Erico CADWELD Electrical Connections User Manual

Installers and Inspectors Guide for CADWELD® Electrical Connections

10www.erico.comProperinspectionofaCADWELD® connection reliesonthejudgmentoftheeldpersonnel.Lookcloselyatthesize,color,surfacenis

11www.erico.comType VSType GTType SSHigher than normalMinimum acceptableNormalHigher than normalMinimum acceptableNormalHigher than normalMinimum acce

12www.erico.comColorThe color of a CADWELD® connection is best seen after a light wire brushing of the connection. It should normally be gold to bronz

13www.erico.comPhotographic GuidesLike all electrical connections, a visual inspection is no guarantee of performance. Crimped or bolted connections c

14www.erico.comGood.A solid weld with only minor surface imperfections.Acceptable.Fillislowerthannormal,butstillsufcient.Acceptable.A worn or

15www.erico.comAcceptable.The presence of water/moisture in conductor strands or mold indicates that one or both were not properly dried. Although the

16www.erico.comReject.Light carbon traces on cable and connection are evidenceofoiloncablestrands.Oilycablesmustbe cleaned with safety solven

17www.erico.comReject.Filltoolow.Weldcavitywasnotlledovercablestrands.“Fins”indicatethatthemoldwasnotclosed tightly due to incorrec

18www.erico.comMostelddifcultiescanbeovercomebycheckingthe following problems.PROBLEM AThe mold doesn’t close tightly.Check for:1. Adjustmen

19www.erico.comPROBLEM DThe connection is porousCheck for:1.Presenceofmoistureeitherinconductorormold.Remedy: (a) Dry the conductor by wiping

2www.erico.comThis handbook is designed to guide the person in the field with the installation and inspection of CADWELD® exothermic welds, including C

20www.erico.com (b) Check to be sure gap is centered under tap hole. NOTE: In some cases, the run (thru) conductor must be cut and gapped. F

21www.erico.comRemedy: (a)SeeProblemF. (b)SeeProblemG. (c)SeeProblemH.4. Conductor movement.PROBLEM JThe riser is too high.Check for:1. Us

22www.erico.comPROBLEM MWhen welding to ductile iron or cast iron, the weld does not “stick” to the surface.Remedy:1. Remove all coatings before clean

23www.erico.comBelowaretypicaleldsituationsrelatedtoCADWELD®ONESHOTconnections.PROBLEM AWeld does not “stick” to ground rod.Remedy:1. Groun

Copperweld is a registered trademark of Copperweld Steel Company, Fayetteville, TN. Cor-Ten is a registered trademark of United States Steel Corp. Eve

3www.erico.comThe CADWELD® Process ... 4The CADWELD Connection ... 5It’s Easy to Make CADWELD Connection

4www.erico.comThe CADWELD® process is a method of making electrical connections of copper to copper or copper to steel in which no outside source of

5www.erico.comThe CADWELD® process is applicable to materials other than copper. Some of these materials are:Common steelChromax*Everdur®Steel railCop

6www.erico.comIt’s Easy to Make CADWELD® ConnectionsDetailed instructions and safety precautions are provided with every CADWELD® mold. You must rea

7www.erico.com3.• Dumptheweldingmaterialintothemold.• Sprinklethestartingmaterialoverthewelding material and onto the lip of the mo

8www.erico.comAll CADWELD® materials are produced to high standards under stringent quality control. All CADWELD connections are designed and tested u

9www.erico.comA CADWELD® mold is designed to last for an average of 50 connections. This will vary according to the care given the mold during use. In