAX

e ClampHC-001 HANDLE CLAM

e cartridge for mold. Check ID plate for mold and compare with numbbottom of cartridge.

uch spillage when Carefull

Insufficient metal to make ld.

Wrong mold for conductor beingused.

Replace with correct mold. In some applications, shimstock or adapter sleeves can be used to enlarge cableto fit mold.

we

PS

For most connections involving lugs, cable or rectangular bus, Handle Clamps are used. These Handles Clamps make possible the use of manydifferent sizes and types of molds with only two different clamps. Thesewill fit 95% all standard molds.

AXHA-001 HANDLE ATTACHMENTS

Handle Attachment is used to hold a molds in position. It is easily attached to the Handle Clamps.

Trouble Shooting Tips

PROBLEM PROBLEM CAUSE CORREECTION TO MAKE Worm mold resulting in leakingweld metal.

Replace mold or if only worn around conductoropening, use duct seal around conductor. Do not getduct seal into mold cavity.

Wrong siz er on

Too mdumping powder.

y open lid while holding over crucible and dump.

Handle clamps not properlyadjusted.

Remove set screw between the handles or the mold and adjust handle tension by backing out the eyebolt.

Dirt or slag stuck in parting line of mold.

Clean mold thoroughly between connections.

Mold does not close tightly causing weld metal to leakout.

r out-of-round cable. Straighten or cut out bad section of cable.Bent o

Handle clamps will not lock Handlclosed.

e Clamps not properlyadjusted.

Remove set screw between the handles or the mold and adjust handle tension by backing out the eyebolt.

M -heoisture in mold. Pre at mold to above 220o F with a propane torch.

reign material on nductors.

conductors with prush on conductor to remove any residue left ntors. If welding to

must be cleaned down to bright metal.

ct seal pecial precautions to keep duct seal out or weld

Ww

eld powder has gotten t.

R e with fresh, dry weld powder.

ound disc seal allowingwder to levity.

Weld metal blows out top of mind.

bo cible.e po

Forgot todid

use steel disc ornot seat if properly at

ttom of cru

Make suth

re disc is seated at bottom of crucible before pouringwder into crucible.

Oil, grease, moisture orfoco

Pre-heat opane torch then use a cleanwire brconduc cast iron or steel surface, weld area

Du in weld cavity. Take scavity.

Excessively high weld,bubbly or gassy appearance, poor weld.

eeplac

Mold worn or chippedarpo ak into moldca

Replace mold.

PROBLEM PROBLEM CAUSE CORREECTION TO MAKE Insufficient startiignition pocket on mold lid

ng powder.

in Place at least half of starting powder in ignition pocket of mold lid.

Flint ignitor not shootispark.

ng enough Clean flint ignitor according to directions on box orreplace flint ignitor.

Cannot ignite powder.

Starting powder lumped ith edge of powdertogether.

Break up starting powder on lid wtube.

Urag to clean mold between shotsbrush or screwdriver on molds.

Weight of mold not sduring reaction causing molslip when cable melts.

upport ing pliers on ground rod under mold to he weight of the mold during the reaction.

edd to

Use locksupport t

Poor weld to ground rod.

re or contaminant on Pre-heat conductors with propane torch then use a Moistucable or ground rod. clean wire brush on conductors to remove any residue

left on conductors.

Improperly cleanel

Mold wearing out ot fast. Improper cleaning of mold. se mold cleaner, soft natural bristle brush or clean. Do not use wire

d area on steel.

An area larger than the weld area should be cleaneddown to bright clean metal.

Moisture or contaminant on cab

Pre-heat conductors with propane torch then use a clean wir residueleft on cond

le or steel surface. e brush on conductors to remove anyuctors.

Cable is improperly positione

metal.

Position cable in mol

of cable in the center of where the liquid weld metalhits the steel.

All of the causes listed unwelding to

dersteel surface also

apply to this section.

Specify "CI" behind cartridge when order powder.

when it is fired. under tension. Cut out severely twisted cable.

Weld will not stick to steesurface.

d in mold, blocking the flow of weld

d in accordance with directionsfor mold. If directions are not available, position top

Weld will not stick to cast iron surface.

Not using CI (Cast Iron) powder.

Cable pulls out of mold Cables are either twisted or Use cable clamp or other method to remove tension.

Documents

CAT 7 - AXIWELD EXOTHERMIC