Installers and Inspectors Guide for

making Exothermic Connections • Grounding

• Lightning Protection

• Cathodic Protection

• Rail®

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This handbook was written to give installers and

inspectors in the fi eld a guide for making high

quality Ultraweld connections.

The tips for using NUWTube® and UltraShot® have

been developed based on testing done by Harger

as well as many years of experience in the fi eld of

exothermic welding.

If you have any questions about this guide or

any methods or tips described herein, please

don’t hesitate to contact either your Harger

Representative or the experienced technical help

personnel at the Harger main offi ce, 800.842.7437

or www.harger.com.

contents

What is Ultraweld.................................................. 2

The Ultraweld Connection .................................... 3

Tips for Making Quality Connections .................... 3

Making an UltraShot Connection .......................... 4

Making a NUWTube Connection .......................... 6

Inspecting an Ultraweld Mold ............................... 8

Inspecting Ultraweld Welds .................................. 9

Troubleshooting Tips .......................................... 14

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What is Ultraweld

The Ultraweld processes (NUWTube and UltraShot) use

the same, time proven way to connect conductors at

the molecular level. This process involves the reduction

of copper oxide by aluminum which creates Aluminum

Oxide and enough heat to provide molten copper for the

connection.

The reaction is encapsulated by a graphite mold that is

designed for specifi c conductors. These molds provide a

portable and economical way to make the best electrical

connection.

2

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The Ultraweld Connection

An Ultraweld connection produces an electrical connection

superior in performance to any known mechanical or

pressure type connection. These connections are made

in several applications including; Grounding, Lightning

Protection, Cathodic Protection, and Rail.

The molecular bond formed when making an Ultraweld

between two or more conductors has the following

advantages:

• Will not loosen

• Current carrying capacity greater than the conductors

• No increase in resistance over time

• Will last longer than the conductor being welded

• Made with materials that are inexpensive, portable, and

require little training

• Easily inspected through non destructive means

Tips for Making Quality

Connections

As with all products, there are tips to make the Ultraweld

process easier and to insure a quality connection. Some of

these tips are as follows:

• Read all instructions that accompany the mold. The type

of mold can be found on the mold tag. This will indicate

which drawing should be viewed to understand the

placement of the conductors in the weld cavity.

• Dry the mold with a torch to remove any moisture in the

mold. Mold should be heated above 220 degrees F.

• Clean and dry all conductors to be welded. All metal

surfaces should be cleaned down to bright metal.

• Make sure mold can stay in the vertical position while

making the weld as this process is a gravity fed system.

• Make sure handle closes mold tightly and handles lock

properly.

• Check all conductor holes in the graphite to make sure

they aren’t worn or cracked.

• Make sure conductors fi t snug in the mold to seal in the

weld metal.

• Clean mold with a natural bristle brush. Do not use a

metal or plastic brush on the mold.

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step 1Dry and Clean the mold and conductor.

step 2Place conductors and UltraShot® cartridge into

mold.

step 3Close the lid and attach DRONE cord to the

UltraShot® igniter.

Making an UltraShot

Connection (drop-in steps)

step 1

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step 4Push and hold both igniter buttons at the same time.

step 5Open mold and remove connection, remove

slag and clean mold before making the next

connection.

A Completed UltraShot® connectionA Completed UltraShot® connection®

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Making a NUWTube

Connection (pour-in steps)

Step 1:

Torch dry the mold before making the fi rst connection.

Step 2:

Clean and dry conductors, insert conductor into mold, close handle clamp and lock mold.

Step 4:

Remove Clear plastic cap from NUWTube, pour weld metal into mold.

Step 3:

Insert disk into mold.

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Step 6:

Ignite material located on top of the lid using a fl int igniter (FLTIG).

Step 7:

After the connection is complete, open the mold and remove the connection, remove slag and clean mold before making the next connection.

Complete NUWTUBE connection

Step 5:

Close lid, remove Orange cap from starting powder chamber and sprinkle next to ignition hole.

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Inspecting an Ultraweld

Mold

An Ultraweld graphite mold is designed to last an average

of at least 50 shots but can last longer with proper care and

cleaning. Using the UltraShot system has proven to more

than double the life of the mold.

Inspect the mold regularly for the following items:

1. Conductor Openings – The conductors should fi t tight

to keep the mold from leaking when fi red.

2. Weld Cavity – The weld cavity should be well defi ned

without large chips or cracks that may effect the weld.

3. Tap Hole – Should be well defi ned without major chips.

4. Disk Seat – Should be well defi ned and capable of

sealing the weld metal in the crucible area while the

reaction is taking place.

5. Mold Parting Surface – Needs to be without major

chips or cracks and capable of sealing the reaction in

the mold.

6. Crucible – Should be able to safely hold the reaction.

8

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Inspecting Ultraweld Welds

In order to properly inspect an Ultraweld connection, you

must fi rst familiarize yourself with the terms used for the

different parts of the mold and the different parts of the weld.

The mold was described in the previous section. The weld is

detailed below.

Weld

Sleeve

Riser

Weld Body

Conductor

Weld Sleeve – The area of the weld that comes out from the

weld body and helps give mechanical strength to the area

where the molecular bond is made.

Conductor – The metal materials that are to be welded

together.

Riser – The area on top of the weld that is used for excess

weld material and slag.

Weld Body – The area under the tap where the conductors

are welded or melted together at the molecular level.

9

An exothermic weld can conduct more current than a

mechanical connection because the cross section of weld

body is greater than the cross section of the conductor being

welded.

To have a quality weld you must have a solid weld body with

a cross section greater than the conductors, the sleeves

must be complete, there should be limited slag in the weld,

and there should be limited signs of contamination in the

riser. The riser should be higher than the level of the highest

conductor.

Good Welds

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Good Welds continued

Inspecting Ultraweld Welds

10

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Inspecting welds to steel, cast iron, galvanized steel and

copper bar.

1. Make sure the surface is ground down to bright metal

with all coatings and oxide removed.

2. In most cases, you will be able to see a discoloration of

the metal surface around the weld.

3. Tap weld with a 12 to 16 oz. ball peen hammer at

90 degrees to weld and in such a way that you do not

damage the conductor or hard enough that you deform

the weld. A bad weld will pop off if not made properly.

Inspecting Ultraweld Welds

11®

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Weld has too much slag in the weld that may compromise

the resistance of the connection. Sleeves not fi lled out

which may affect the strength of the weld. Disk not properly

placed or a leak in the mold are possible causes.

Bad weld due to under fi lling. Body of weld is too low, it is

lower than the top of the conductors. Sleeves are not fi lled

out. It could compromise the resistance. Wrong weld metal

used or there was a leak in the mold.

Inspecting Ultraweld Welds

Bad Welds

12

Bad weld due to gas in the weld. This is usually apparent by

the color of the weld which will be lighter in color, the riser

will be high with a mushroom top, and there will be pin holes

apparent in top of the riser.

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The above weld cut in half reveals the amount of voids in

the weld. These can be caused by contaminates in the mold,

conductor or weld metal.

Note: A small number pin holes are acceptable, up to 20%.

Inspecting Ultraweld Welds

Bad Welds

13

Weld was not closed properly or it was worn out and leaked

signifi cantly. Also there is too much slag in the weld. Replace

mold if needed.

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UltraShot Troubleshooting

Tips

PR

OB

LE

MP

OS

SIB

LE C

AU

SE

Su

gg

este

d C

orre

cti

on

s

Ultra

Shot did

not

fi re

Battery

not charg

ed

Charg

e b

attery

and r

etr

y.

Try

diffe

rent battery

pack if availa

ble

.

Igniter

not pro

perly c

onnecte

d

to p

lug

Push igniter

all

the w

ay into

plu

g.

NU

WT

ube S

tart

ing

Pow

der

would

not

ignite

Old

fl int gun

Repla

ce fl int gun.

Sta

rtin

g p

ow

der

bein

g u

sed

impro

perly

Sprinkle

sta

rtin

g p

ow

der

on t

he s

ide o

f th

e lid

’s ignitio

n p

ock

et.

Weld

cavity u

nder

fi lls

Wro

ng s

ize c

art

ridge for

mold

Check ID

pla

te o

n m

old

for

pro

per

siz

e w

eld

mate

rial to

be u

sed.

Mold

leaked too m

uch m

olten

copper

to m

ake p

roper

weld

Worn

mold

. O

penin

g in m

old

is too larg

e to s

eal th

e m

old

pro

perly.

Repla

ce m

old

.

Wro

ng m

old

used for

the c

onducto

rs b

ein

g w

eld

ed.

Buy c

orr

ect

mold

.

Mold

did

not clo

se c

om

ple

tely

. A

dju

st handle

cla

mps a

s n

eeded t

o g

et

mold

clo

sed c

om

ple

tely

.

Wro

ng m

old

bein

g u

sed

Buy c

orr

ect m

old

.

14

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UltraShot Troubleshooting

TipsP

RO

BL

EM

PO

SS

IBL

E C

AU

SE

Su

gg

este

d C

orre

cti

on

s

Weld

not stickin

g

to s

teel or

cast iron

surf

ace

Surf

ace n

ot pre

pare

d p

roperly

Cle

an s

urf

ace d

ow

n t

o b

right

meta

l by e

ither

grindin

g o

r u

sin

g t

oo

ls s

ug

ge

ste

d in

th

e instr

uctio

ns.

Cable

not pla

ced in m

old

accord

ing to instr

uctions

Be s

ure

to f

ollo

w t

he m

old

instr

uction o

n the p

lacem

en

t o

f th

e c

on

du

cto

rs in

th

e m

old

to m

ake

su

re

suffi c

ient

heat

is t

ransfe

rred t

o t

he s

teel surf

ace t

o m

ake

th

e w

eld

.

Not usin

g c

ast iron p

ow

der

when

weld

ing to c

ast iron s

urf

ace

Ord

er

cast

iron p

ow

der.

Pro

ble

ms w

eld

ing to

gro

und r

od

Surf

ace n

ot pre

pare

d p

roperly

Cle

an a

nd p

repare

surf

aces a

ccord

ing t

o instr

uction

s.

Mold

not support

ed d

uring w

eld

ing

Pla

ce v

ice g

rips o

r cla

mp u

nder

mold

to s

upport

it d

urin

g w

eld

ing

pro

ce

ss.

Cable

not pla

ced in m

old

accord

ing t

o

instr

uctions

Be s

ure

to f

ollo

w t

he m

old

instr

uctions o

n t

he p

lace

me

nt

of

the

co

nd

ucto

rs in

th

e m

old

to

ma

ke

su

re

suffi c

ient

heat

is t

ransfe

rred t

o t

he g

round r

od t

o m

ake

th

e w

eld

.

Mold

does n

ot clo

se

all

the w

ay o

r handle

cla

mps w

on’t lock

Handle

cla

mp is n

ot adju

ste

d p

roperly

Follo

w instr

uctions o

n a

dju

sting h

andle

cla

mp t

o a

dju

st

the

m p

rop

erly.

Dirt, s

lag o

r oth

er

mate

rial stu

ck in t

he

part

ing lin

e o

r on the d

ow

el pin

sC

lean o

ff a

ll m

ate

rial to

get

a g

ood s

eal.

Bent or

out of ro

und c

onducto

rsS

traig

hte

n c

onducto

rs o

r cut

out

bad s

ections a

nd r

etr

y.

Mold

gets

stu

ck o

n

weld

Mold

left o

n w

eld

too long

Rem

ove m

old

fro

m w

eld

within

about

30 s

econds to

we

ld b

ein

g m

ad

e,

esp

ecia

lly o

n w

eld

s t

o s

tee

l.

15®

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PR

OB

LE

MP

OS

SIB

LE C

AU

SE

Su

gg

este

d C

orre

cti

on

s

Excessiv

ely

hig

h w

eld

or

excessiv

e g

as in

weld

Mois

ture

or

fore

ign s

ubsta

nce o

n t

he

mold

or

conductu

rs

Pre

heat

mold

s a

nd c

onducto

rs w

ith a

torc

h t

o a

tem

pe

ratu

re t

ha

t w

ill b

urn

off a

ny w

ate

r o

r o

rga

nic

mate

rial. U

se s

teel bru

sh t

o r

em

ove a

ny r

esid

ual m

ate

ria

l fr

om

co

nd

ucto

rs.

Do

no

t u

se

ste

el b

rush

on

gra

phite m

old

.

Wro

ng s

ize c

art

ridge u

sed

Double

check t

he m

old

ID

pla

te t

o m

ake s

ure

the p

rop

er

we

ld c

art

rid

ge

is b

ein

g u

se

d.

Mois

ture

in w

eld

meta

lR

epla

ce w

ith n

ew

weld

meta

l.

Duct seal in

weld

cavity

Duct

seal is

to b

e u

sed o

n t

he o

uts

ide p

ort

ion o

f th

e m

old

on

ly a

s a

la

st

reso

rt.

If it

ha

s to

be

use

d d

o

not

let

it m

igra

te into

the w

eld

cavity.

Conducto

rs p

ull

out of

mold

during p

rocess

Conducto

rs a

re u

nder

tensio

nR

em

ove t

ensio

n f

rom

conducto

rs o

r use w

ire c

lam

p G

RC

C t

o r

em

ove

te

nsio

n f

rom

co

nd

ucto

rs.

Mold

wearing o

ut

too fast

Impro

per

cle

anin

g o

f m

old

s

Only

use s

oft b

ristle b

rush o

r cotton r

ag to c

lean o

ut

the m

old

. U

se o

f m

eta

l bru

shes,

scre

w

driver, o

r oth

er

meta

l obje

cts

will

scra

tch the m

old

. A

lso,

do n

ot

use p

lastic o

n the m

old

as it

will

melt a

nd c

ause g

assy w

eld

s.

Bent, b

urr

ed, or

out of ro

und

conducto

rs

Clo

sin

g the m

old

on c

onducto

rs that are

bent,

burr

ed,

or

out

of

round w

ill c

rack a

nd c

hip

the

mold

s. T

ry r

em

ovin

g the d

am

aged s

ections if possib

le.

Insert

ing c

onducto

rs a

fter

mold

is

clo

sed

Try

to c

lose the m

old

with the c

onducto

rs a

lready insert

ed. T

his

will

reduce t

he w

ear

on t

he

conducto

r openin

gs.

UltraShot Troubleshooting

Tips

16

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301 Ziegler Drive • Grayslake, IL • 60030

800.842.7437 • 847.548.8700

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IG - 11.18

Ultraweld® Exothermic Welding Certifi cation

Training by Harger

This training is hands-on and provides your team with

understanding of Harger’s Ultraweld exothermic welding

process.

The tools required to make a connection as well as the

inspection process, safety and troubleshooting are also

discussed.

Attendees become certifi ed!

How Do You Get Started?

• Work with your Harger Sales Representative to pick a

date and time that works best for you and your team.

• Harger will provide the training materials and train

your team at your designated location, ex; jobsite or at

your offi ce.

• Attendees must sign-in and pass a test prior to

certifi cation.

• Individual certifi cation cards will be sent for distribution

after successful class completion.

• Depending on class size, training typically takes

1 to 3 hours.