Safety and Protection

Exothermic Process
The 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.

Application – Connections
• 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

UltraWeld Pour & Shoot Process UltraShot Drop-In Process

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

Step 2: Step 2
• Close handle clamp and lock mold • Close handle clamp and lock mold
• Insert disk into mold
• Insert UltraShot™ drop-in into mold

Step 3: Step 3
• Pour weld metal into mold • Attach cord to UltraShot™ igniter

Step 4: Step 4
• Sprinkle starting material over the weld metal and close lid • Push and hold both igniter buttons at the same time
• Sprinkle remaining starting material in the ignition pocket on the top of the
TOP-LIGHT lid
Step 5: Step 5
• Ignite using the FLTIG flint igniter • Reaction is made
• Open mold and remove connection
• Remove slag before next connection
Step 6: A completed UltraShot™ connection
• After reaction is complete, open the mold and remove the connection
• Remove slag from the mold before making the next connection

A complete Ultraweld connection

Materials, Tools & Accessories

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® (Drop-In) Weld Metal UltraShot Weld Metal

Size Qty. / Ctn Size Qty. / Ctn
US25 20 US200 10 • The weld metal, a mixture of copper oxide and aluminum, is
US32 20 US250 10 packaged in individual, moisture resistant copper drop-ins.
US45 20 US300 10 • The copper drop-in is consumed during the reaction process.
US65 20 US400 5
• Each drop-in is marked with the size.
US90 10 US500 5
US115 10 US600 5
US150 10 US750 5

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 Safety and Protection
Ultraweld® (Pour & Shoot) Weld Metal UltraWeld Weld Metal
Size Qty. / Ctn Size Qty. / Ctn
UWM15 20 UWM115 10 • The weld metal, a mixture of copper oxide and aluminum, is
UWM25 20 UWM150 10 packaged in individual, moisture resistant plastic cartridges.
UWM32 20 UWM200 10
• Each cartridge is marked with the size.
UWM45 20 UWM250 10
UWM65 20 UWM500 5 • Each box also contains instructions and metal disks.
UWM90 10 • One metal disk is used for each connection.
• The plastic box is shrink-wrapped to provide additional moisture protection.
Open Mold Closed Mold

Molds

• Depending on the care and treatment of the mold, it will average

Smokeless 50 or more welds. Substantially more with the UltraShot process.
Mold
• The Ultraweld smokeless process uses an integrated filter system on
Open Mold Closed Mold the mold and electric ignition of the weld metal to produce a
finished connection with minimal smoke emission. Ideal for indoor
USCONTROLLER and confined space working conditions.
• For Ultraweld smokeless process, ignition is accomplished with the
Smokeless use of a USCONTROLLER.
Mold
• Mold Handle not included.

Flint Igniter Mold Accessories

USCONTROLLER

• When making an Ultraweld connection, Flint Igniters are used to

ignite the starting material.
• Flint Igniters comes with MH1 and MH2 handle clamps.
36" Extension • Torches are required to remove moisture from the mold and
Torch Head conductors before making the Ultraweld connections.

Cable & Work Surface Preparation

• Card Cloth Brush has short, stiff, metal bristles which are generally
MCBRSH1 MCBRSH2
preferred for cleaning concentric conductors and busbars, that
are not heavily oxidized.
Card Cloth Brush Cable Cleaning Brush Rasp
• 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 Cleaning Spades

Mold Care & Use
• Slag can be removed from molds by using a Mold Cleaning Brush.
Patented
• Slag can be cleaned from the molds by using a Mold Cleaning Spade.
MCBRSH1 MCBRSH2 • 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.
Chain Support Handle Clamps Magnetic Support Handle Clamps
Patented Mold Fastening & Mounting
Patented
• Mold Handle Clamps are required for all molds.
MH1, MH2

MH3 MH4 Patented

• 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.
Patented

Mold Blanket
Safety & Protection

• 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.
Patented

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
Patented

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 Safety and Protection
Exothermic Connections
Cable to Cable

BS RT XX XO CS PRPT PD PHD PV RATD PB

DPRT DX1C DPRDT DX

Cable to Ground Rod

GCU GV GU GD GSC GO GOT GOXX GT GF

Ground Rod to Ground Rod

GG GRH90B GRT GRXO GRHT GRS GROT

Cable to Steel Surface / Pipe

HB HD HU HT HRT HTCP VU VD VR VT

VH VA

Cable to Lug

LE LBJ

Cable to Busbar

BCE BC BU BD BL BTE BH BCB BE BV

BCF BCX

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

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 Safety and Protection
Busbar to Busbar

BB BHEBVTT BT BA BBC BHEBHT BHFBHX BMB

Busbar to Ground Rod

GVSD GVSO GVSS GSSD GVSAS GLV GVSP GHSD GHSO

Busbar to Steel Surface

BBDVS BBHTVS

Cable to Rebar

RCB RE RO RB RS RP HRCT

Cable to Rail

RMFPL RMFT RMVL RMVH

Equipment Ground Plate

EGPCB EGPCT EGPCVD EGPBS EGPGRT EGPHB EGPID EGPIO

Aircraft Ground Receptacle

Safety & Protection

FGRGD FGRGO FGRBS FGRIGD FGRIGO

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

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