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• Cable to cable • Cable to ground rod • Ground rod to ground rod• Cable to steel surface / pipe • Cable to lug • Cable to busbar • Busbar to busbar • Busbar to ground rod • Busbar to steel surface • Cable to rebar • Cable to rail • Equipment ground plate • Aircraft ground receptacle

Application – Connections

UltraWeld Pour & Shoot Process UltraShot Drop-In Process

Exothermic ProcessThe exothermic Process is an effective and safe method of welding copper to copper or copper to steel for the purpose of producing permanent electrical connections. exothermically welded connections are produced from the energy and molten copper metal liberated from an exothermic reaction between powdered copper oxide and aluminum. The exothermic reaction takes place at a theoretical temperature of 4600°F and as a result, molten copper alloy is created and used to melt the conductors and cast the finished connection. The exothermic reaction takes place in a semi-permanent graphite mold that will last 50 or more welds if properly cared for. The process is simple and easy to implement providing an on-site means to make welded electrical connections without requiring external power, equipment or the special training usually required for brazing and welding. The process will provide a finished connection that will never corrode, loosen or increase in resistance. The finished connection also provides an ampacity that exceeds that of the conductors being joined.

UltraShot Controller

• Patented copper drop-in cartridge consumed during the reaction process.

• Rugged long lasting 12-volt rechargeable battery control unit ignites hundreds of connections on a single charge.

• Cartridge is consumed leaving no waste such as plastic or metal containers on the job site.

• Long lasting Ultra-reliable ignition process allows for little to no downtime on the job site.

UltraShot Weld Metal

• The weld metal, a mixture of copper oxide and aluminum, is packaged in individual, moisture resistant copper drop-ins.

• The copper drop-in is consumed during the reaction process.• Each drop-in is marked with the size.

Materials, Tools & Accessories

Size Qty. / CtnUS25 20US32 20US45 20US65 20US90 10US115 10US150 10

A complete Ultraweld connection

Step 1:• Clean and dry conductors and mold• Insert conductors into mold

Step 2:• Close handle clamp and lock mold• Insert disk into mold

Step 3:• Pour weld metal into mold

Step 4:• Sprinkle starting material over the weld metal and close lid• Sprinkle remaining starting material in the ignition pocket on the top of the

ToP-LiGHT lid

Step 5:• Ignite using the FLTIG flint igniter

Step 6:• After reaction is complete, open the mold and remove the connection• Remove slag from the mold before making the next connection

Step 1• Clean and dry conductors and mold• insert conductors into mold

Step 2• Close handle clamp and lock mold• insert UltraShot™ drop-in into mold

Step 3• Attach cord to UltraShot™ igniter

Step 4• Push and hold both igniter buttons at the same time

Step 5• Reaction is made• open mold and remove connection• Remove slag before next connection

A completed UltraShot™ connection

UltraShot® (Drop-In) Weld MetalSize Qty. / CtnUS200 10US250 10US300 10US400 5US500 5US600 5US750 5

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Size Qty. / CtnUWM15 20UWM25 20UWM32 20UWM45 20UWM65 20UWM90 10

UltraWeld Weld Metal

• The weld metal, a mixture of copper oxide and aluminum, is packaged in individual, moisture resistant plastic cartridges.

• Each cartridge is marked with the size.• Each box also contains instructions and metal disks.• One metal disk is used for each connection.• The plastic box is shrink-wrapped to provide additional moisture protection.

Mold Accessories

• When making an Ultraweld connection, Flint Igniters are used to ignite the starting material.

• Flint Igniters comes with MH1 and MH2 handle clamps.• Torches are required to remove moisture from the mold and

conductors before making the Ultraweld connections.

Cable & Work Surface Preparation

• Card Cloth Brush has short, stiff, metal bristles which are generally preferred for cleaning concentric conductors and busbars, that are not heavily oxidized.

• Cable Cleaning Brush is ideal for cleaning concentric stranded cable, especially very dirty or oxidized conductors.

• Rasp is ideal for removing mill scale and rust from steel surfaces.

Mold Care & Use

• Slag can be removed from molds by using a Mold Cleaning Brush.• Slag can be cleaned from the molds by using a Mold Cleaning Spade.• The cleaning spades are specifically designed to fit the mold crucible

for a given range of weld metal sizes.

Disks

• The disk rests on the bottom of the crucible and holds the weld metal powder in place until the reaction occurs.

• A new disk is required each time a weld is made.• Disks are included with the Weld Metal.

SmokelessMold

USCONTROLLER

Open Mold Closed Mold

SmokelessMold

USCONTROLLER

Open Mold Closed Mold

Flint Igniter

36" Extension

MCBRSH1 MCBRSH2

MH4MH3

Patented

MH1, MH2

Torch Head

Card Cloth Brush RaspCable Cleaning Brush

MCBRSH1 MCBRSH2

Mold Cleaning Spades

Mold Fastening & Mounting

• Mold Handle Clamps are required for all molds.• Some molds are used with specialized frames.• Chain Support Handle Clamps are used to securely hold the mold

to either a vertical or horizontal pipe.• Magnetic Support Handle Clamp allows mold to be securely held

in place to steel surfaces.

Mold Blanket

• Extends mold life by protecting against shock impact caused by rough handling.

• Protects exothermic welders from coming into contact with hot molds; Used as a protection blanket against weld splatter.

Toolkit

• Toolkit Includes: TOOLBOX: 22” x 9.5” x 9.75” plastic toolbox with tray; 9” Cable

Cutters; Lineman’s Pliers; 6” Screwdriver; 10” Vise-Grips; Flint igniter; Card Cloth Brush; Mold Cleaning Brush; Disk Kit

MH4MH3

Patented

MH1, MH2

Patented

Patented

Patented

Chain Support Handle Clamps

Patented

Patented

Patented

Magnetic Support Handle Clamps

Size Qty. / CtnUWM115 10UWM150 10UWM200 10UWM250 10UWM500 5

Ultraweld® (Pour & Shoot) Weld Metal

• Depending on the care and treatment of the mold, it will average 50 or more welds. Substantially more with the UltraShot process.

• The Ultraweld smokeless process uses an integrated filter system on the mold and electric ignition of the weld metal to produce a finished connection with minimal smoke emission. ideal for indoor and confined space working conditions.

• For Ultraweld smokeless process, ignition is accomplished with the use of a USCoNTRoLLeR.

• Mold Handle not included.

Molds

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Exothermic Connections

BS CS

DPRDTDPRT DXDX1C

PHDXX PRPT PV RATDRT XO PD PB

GCU GD GFGO GOT GOXX GTGSCGUGV

GG GRH90B GRHT GROTGRSGRT GRXO

HD HRTHT HTCPHU

VA

HB VD

VH

VR VTVU

LBJLE

BC BCBBCE

BCF BCX

BD BH BEBL BTEBU BV

Cable to Cable

Cable to Ground Rod

Ground Rod to Ground Rod

Cable to Steel Surface / Pipe

Cable to Lug

Cable to Busbar

BABB BBC BHEBHTBHEBVTT BHFBHX BMBBT

HRCTRBRCB RE RO RPRS

RMFPL RMFT RMVHRMVL

EGPBSEGPCB EGPCT EGPCVD EGPGRT EGPHB EGPID EGPIO

FGRBSFGRGD FGRGO FGRIGD FGRIGO

BBDVS BBHTVS

GHSD GHSOGLVGSSD GVSASGVSD GVSO GVSS GVSP

* Please refer to Harger manual for full range of exothermic connections

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BS CS

DPRDTDPRT DXDX1C

PHDXX PRPT PV RATDRT XO PD PB

GCU GD GFGO GOT GOXX GTGSCGUGV

GG GRH90B GRHT GROTGRSGRT GRXO

HD HRTHT HTCPHU

VA

HB VD

VH

VR VTVU

LBJLE

BC BCBBCE

BCF BCX

BD BH BEBL BTEBU BV

BABB BBC BHEBHTBHEBVTT BHFBHX BMBBT

HRCTRBRCB RE RO RPRS

RMFPL RMFT RMVHRMVL

EGPBSEGPCB EGPCT EGPCVD EGPGRT EGPHB EGPID EGPIO

FGRBSFGRGD FGRGO FGRIGD FGRIGO

Busbar to Busbar

Cable to Rebar

BBDVS BBHTVS

Busbar to Steel Surface

Equipment Ground Plate

Aircraft Ground Receptacle

GHSD GHSOGLVGSSD GVSASGVSD GVSO GVSS GVSP

Busbar to Ground Rod

Cable to Rail

* Please refer to Harger manual for full range of exothermic connections

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