NVent ERICO Cadweld Plus For Rail
nVent ERICO Cadweld Plusfor RailThe Reliable Connection that is Safe, Fast and Easy,from the Worldwide Leader in Exothermic Connection Technology 1 800.447.RAIL rail@nVent.com
Table of contentsnVent ERICO Cadweld Plus for Rail.3Why Exothermics.4Overview of nVent ERICO Cadweld Plus Rail Applications.4Overview of the nVent ERICO Cadweld Plus System.5Installation is Easy!.6Selecting nVent ERICO Cadweld Plus.72 nVent.com/ERICO
nVent ERICO Cadweld Plus for RailSince 1939, nVent ERICO Cadweld has been the rail industrystandard for making critical exothermic cable-to-rail weldedbonds for signal, power and grounding applications. With thelaunch of Cadweld Plus for Rail, nVent ERICO has upgradedthe weld material and ignition system components, makingthe system SAFER, EASIER and MORE CONVENIENT touse. Upgrading to Cadweld Plus is easy; the enhancementscontained in Cadweld Plus are compatible with the unchangedcore elements of the Cadweld kit, including the molds, welderframe, hardware and Bondstrand.Cadweld Plus contains the same core components asCadweld Traditional, including:Complete Welder AssemblyBonds and ConnectorsCADWELD PLUS ENHANCEMENTSEnhanced FeaturesBenefitsIntegrated, Self-containedWeld Material PackagePlus cups make the Cadweld system EASIER AND MORE CONVENIENT TO USE. By virtually eliminating therisk of weld powder contamination through the use of an innovative self-contained weld pack, it is much easierto make the proper weld the first time. This makes training personnel on Cadweld plus easier as well. Weld package (cup) is waterproof and tamper-proof with a longer shelf-lifeUpgrade overTraditional Blue TubeElectronic Ignition System No loose powder, means no spilling in the field which ensures that every weld contains the right amountof ignition power to weld material. Cadweld is an engineered solution, and this formulated ratio is key toachieving the highest quality weld each, and every time.nVent ERICO Cadweld Plus Impulse Exothermic Welding Ignition System INCREASES SAFETY for the userand nearby personnel. With the ignition system, the user performs the weld standing back at a distance of either 6' or 15' - bothcable lead sizes are available. This is a significant safety advantage over a flint gun, which requires the userto be in close proximity to ignite the weld. The control unit features an ergonomic grip with built-in trigger guard to prevent an accidental discharge. The ignition timing LED Count Up Display to provide positive feedback on the status of the ignition sequence,and features a visual battery life indicator.The control unit- upgrade overTraditionalFlint Ignitor Ignition system offers battery unit flexibility with included AA Batteries (Lithium) and optional tool batteryadapters for Milwaukee 18 V and DEWALT 20 V batteries. The control unit meets the recommendations of AREMA (the American Railway Engineering andMaintenance-of-Way Association) C&S Manual Recommendations; Part 8.1.34, 2013. 1 800.447.RAIL rail@nVent.comnVent.com/ERICO 3
Why Exothermics Establishes a permanent molecular bond thatwill not loosen or corrode, perfectly suited toperform in the harshest rail conditions Has a current carrying capacity equal to orgreater than that of the conductor Can withstand repeated fault currentswithout failing Over-time will maintain a lower resistancecompared to a mechanical connections.Overview of nVent ERICO Cadweld Plus Rail ApplicationsEXOTHERMIC WELD KITS FOR SIGNAL & POWER CONNECTIONS, GROUNDINGApplicationsConnection TypeTermination StylesConductors SizesRail SectionsSignal and PowerConnections Joint Head Bond Welderstyles for bonding inside oroutside joint bar 3/4" Tab BONSTRAND 3/16" , 5/16" 1" Tab CONCENTRIC 1/0, 2/ 0, 4/0 85 lb to 141 lb(AREMA) T-Rail ROPELAY 1/0, 2/ 0, 4/035 mm²50 mm² 95 mm² 120 mm² UIC R160 KCMIL 250, 300, 350, 500 Girder Rail 3/4" Tab BONSTRAND 3/16" , 5/16" 84 lb Composite Cable to Rail 1" Tab CONCENTRIC 1/0, 2/ 0, 4/0 85 lb Composite Cable to Ground Rod orOther Rounds, Rail 3/4" XS ROPELAY 1/0, 2/ 0, 4/035 mm²50 mm² 95 mm² 120 mm² 150 lb Bethlehem Cable-to web-of-rail Special Trackwork 3/4" XS Head Free Third Rail Stud to RailGroundingApplications forRail Properties Cable to Cable, Rail Cable to Lug or Busbar, Rail Cable to Rebar, Rail Cable to Steel, Rail Cable to Cable to Cable, Rail Busbar to Busbar, Rail Head Free KCMIL 250, 300, 350, 500 150 lb Bethlehem(Inverted) 85 lb to 150 lbT-Rail Sections RI52 RI59 Girder Rail 30 lb ASCE 40 lb ASCE Lug or Busbar to Steel, Rail 60 lb ASCE Lug to Rail 171 lb Crane Rail Copper or Steel Stud to Rail Cable to Cable to GroundRod or Other Rounds, Rail4 nVent.com/ERICO 1 800.447.RAIL rail@nVent.com
Overview of the nVent ERICO Cadweld Plus SystemThe Cadweld system comes in a kit that is portable and easy to use in the field. It is centered around a graphite mold containing aweld cavity where a cable is inserted to connect to rail, or to other cables. Above the cavity is a crucible containing a pack of weldmaterial that, once ignited, liquefies causing molten weld metal to flow into the weld cavity. In a matter of seconds a permanentmolecular bond is formed. nVent ERICO Cadweld Plus for Rail meets the recommendations of AREMA and Institute of Electricaland Electronics Engineers (IEEE) standards.nVent ERICO Cadweld Plus ImpulseExothermic Welding Ignition SystemnVent ERICO providescomprehensive trainingand ongoing support forCadweld rail customers .Ignition countup LED timerControl unitnVent ERICO Cadweld Plus for Rail ComponentsWelder frameCable leadIgnitor stripColor coded coverCadweld Plus Welding MaterialTap holeWeld cavityConductor 1 800.447.RAIL rail@nVent.comGraphite moldnVent.com/ERICO 5
Installation is Easy!Proper rail surface preparation is paramount for any rail bond connection. Lightly grinding the rail surface, removing surfaceoxidation on the conductors, and drying and heating the rail and molds are highlighted in the instruction print. Once thepreparation is completed, the four steps below complete the Cadweld Plus process.1Insert Cadweld Plus cup into mold.32Attach control unit termination clip to ignition strip.4Release the control unit trigger guard, press and hold the switch and wait for the ignition.56After reaction, open the mold and remove the expended steel cup – no special disposal required.6 nVent.com/ERICO 1 800.447.RAIL rail@nVent.com
Selecting nVent ERICO Cadweld PlusNVENT ERICO CADWELD KITS AND COMPONENTSThe nVent ERICO Cadweld Plus for Rail components consist of a welder frame, graphite mold (with available hardware and moldcleaner), grinding wheel and available grinding tools, weld material and electronic ignition system. Cadweld Plus for Rail is sold inkits that include various combinations of these products, individual items are also sold separately*. With the exception of the weldcup(s) and bond strand in use, each of these components is designed for a multiple-use service life. To find and select Cadweldand Cadweld Plus kits and individual components, visit erico.com and view the sections detailing Rail Bonds and Power Bonds.E-mail rail@nVent.com to request the nVent ERICO Rail Products Catalog.Welder Frameand Mold SetupBonds andConnectors nVent ERICOCadweldPlus ImpulseExothermicWeldingControl UnitWeldMaterial *Acetylene torch, approved grinding wheel and tools are also required. nVent ERICO offers all necessary Cadweld accessories.NVENT ERICO CADWELD PLUS IMPULSE IGNITION SYSTEMComponents Included in the Impulse Ignition KitControl UnitLeadsAA Batteries (Lithium)Adaptor included in kit123Battery Adapters(Sold Separately)System KitsPart NumberDescriptionPBPLUSCU2L6Kit w/ 6' / 1.8m LeadPBPLUSCU2L15Kit w/ 15' / 4.5m LeadPart NumberDescriptionPLUSCU2BAAAA Battery Adapter (1), also included in kitPLUSCU2BMMilwaukee 18 V Battery Adapter (2)PLUSCU2BDDEWALT 20 V Battery Adapter (3)nVent ERICO Cadweld PlusImpulse Exothermic WeldingControl Unit for RailReplacement Leads(Sold Separately)Download the Data SheetOur latest innovation, nVent ERICO Cadweld Plus Impulse Exothermic Welding Control Unit for Rail, brings you the highest level offlexibility and ease of use of any of our ignition systems. Precision engineered, the control unit lets you choose your power source:from off-the-shelf AA-batteries to the rechargeable Lithium-Ion packs you have on your job site.Why should you choose our latest ignition system? Safety, power and ease-of-use.SAFETY Self-closing trigger guard prevents accidental ignition, providingadded safety LED ignition counter provides instant feedback on the timing ofthe ignition and is visibile in sunny outdoor conditions Five second delay in ignition is a safety feature to allow the userto stop ignition, if necessaryFor more information on the nVent ERICOCadweld Plus Impulse Exothermic WeldingControl UnitPOWER Battery life indicator integrated into the unit for real-time updateson battery life; compatible with both AA and rechargeable batteriesPart Number Includes AA alkaline batteries to power approximately600 connectionsDescription Rechargeable batteries from Milwaukee or DEWALT can be usedto power approximately 1500 connections using a 4Ah battery Battery adapters available for use with either Milwaukee orDEWALT rechargeable batteries (sold separately)EASE-OF-USE High temperature lead with single molded insert into the controlunit keeps the most-often replaced component of ignition systemsmore securely attached and reliable Easy-to-use alligator clip design of the termination clearly showsa positive connection in the viewing windowPLUSCU2RLD66' / 1.8mPLUSCU2RLD1515' / 4.5m Enhanced power tool style grip is ergonomic and easy to holdPart NumberCable LengthBatteriesWorking TemperaturePBPLUSCU2L66'8 Lithium AA Batteries–40 F – 140 FPBPLUSCU2L1515'8 Lithium AA Batteries–40 F – 140 06CADWELD PLUS WELD MATERIALnVent.com/ERICO 1CADWELD TOOLSnVent ERICO offers a variety of equipment and accessories foruse with Cadweld, including rail grinders, hand tools and more.Part NumberColor Code RingPackage QuantitySB25PLUSF80Red20 pcSB32PLUSF80White20 pcPB45PLUSF80Light Blue20 pcPB65PLUSF80Dark Green20 pcSBG100PB90PLUSF80Gray10 pcPB115PLUSF80Orange10 pcPB150PLUSF80Dark Blue10 pcPB200PLUSF80Yellow10 pcPB250PLUSF80Purple10 pcPB300PLUSF80Light Green10 pcPB400PLUSF80Brown10 pcPB500PLUSF80Light Brown10 pcPortable RailGrinder withorganic grindingwheels thatdoes not leaveresin on bondingsurface. 1 800.447.RAIL rail@nVent.comnVent.com/ERICO 7
Our powerful portfolio of com/ERICO 2020 nVent. All nVent marks and logos are owned or licensed by nVent Services GmbH or its affiliates. DEWALT is a registered trademark of Black & Decker Corporation. Milwaukee is a registered trademark of Milwaukee Electric ToolCorporation. All other trademarks are the property of their respective owners. nVent reserves the right to change specifications without 6 1 800.447.RAIL rail@nVent.com
*Acetylene torch, approved grinding wheel and tools are also required. nVent ERICO offers all necessary Cadweld accessories. nVent ERICO offers a variety of equipment and accessories for use with Cadweld, including rail grinders, hand tools and more. SBG100 Portable Rail Grinder with organic grinding wheels that does not leave resin on bonding
Cadweld Plus System completes welds at distances of up to 6 ft/1.8 meters, 2 lbs. nVENT ERICO CADWELD PLUS VERTICAL STEEL SURFACE MOLD When making a Cadweld connection, an accurate control of the Cadweld process is . The Electronic Ignitor Assembly is used to light the Magnum Torch or oth
nVent ERICO Cadweld welded electrical connections nVent ERICO grounding and bonding products, lightning protection systems, surge protection devices NVENT LENTON CONCRETE REINFORCEMENT PRODUCTS Rebar splicing systems and other reinforcing products utilized to connect steel reinforcement rods in concrete. RAIL AND INDUSTRIAL PRODUCTS
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CAS20F Cadweld Adapter Sleeve for . The PBPLUSCU control unit electronic ignitor is primarily designed for ignition of nVent ERICO Cadweld Plus WELDING MATERIAL, F80 PBPLUSCU meet
to approximately 250 degrees Fahrenheit (120 degrees Celsius). Fig. 11 The conductors should be clean and dry before the connection is made. Use a propane torch to dry wire conductors and remove remaining cleaning residue, solvent, or water before making the Cadweld connection. Fig. 12 Next, use a wire brush to further prepare the surface of the
Cadweld Plus gear, simply purchase one of these kits Wricon – with and without plates, standard and custom length cables, the range is extensive. CADWELD PLUS ONE SHOT RANGE Earth Connections made easy – the CADWELD PLUS system boasts an electronic ignitor unit, making i
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