Catalog thuốc hàn hóa nhiệt Axis Weld Exo - thiết bị tiếp địa chống sét

1. 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

2. 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.

3. 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.

4. 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 exposed
bare steel.

5. 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. 6. Close the lid of mould & from the side ignite the starting p
with the flint gun.
owder

7. Use Recommended Powder for
Recommended Joint.
Powders Are Available In Different Gramage For
Different Joint.
Avail.
Gram.
Given
Code
1 15 gram AWP15
2 25 gram AWP25
3 32 gram AWP32
4 45 gram AWP45
5 65 gram AWP65
6 90 gram AWP90
7 115 gram AWP115
8 150 gram AWP150
9 200 gram AWP200

8. 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 the
Grounding & Lightning protection system including the survey, designs, material
supplies, installation, trial maintenance, consultation and problem solving.
All this leads to our high quality products at reasonable prices, which answers our
slogan " We will give the best to our customers" which we will cherish forever.

9. Cable To Cable
Horizontal End To End
Powder Mould ClampA
mm2 ( g ) Type Type
10 15 ACC1-C-10 AHCC
16 25 ACC1-C-16 AHCC
25 32 ACC1-C-25 AHCC
35 32 ACC1-C-35 AHCC
50 45 ACC1-C-50 AHCC
70 65 ACC1-C-70 AHCC
95 90 ACC1-C-95 AHCC
120 90 ACC1-C-120 AHCC
150 115 ACC1-C-150 AHCC
185 150 ACC1-C-185 AHCC
240 200 ACC1-D-240 AHCD
300 200 ACC1-D-300 AHCD
500 200 x 2 ACC1-E-500 AHCD

10. 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
25 25 45
ACC4-C-
2525 AHCC 150 50 150 ACC4-C-15050 AHCC
35 35 65
ACC4-C-
3535 AHCC 150 35 115 ACC4-C-15035 AHCC
35 25 65
ACC4-C-
3525 AHCC 150 25 115 ACC4-C-15025 AHCC
50 50 90
ACC4-C-
5050 AHCC 185 185 150 x 2
ACC4-E-
185185 AHCD
50 35 90
ACC4-C-
5035 AHCC 185 150 250
ACC4-D-
185150 AHCD
50 25 90
ACC4-C-
5025 AHCC 185 120 250
ACC4-D-
185120 AHCD
70 70 115
ACC4-C-
7070 AHCC 185 95 200 ACC4-D-18595 AHCD
70 50 115
ACC4-C-
7050 AHCC 185 70 200 ACC4-D-18570 AHCD
70 35 115
ACC4-C-
7035 AHCC 185 50 200 ACC4-C-18550 AHCC
70 25 115
ACC4-C-
7025 AHCC 185 35 150 ACC4-C-18535 AHCC
95 95 150
ACC4-C-
9595 AHCC 185 25 150 ACC4-C-18525 AHCC
95 70 150
ACC4-C-
9570 AHCC 240 240 250x2
ACC4-D-
240240 AHCD
95 50 115
ACC4-C-
9550 AHCC 240 185 200x2
ACC4-D-
240185 AHCD
95 35 115
ACC4-C-
9535 AHCC 240 150 200x2
ACC4-D-
240150 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
120 70 150
ACC4-C-
12070 AHCC 240 50 250 ACC4-C-24050 AHCC
120 50 150
ACC4-C-
12050 AHCC 300 300 200x3
ACC4-D-
300300 AHCD

11. 120 35 115
ACC4-C-
12035 AHCC 300 240 200x3
ACC4-D-
300240 AHCD
120 25 115
ACC4-C-
12025 AHCC 300 185 250x2
ACC4-D-
300185 AHCD
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 Clamp
mm2 mm2 ( g ) Type Type
10 10 45
ACC6-C-
1010 AHCC
16 16 45
ACC6-C-
1616 AHCC
25 25 45
ACC6-C-
2525 AHCC
35 35 65
ACC6-C-
3535 AHCC
50 50 90
ACC6-C-
5050 AHCC
50 35 65
ACC6-C-
5035 AHCC
50 25 65
ACC6-C-
5025 AHCC
70 70 115 ACC6-C- AHCC

12. 7070
70 50 115
ACC6-C-
7050 AHCC
70 35 90
ACC6-C-
7035 AHCC
70 25 90
ACC6-C-
7025 AHCC
95 95 150
ACC6-C-
9595 AHCC
95 70 115
ACC6-C-
9570 AHCC
95 50 115
ACC6-C-
9550 AHCC
95 35 115
ACC6-C-
9535 AHCC
120 120 200
ACC6-C-
120120 AHCC
120 95 200
ACC6-C-
12095 AHCC
120 70 150
ACC6-C-
12070 AHCC
120 50 115
ACC6-C-
12050 AHCC
Cable To Cable
Horizontal Cable Tap To Horizontal Cable Run

13. A B Powder Mould Clamp A B Powder Mould Clamp
mm2 mm2 ( g ) Type mm2 mm2 ( g ) Type
10 10 25 ACC2-C-1010 AHCC 150 25 90 ACC2-C-15025 AHCC
16 16 32 ACC2-C-1616 AHCC 185 185 200
ACC2-D-
185185 AHCD
25 25 45 ACC2-C-2525 AHCC 185 150 200
ACC2-D-
185150 AHCD
35 35 45 ACC2-C-3535 AHCC 185 120 200
ACC2-D-
185120 AHCD
35 25 45 ACC2-C-3525 AHCC 185 95 150 ACC2-C-18595 AHCC
50 50 90 ACC2-C-5050 AHCC 185 70 90 ACC2-C-18570 AHCC
50 35 45 ACC2-C-5035 AHCC 185 50 90 ACC2-C-18550 AHCC
50 25 45 ACC2-C-5025 AHCC 185 35 90 ACC2-C-18535 AHCC
70 70 90 ACC2-C-7070 AHCC 185 25 90 ACC2-C-18525 AHCC
70 50 90 ACC2-C-7050 AHCC 240 240 150 x 2
ACC2-E-
240240 AHCD
70 35 45 ACC2-C-7035 AHCC 240 185 200
ACC2-D-
240185 AHCD
70 25 45 ACC2-C-7025 AHCC 240 150 200
ACC2-D-
240150 AHCD
95 95 115 ACC2-C-9595 AHCC 240 120 200
ACC2-D-
240120 AHCD
95 70 90 ACC2-C-9570 AHCC 240 95 150 ACC2-C-24095 AHCC
95 50 90 ACC2-C-9550 AHCC 240 70 90 ACC2-C-24070 AHCC
95 35 90 ACC2-C-9535 AHCC 240 50 90 ACC2-C-24050 AHCC
95 25 90 ACC2-C-9525 AHCC 240 35 90 ACC2-C-24035 AHCC
120 120 150
ACC2-C-
120120 AHCC 240 25 90 ACC2-C-24025 AHCC
120 95 150
ACC2-C-
12095 AHCC 300 300 200 x 2
ACC2-E-
300300 AHCD
120 70 90
ACC2-C-
12070 AHCC 300 240 200 x 2
ACC2-E-
300240 AHCD
120 50 90
ACC2-C-
12050 AHCC 300 185 250
ACC2-D-
300185 AHCD
120 35 90
ACC2-C-
12035 AHCC 300 150 200
ACC2-D-
300150 AHCD
120 25 90
ACC2-C-
12025 AHCC 300 120 150
ACC2-D-
300120 AHCD
150 150 200
ACC2-D-
150150 AHCD 300 95 150 ACC2-C-30095 AHCC
150 120 150
ACC2-C-
150120 AHCC 300 70 150 ACC2-C-30070 AHCC
150 95 150
ACC2-C-
15095 AHCC 300 50 150 ACC2-C-30050 AHCC
150 70 90
ACC2-C-
15070 AHCC 300 50 150 ACC2-C-30050 AHCC
150 50 90
ACC2-C-
15050 AHCC 300 35 150 ACC2-C-30035 AHCC
150 35 90
ACC2-C-
15035 AHCC 300 25 150 ACC2-C-30025 AHCC
Cable To Cable

14. Horizontal Parallel Through Cables.
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
120 120 200
ACC7-C-
120120 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

15. Cable To Cable
Horizontal Parallel Through Cables.
A B Powder Mould Clamp
mm2 mm2 ( g ) Type Type
25 25 65 ACC11-M-2525 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

16. 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
Cable To Ground Rod
Horizontal Cable Terminal To Ground Rod
A B Powder Mould Clamp
mm mm2 ( g ) Type Type
10 65
ACR1-C-
12710 AHCC
16 65
ACR1-C-
12716 AHCC
25 65
ACR1-C-
12725 AHCC
12.7 35 65
ACR1-C-
12735 AHCC
50 65
ACR1-C-
12750 AHCC
70 90
ACR1-C-
12770 AHCC
95 90
ACR1-C-
12795 AHCC
120 90
ACR1-C-
127120 AHCC
10 65
ACR1-C-
14210 AHCC
16 65
ACR1-C-
14216 AHCC
25 65
ACR1-C-
14225 AHCC
35 90
ACR1-C-
14235 AHCC
50 90 ACR1-C- AHCC

17. 14250
14.2 70 90
ACR1-C-
14270 AHCC
95 90
ACR1-C-
14295 AHCC
120 90
ACR1-C-
142120 AHCC
150 115
ACR1-C-
142150 AHCC
185 150
ACR1-C-
142185 AHCC
240 150
ACR1-C-
142240 AHCC
10 65
ACR1-C-
17210 AHCC
16 65
ACR1-C-
17216 AHCC
25 65
ACR1-C-
17225 AHCC
35 65
ACR1-C-
17235 AHCC
50 90
ACR1-C-
17250 AHCC
70 90
ACR1-C-
17270 AHCC
17.2 95 90
ACR1-C-
17295 AHCC
120 90
ACR1-C-
172120 AHCC
Cable To Ground Rod
Horizontal Cable Terminal To Ground Rod Continued….
150 115
ACR1-C-
172150 AHCC
17.2 185 150
ACR1-C-
172185 AHCC
240 150
ACR1-C-
172240 AHCC
300 200
ACR1-C-
172300 AHCC

18. Cable To Ground Rod
Horizontal Through To Ground Rod

19. A B Powder Mould Clamp
mm mm2 ( g ) Type Type
10 90
ACR2-C-
12710 AHCC
16 90
ACR2-C-
12716 AHCC
25 90
ACR2-C-
12725 AHCC
12.7 35 90
ACR2-C-
12735 AHCC
50 90
CR2-C-
12750 AHCC
70 90
ACR2-C-
12770 AHCC
95 115
ACR2-C-
12795 AHCC
120 150
ACR2-C-
127120 AHCC
10 65
ACR2-C-
14210 AHCC
16 65
ACR2-C-
14216 AHCC
25 90
ACR2-C-
14225 AHCC
35 90
ACR2-C-
14235 AHCC
50 90
ACR2-C-
14250 AHCC
14.2 70 115
ACR2-C-
14270 AHCC
95 115
ACR2-C-
14295 AHCC
120 150
ACR2-C-
142120 AHCC
150 200
ACR2-C-
142150 AHCC
185 200
ACR2-C-
142185 AHCC
240 250
ACR2-C-
142240 AHCC
10 65
ACR2-C-
17210 AHCC
16 65
ACR2-C-
17216 AHCC
25 90
ACR2-C-
17225 AHCC
35 90
ACR2-C-
17235 AHCC
50 115 ACR2-C- AHCC

20. 17250
70 115
ACR2-C-
17270 AHCC
17.2 95 115
ACR2-C-
17295 AHCC
120 150
ACR2-C-
172120 AHCC
150 200
ACR2-C-
172150 AHCC
185 200
ACR2-C-
172185 AHCC
240 250
ACR2-C-
172240 AHCC
300 150x2
ACR2-D-
172300 AHCD
Cable To Ground Rod
Horizontal Run & Tap Cable To Ground Rod
A B Powder Mould Clamp
mm mm2 ( g ) Type Type
25 90 ACR17-C-12725 AHCC
35 90 ACR17-C-12735 AHCC
50 115 ACR17-C-12750 AHCC
12.7 70 150 ACR17-C-12770 AHCC
95 200 ACR17-C-12795 AHCC
120 200 ACR17-C-127120 AHCC
25 90 ACR17-C-14225 AHCC
35 115 ACR17-C-14235 AHCC
50 150 ACR17-C-14250 AHCC
14.2 70 200 ACR17-C-14270 AHCC
95 250 ACR17-C-14295 AHCC
120 150x2 ACR17-D-142120 AHCD
150 200x2 ACR17-D-142150 AHCD
25 90 ACR17-C-17225 AHCC
35 115 ACR17-C-17235 AHCC

21. 50 ACR17-C-17250 AHCC
70 ACR17-C-17270 AHCC
17.2 95 ACR17-C-17295 AHCC
120
150
200
250
150x2 ACR17-D-172120 AHCD
150 200x2 ACR17-D-172150 AHCD
185 200x2 ACR17-D-172185 AHCD
240 200x3 ACR17-D-172240 AHCD
25 115 ACR17-C-23125 AHCC
35 150 ACR17-C-23135 AHCC
50 200 ACR17-C-23150 AHCC
70 250 ACR17-C-23170 AHCC
23.1 95 150x2 ACR17-D-23195 AHCD
120 200x2 AHCD
150 250x2 AHCD
185 250x2 AHCD
240 250x3 AHCD
Cable To Ground Rod
A B Powder Mould
ACR17-D-231120
ACR17-D-231150
ACR17-D-231185
ACR17-D-231240
Horizontal Parallel Run Cable To Ground Rod
Clamp
mm mm2 ( g ) Type Type
25 115
ACR24-C-
12725 AHCC
35 115
ACR24-C-
12735 AHCC
12.7 50 150
ACR24-C-
12750 AHCC
70 200
ACR24-C-
12770 AHCC
95 250
ACR24-C-
12795 AHCC
120 150x2
ACR24-D-
127120 AHCD
25 115
ACR24-C-
14225 AHCC
35 150
ACR24-C-
14235 AHCC
50 200 ACR24-C- AHCC

22. 14250
14.2 70 250
ACR24-C-
14270 AHCC
95 150x2
ACR24-D-
14295 AHCD
120 200x2
ACR24-D-
142120 AHCD
150 250x2
ACR24-D-
142150 AHCD
185 250x2
ACR24-D-
142185 AHCD
240 250x3
ACR24-D-
142240 AHCD
25 115
ACR24-C-
17225 AHCC
35 150
ACR24-C-
17235 AHCC
50 200
ACR24-C-
17250 AHCC
70 250
ACR24-C-
17270 AHCC
17.2 95 150x2
ACR24-D-
17295 AHCD
120 200x2
ACR24-D-
172120 AHCD
150 250x2
ACR24-D-
172150 AHCD
185 250x2
ACR24-D-
172185 AHCD
240 250x3
ACR24-D-
172240 AHCD
25 150
ACR24-C-
23125 AHCC
35 200
ACR24-C-
23135 AHCC
50 250
ACR24-C-
23150 AHCC
70 150x2
ACR24-D-
23170 AHCD
23.1 95 200x2
ACR24-D-
23195 AHCD
120 250x2
ACR24-D-
231120 AHCD
150 200x3
ACR24-D-
231150 AHCD
185 200x3
ACR24-D-
231185 AHCD

23. Cable To Ground Rod
Horizontal Through Cable to Side of Ground Rod
A B Powder Mould Clamp
mm mm2 ( g ) Type Type
10 90 ACR3-E-12710 AHCD
16 90 ACR3-E-12716 AHCD
25 90 ACR3-E-12725 AHCD
12.7 35 90 ACR3-E-12735 AHCD
50 115 ACR3-E-12750 AHCD
70 115 ACR3-E-12770 AHCD
95 115 ACR3-E-12795 AHCD
120 150 ACR3-E-127120 AHCD
10 90 ACR3-E-14210 AHCD
16 90 ACR3-E-14216 AHCD
25 90 ACR3-E-14225 AHCD
35 90 ACR3-E-14235 AHCD
50 115 ACR3-E-14250 AHCD
14.2 70 115 ACR3-E-14270 AHCD
95 115 ACR3-E-14295 AHCD
120 150 ACR3-E-142120 AHCD
150 200 ACR3-E-142150 AHCD
185 250 ACR3-E-142185 AHCD
240 200x2 ACR3-J-142240 AHCD
10 90 ACR3-E-17210 AHCC
16 90 ACR3-E-17216 AHCC
25 90 ACR3-E-17225 AHCC
35 90 ACR3-E-17235 AHCC
50 115 ACR3-E-17250 AHCC
70 150 ACR3-E-17270 AHCC
17.2 95 150 ACR3-E-17295 AHCC
120 200 ACR3-E-172120 AHCC
150 250 ACR3-E-172150 AHCC
185 200x2 ACR3-J-172185 AHCC
240 200x2 ACR3-J-172240 AHCC
300 200x3 ACR3-J-172300 AHCD

24. Cable To Steel Surface
Horizontal Cable to Horizontal Steel Surface
A Powder Mould Clamp
mm2 ( g ) Type Type
10 45 ACS1-A-10 AHCA
16 45 ACS1-A-16 AHCA
25 45 ACS1-A-25 AHCA
35 45 ACS1-A-35 AHCA
50 90 ACS1-C-50 AHCC
70 90 ACS1-C-70 AHCC
95 115 ACS1-C-95 AHCC
120 115 ACS1-C-120 AHCC
150 150 ACS1-C-150 AHCC
185 200 ACS1-C-185 AHCC
240 200 ACS1-C-240 AHCC
300 250 ACS1-C-300 AHCC

25. Cable To Steel Surface
Horizontal Through Cable To Horizontal Steel Surface
A Powder Mould Clamp
mm2 ( g ) Type Type
10 45 ACS2-A-10 AHCA
16 45 ACS2-A-16 AHCA
25 45 ACS2-A-25 AHCA
35 45 ACS2-A-35 AHCA
50 90 ACS1-C-50 AHCC
70 115 ACS1-C-70 AHCC
95 115 ACS1-C-95 AHCC
120 150 ACS1-C-120 AHCC
150 200 ACS1-C-150 AHCC
185 250 ACS1-C-185 AHCC
240 150x2 ACS1-D-240 AHCD
300 200x2 ACS1-D-300 AHCD

26. Cable To Steel Surface
Angular Cable to vertical Steel Surface
ACS–3 Type mold are used to join the end of a copper cable
l steel surface
at a 45° angle
to a vertica
A Powder Mould Clamp
mm2 ( g ) Type Type
10 45 AC 0 AHCAS3-A-1
16 45 ACS3-A-16 AHCA
25 45 ACS3-A-25 AHCA
35 45 ACS3-A-35 AHCA
50 90 ACS3-C-50 AHCC
70 90 ACS3-C-70 AHCC
95 115 ACS3-C-95 AHCC
20 115
ACS3-C-
120 AHCC
150 150
ACS3-C-
150 AHCC
185 200
ACS3-C-
185 AHCC
240 200
ACS3-C-
240 AHCC
300 250
ACS3-C-
300 AHCC
1

27. Cable To Steel Surface
Vertical Through cable To Vertical Steel Surface
ACS-4 Type mould are used to join a vertical through copper
cable
A Powder Mould Clamp
mm2 ( g ) Type Type
25 90 AC 5 AHCCS4-Y-2
35 115 ACS4-Y-35 AHCC
50 200 ACS4-Y-50 AHCC
70 200 ACS4-Y-70 AHCC
95 250 ACS4-Y-95 AHCC
20 250 CS4-Y-120 AHCC
150 250 ACS4-Y-150 AHCC
1 A

28. Cable To Steel Surface
ACS-7 Overhead Vertical Tap Cable to vertical Steel Surface
ACS-7 Type Mould are used to join an overhead vertical
nductor drop tap to a vertical steel surface.Note that the
ce
copper
co
cable is surface.
on the Surfa
A Powder Mould Clamp
mm2 ( g ) Type Type
10 65 AC 0 AHCCS7-C-1
16 65 ACS7-C-16 AHCC

29. 25 65 ACS7-C-25 AHCC
35 65 ACS7-C-35 AHCC
50 150 ACS7-C-50 AHCC
70 150 ACS7-C-70 AHCC
95 200 ACS7-D-95 AHCD
ACS7-D-
120
150
185
240
300
120 200 AHCD
150 250
ACS7-D-
AHCD
185 150x2
ACS7-D-
AHCD
240 200x2
ACS7-D-
AHCD
300 200x2
ACS7-D-
AHCD
Cable To Steel Surface
ACS-3 Type Mould used to join the end of a copper cable at a
al steel surface
45° angle to
a vertic

30. A PIPE Powder Mould Clamp
mm2 SIZE ( g ) Type Type
10 45 AC -10 AHCCS3.1-C
16
1 1/4" to
4" 45 ACS3.1-C-16 AHCC
25 4" to 6" 90 ACS3.1-C-25 AHCC
35 6" to 10" 90 ACS3.1-C-35 AHCC
50 12" 7 up 115 ACS3.1-C-50 AHCC
70 115 ACS3.1-C-70 AHCC
BusBar To Tape , Cable and other Steel Surface
l copper bus
teel surface. Bus flat side is parallel to surface.
ABS-1 Type Mould are used to connect a vertica
bar tap to a
vertical s
A Powder Mould Clamp
mmxmm ( g ) Type Type
20x2 65 AB 2S1-C-20 AHCC

31. 20x3 65 ABS1-C-202 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
l copper bus
teel surface. Bus flat side is parallel to surface.
Continued…
50x6 150x2 ABS1-D-506 AHCD
ABS-1 Type Mould are used to connect a vertica
bar tap to a
vertical s
50x8 200x2 ABS1-D-508 AHCD
60x6 200x2 ABS1-D-606 AHCD
60x8 250x2 ABS1-D-608 AHCD
60x10 200x3
ABS1-D-
6010 AHCD

32. 80x6 250x2 A 6BS1-D-80 AHCD
80x8 200x3 ABS1-D-808 AHCD
80x10 250x3
ABS1-D-
8010 AHCD
ABS-2 Horizontal Tap to Horizontal Steel Surface
tal copper
to a horizontal steel surface. Bus flat side is parallel to
ABS-2 Type Mould are used to connect a horizon
bus bar
tap
surface.
A Powder Mould Clamp
mmxmm ( g ) Type Type
20x2 65
ABS2-C-
202 AHCC
20x3 90
ABS2-C-
203 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
to a horizontal steel surface. Bus flat side is parallel to
ABS-2 Type Mould are used to connect a horizontal copper
bus bar
tap
surface.

33. Continued………
150 ABS2-C-304 AHCC30x4
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

34. ABB-2 Type Mould are used to join horizontal copper bus bar
t right
of
a
angles a vertical steel surface to the top of vertical bus bar.
Flat sides
both are vertical and parallel.
A Powder Mould Clamp
mmxmm ( g ) Type Type
25x3 65
ABB2-C-
253 AHCC
255
256
258
2512
316
383
386
388
503
504
505
506
508
25x5 90
ABB2-C-
AHCC
25x6 115
ABB2-C-
AHCC
25x8 150
ABB2-C-
AHCC
25x12 250
ABB2-C-
AHCC
31x6 150
ABB2-C-
AHCC
38x3 115
ABB2-C-
AHCC
38x6 200
ABB2-C-
AHCC
38x8 250
ABB2-C-
AHCC
50x3 90
ABB2-C-
AHCC
50x4 115
ABB2-C-
AHCC
50x5 200
ABB2-C-
AHCC
50x6 250
ABB2-C-
AHCC
50x8 150x2
ABB2-D-
AHCD

35. BusBar To Tape , Cable and other Steel Surface
Steel SurfaceABS-4 Horizontal or Vertical Thru Bar to Horizontal
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
A Clamp
mmxmm Type
20x2 90 AB 2S4-C-20 AHCC
20x3 90 ABS 03 AHCC4-C-2
25x2 115 ABS4-C-252 AHCC
25x3 115 ABS4-C-253 AHCC
25x4 150 ABS4-C-254 AHCC
25x6 150 ABS4-C-256 AHCC
30x2 115 ABS4-C-302 AHCC
30x3 115 ABS4-C-303 AHCC
30x4 200 ABS4-C-304 AHCC
30x5 200 ABS4-C-305 AHCC
31x3 150 ABS4-C-313 AHCC
31x6 200 ABS4-C-316 AHCC
38x3 150 ABS4-C-383 AHCC
38x5 200 ABS4-C-385 AHCC
38x6 250 ABS4-C-386 AHCC
40x3 150 ABS4-C-403 AHCC
40x4 200 ABS4-C-404 AHCC

36. 40x5 200 ABS4-C-405 AHCC
40x6 250 ABS4-C-406 AHCC
50x3 200 ABS4-C-503 AHCC
50x4 250 ABS4-C-504 AHCC
50x8 200x2 ABS4-D-508 AHCD
60x6 200x2 ABS4-D-606 AHCD
60x8 250x2 ABS4-D-608 AHCD
0x10 250x3
ABS4-D-
6010 AHCD6
Tape To Cable
al Cable Tap to Horizontal Lug or BusACB-1 Horizont
ACB-1 Type Mould are used to connect a copper
orconduct
to a copper lug or bus bar.
A Powder Mould Clamp
mm2 ( g ) Type Type
10 32 ACB 021-C-102 AHCC
16 32 ACB 202 AHCC1-C-16
16 32 ACB1-C-16203 AHCC
16 45 ACB1-C-16253 AHCC
25 32 ACB1-C-25202 AHCC
25 45
AACB1-C-
25203 AHCC
35 32 ACB 021-C-352 HCC
35 45 ACB1-C-35203 AHCC
35 45 ACB1-C-35253 AHCC
50 45 ACB1-C-50202 AHCC
50 45 ACB1-C-50203 AHCC
50 65 ACB1-C-50253 AHCC
25 45 ACB1-C-25253 AHCC

37. 70 65 ACB1-C-70253 AHCC
70 90 ACB1-C-70254 AHCC
70 90 ACB1-C-70256 AHCC
95 90 ACB1-C-95253 AHCC
95 90 ACB1-C-95254 AHCC
95 90 ACB1-C-95255 AHCC
95 90 ACB1-C-95256 AHCC
20 90 ACB1-C-120253 AHCC
20 90 ACB1-C-120254 AHCC
120 115 ACB1-C-120255 AHCC
120 115 ACB1-C-120256 AHCC
120 115 ACB1-C-120305 AHCC
120 115 ACB1-C-120503 AHCC
120 150 ACB1-C-120506 AHCC
1
1
Tape To Cable
al Cable Tap to Horizontal Lug or Bus
115 ACB1-C-150256 AHCC
ACB-1 Horizont
ACB-1 Type Mould are used to connect a copper
conductor
to a copper lug or bus bar.
Continued…….
150
150 115 ACB1-C-150305 AHCC
150 150 ACB1-C-150405 AHCC
150 115 ACB1-C-150503 AHCC
150 115 ACB1-C-150504 AHCC
185 150 ACB1-C-185305 AHCC
185 150 ACB1-C-185316 AHCC
185 150 ACB1-C-185386 AHCC
185 150 ACB1-C-185405 AHCC
185 150 ACB1-D-185504 AHCD
185 200 ACB1-D-185505 AHCD
185 200 ACB1-D-185506 AHCD
240 200 ACB1-D-240503 AHCD
240 200 ACB1-D-240504 AHCD
240 200 ACB1-D-240505 AHCD
240 150x2 ACB1-D-240506 AHCD

38. 300 150x2 ACB1-D-300506 AHCD
300 200x2 ACB1-D-300508 AHCD
Tape To Cable
l Cable Tap to Horizontal Bus
ntal copper
ACB-4 Horizonta
ACB-4 Type Mould are used to connect horizo
cable tap
to a horizontal copper bus bar with the flat side horizontal
B Powder Mould
mmxmm ( g ) Type
A Clamp
mm2 Type
10 20x2 25
ACB4-C-
10202 AHCC
16 20x2 32
ACB4-C-
16202 AHCC
16 20x3 32
ACB4-C-
16203 AHCC
16 25x3 32
ACB4-C-
16253 AHCC
25 20x2 25 ACB4-C- AHCC

39. 25202
25 20x3 32
ACB4-C-
25203 AHCC
25 25x3 32
ACB4-C-
25253 AHCC
35 20x2 32
ACB4-C-
35202 AHCC
35 20x3 45
ACB4-C-
35203 AHCC
35 25x3 45
ACB4-C-
35253 AHCC
50 20x3 45
ACB4-C-
50203 AHCC
50 25x2 45
ACB4-C-
50252 AHCC
50 25x3 45
ACB4-C-
50523 AHCC
50 25x4 65
ACB4-C-
50254 AHCC
50 25x6 65
ACB4-C-
50256 AHCC
70 25x3 65
ACB4-C-
70253 AHCC
70 25x4 65
ACB4-C-
70254 AHCC
70 25x6 90
ACB4-C-
70256 AHCC
95 25x3 90
ACB4-C-
95253 AHCC
95 25x4 90
ACB4-C-
95254 AHCC
95 25x5 90
ACB4-C-
95255 AHCC
95 25x6 115
ACB4-C-
95256 AHCC
120 25x3 90
ACB4-C-
120253 AHCC
120 25x5 90
ACB4-C-
120254 AHCC
120 25x6 115
ACB4-C-
120255 AHCC
120 30x5 115
ACB4-C-
120256 AHCC
150 25x6 115
ACB4-C-
150256 AHCC
150 30x5 115
ACB4-C-
150305 AHCC

40. Tape To Cable
l Cable Tap to Horizontal Bus
ntal copper
horizontal copper bus bar with the flat side horizontal
Continued……..
150 40x5 150
ACB4-C-
AHCC
ACB-4 Horizonta
ACB-4 Type Mould are used to connect horizo
cable tap
to a
150405
185 25x3 150
ACB4-C-
185305 AHCC
185 30x5 150
ACB4-C-
185316 AHCC
185 40x5 150
ACB4-C-
185386 AHCC
185 50x5 150
ACB4-C-
185405 AHCC
185 50x6 150
ACB4-C-
185504 AHCC
240 50x5 200
ACB4-C-
240505 AHCC
240 50x6 250
ACB4-C-
240506 AHCC
300 50x6 150x2
ACB4-D-
300506 AHCD
300 50x8 200x2
ACB4-D-
300508 AHCD

41. Tape To Cable
uld are used to connect horizontal copperACB-5 Type Mo
bus bar, flat side horizontal, to a horizontal through run
cable.
B Powder MouldA Clamp
mm2 ( g ) Type Type
10 20x2 45 ACB 202 AHCC5-C-10
16 20x2 45 ACB5-C-16202 AHCC
16 20x3 45 ACB5-C-16203 AHCC
16 25x3 65 ACB5-C-16253 AHCC
25 20x2 45 ACB5-C-25202 AHCC
25 20x3 45 ACB5-C-25203 AHCC
25 25x3 65 ACB5-C-25253 AHCC
35 20x2 45 ACB5-C-35202 AHCC
35 20x3 45 ACB5-C-35203 AHCC
35 25x3 65 ACB5-C-35253 AHCC
50 20x3 65 ACB5-C-50203 AHCC
50 25x2 65 ACB5-C-50252 AHCC
50 25x3 65 ACB5-C-50523 AHCC
70 25x3 90 ACB5-C-70253 AHCC
70 25x4 115 ACB5-C-70254 AHCC
70 25x6 115 ACB5-C-70256 AHCC
95 25x4 150 ACB5-C-95254 AHCC
95 25x5 150 ACB5-C-95255 AHCC
95 25x6 150 ACB5-C-95256 AHCC
120 25x5 150 ACB5-C-120254 AHCC
120 25x6 150 ACB5-C-120255 AHCC
mmxmm

42. 120 30x5 200 ACB5-C-120256 AHCC
150 25x6 200 ACB5-C-150256 AHCC
150 30x5 200 ACB5-C-150305 AHCC
150 40x5 250 ACB5-C-150405 AHCC
185 30x5 250 ACB5-C-185305 AHCC
185 40x5 250 ACB5-C-185405 AHCC
185 50x5 150x2 ACB5-D-185505 AHCD
240 30x5 250 ACB5-C-240305 AHCC
240 50x6 200x2 ACB5-D-240506 AHCD
300 50x6 250x2 ACB5-D-300506 AHCD
300 50x8 250x2 ACB5-D-300508 AHCD
elect chartS
-5
4
1
3 4 5 6
ACC-1 ACC-2 ACC-3 ACC-4 ACC
ACC-6 ACC-7 ACC-11 ACC-13 ACC-14
ACC-21 ACC-23 ACC-2 ACC-25 ACC-26
ACC-27 ACC-28 ACC-29 ACC-30 ACC-3
ACC-3 ACC-3 ACC-3 ACC-3 ACR-1

43. ACR-2 ACR-4 ACR-3 ACR-5 ACR-6
ACR-7 AACR-9 ACR-12 ACR-13 ACR-14
ACR-15 ACR-16 ACR-18 ACR-17 ACR-19
ACR-20 ACR-22 ACR-25 ACR-24 ACR-27
ACR-30 ACR-31 ACR-32 ACR-35 ACR-36
ARR-1 ARR-2
ARS-1
(STL SURFACE)
ARS-2
(STL SURFACE)
ARS-3
(STL SURFACE)
ACS-1
(STL SURFACE)
ACS-2
(STL SURFACE)
ACS-3
(STL SURFACE)
ACS-4
(STL SURFACE)
ACS-5
(STL SURFACE)
ACS-6
(STL SURFACE)
ACS-7
(STL SURFACE)
ACS-8
(STL SURFACE)
ACS-9
(STL SURFACE)
ACS-11
(STL SURFACE)

44. SURFAC SURFAC SURFAC SURFAC L SURFAC
ACS-22
(STL SURFACE)
ACS-23
(STL SURFACE)
ACS-27
(STL SURFACE)
ACS-28
(STL SURFACE)
ACS-43
(STL SURFACE)
AC C C CE
ACS-12
(STL E)
ACS-13
(STL E)
ACS-14
(STL E)
ACS-15
(STL E)
ACS-18
(ST E)
ACS-46
(STL SURF E)
ARS-3
(STL SURFA E)
ACRS-1
(STL SURFA E)
ACRS-2
(STL SURFA )
ARE-1
ARE-2 ACB-1 ACB-2 ACB-3 ACB-9
ACB-5 ACB-6 ACB-7 ACB-8 ACB-4
B-11 B-12 B-15 B-16 B-17
AC
AC AC AC AC AC
ACB-16 B-17 ACB-19 ACB-20 ACB-21
ACB-2 B-25 ACB-26 ACB-27 ACB-292 AC

45. ACB-38 ABB-1 ABB-2 ABB-3 ABB-4
ABB-5 ABB-6 ABB-7 ABB-12 ABB-14
B-17 ABB-20 B-21 ABB-22 ABB-27AB AB
ABS-5
(STL SURFACE) (STL SURFACE) (STL SURFACE) (STL SURFACE) (STL SURFACE)
ABS-6 ABS-7 ABS-8 ABS-13
ABS-15 ABS-16 ABS-17 ABS-18
ABS-19
(STL SURFACE) (STL SURFACE)
ACRE-1 ACRE-2 ACRE-3
ABS-20
ABB-41
ABS-1
(STL SURFACE)
ABS-2
(STL SURFACE)
ABS-3
(STL SURFACE)
ABS-4
(STL SURFACE)
ABS-14
(STL SURFACE) (STL SURFACE) (STL SURFACE) (STL SURFACE)
ACRE-4 ACRE-5 ACRE-6 ACRE-7 ACRE-8

46. 1 1
ACRE-15 ACRE-16 ACRE-17 ACRE-18 ACRE-19
ACRE-20 ACRE-21 AAC-1 AAC-2 AAR-1
ACRE-9 ACRE-11 ACRE-12 ACRE- 3 ACRE- 4
RAPHITE MOULD EXOTHERMIC WELDING PROCESS
A. Axi-weld Mould is made from graphite which makes it fragile and would crack or
break if not handled with care.
exothermic welding.
uld is totally dry before
every first joint regardless new or used mould. Otherwise, the mould may crack or
D. tors fits snugly and sections of moulds are clamped
ill
E.
ng brush.
G. s hot. Otherwise, the
Do
use a ould. Otherwise, the mould may crack or break or a bad joint produced or
cu
G
B. Designed to withstand high temperatures produced from the
C. Requires pre-heating with a butane torch to ensure the mo
break or a bad joint produced or cuts down the life span of the mould.
Always ensure that the conduc
tightly with the handle clamp to avoid leakage of weldmetal. Leakage w
produced a bad joint and cuts down the life span of the mould.
After every joint produced, always remove the slag with a recommended mould
scrapper, then brush off the smaller particles with a proper mould cleani
F. Caution : Do not use any other hard object and brush that would damage the
mould.
Always keep the mould away from water or damn areas while it i
mould may crack or break.
not over-heat the mould the throughout too many joints. Always either allow to rest or
spare m
ts down the life span of the mould.

47. (1) (2) (3) (4)
Accessories
AXT-001 Cable Cleaning Brush
The Cable Cleaning Brush is recommended for cleaning heavily
oxidized cables. The V-shaped brushes permit their use orv r a
wide range of cable sizes. Brush assembly consists of a handle
that are Rotatable, for longer
life and are replaceable.
e
with two stiff wire bristle brushes
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.

48. AXT-003 Mold Cleaning Brush
The Mold Cleaning brush is used to clean the molds without
damaging the molds.
The Mold Cleaners are used to clean the slag from molds that
AXT-004 Mold Cleaners
are not split through the crucible.
AXT-005 Flint Ignitor
ing powder for making the
xothermic welding joint. Each mold with a frame has a flint
nitor included.
andle Clamp
AXHC-001 HANDLE CLAMPS
This ignitor is used to ignite the strat
e
ig
H
For most connections involving lugs, cable or rectangular
bus, Handle Clamps are used. These Handles Clamps make
possible the use of many different sizes and types of molds
with only two different clamps. These will fit 95% all standard
molds.
AXHA-001 HANDLE ATTACHMENTS

49. 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 leaking
weld metal.
Replace mold or if only worn around conductor
opening, use duct seal around conductor. Do not get
duct seal into mold cavity.
Wrong size cartridge for mold. Check ID plate for mold and compare with number on
bottom of cartridge.
Too much spillage when dumping
powder.
Carefully open lid while holding over crucible and
dump.
Insufficient metal to make
weld.
Wrong mold for conductor being
used.
Replace with correct mold. In some applications, shim
stock or adapter sleeves can be used to enlarge cable
to fit mold.
Handle clamps not properly
adjusted.
Remove set screw between the handles or the mold
and adjust handle tension by backing out the eye bolt.
Dirt or slag stuck in parting line of
mold.
Clean mold thoroughly between connections.
Mold does not close tightly
causing weld metal to leak
out.
Bent or out-of-round cable. Straighten or cut out bad section of cable.
Handle clamps will not lock
closed.
Handle Clamps not properly
adjusted.
Remove set screw between the handles or the mold
and adjust handle tension by backing out the eye bolt.
Moisture in mold. Pre -heat mold to above 220o F with a propane torch.
Oil, grease, moisture or
foreign material on
conductors.
Pre-heat conductors with propane torch then use a clean wire
brush on conductor to remove any residue left n conductors. If
welding to cast iron or steel surface, weld area must be
cleaned down to bright metal.
Duct seal in weld cavity. Take special precautions to keep duct seal out or weld cavity.
Excessively high weld,
bubbly or gassy
appearance, poor weld.
Weld powder has gotten
wet.
Replace with fresh, dry weld powder.
Mold worn or chipped
around disc seal allowing
powder to leak into mold
cavity.
Replace mold.Weld metal blows out top
of mind.
Forgot to use steel disc or did
not seat if properly at bottom
of crucible.
Make sure disc is seated at bottom of crucible before pouring
the powder into crucible.
PROBLEM PROBLEM CAUSE CORREECTION TO MAKE
Cannot ignite powder. Insufficient starting powder in Place at least half of starting powder in ignition pocket

50. ignition pocket on mold lid. of mold lid.
Flint ignitor not shooting enough
spark.
Clean flint ignitor according to directions on box or
replace flint ignitor.
Starting powder lumped together. Break up starting powder on lid with edge of powder
tube.
Mold wearing out ot fast. Improper cleaning of mold. Use mold cleaner, soft natural bristle brush or clean rag
to clean mold between shots. Do not use wire brush or
screwdriver on molds.
Weight of mold not supported
during reaction causing mold to
slip when cable melts.
Use locking pliers on ground rod under mold to support
the weight of the mold during the reaction.
Poor weld to ground rod.
Moisture or contaminant on cable
or ground rod.
Pre-heat conductors with propane torch then use a
clean wire brush on conductors to remove any residue
left on conductors.
Improperly cleaned area on steel. An area larger than the weld area should be cleaned
down to bright clean metal.
Moisture or contaminant on cable
or steel surface.
Pre-heat conductors with propane torch then use a
clean wire brush on conductors to remove any residue
left on conductors.
Weld will not stick to steel
surface.
Cable is improperly positioned in
mold, blocking the flow of weld
metal.
Position cable in mold in accordance with directions for
mold. If directions are not available, position top of
cable in the center of where the liquid weld metal hits
the steel.
All of the causes listed under
welding to steel surface also
apply to this section.
Weld will not stick to cast
iron surface.
Not using CI (Cast Iron) powder. Specify "CI" behind cartridge when order powder.
Cable pulls out of mold
when it is fired.
Cables are either twisted or under
tension.
Use cable clamp or other method to remove tension.
Cut out severely twisted cable.