ERICO CADWELD PLUS Rail Joint Head Bonds - Manual (Page 3)

FIGURE
10
CADWELD PLUS
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IV. WELDING PROCEDURE
1. Place bond in welder with fl at surface against rail head and
end of terminal against bond clip. This correctly positions
bond in weld cavity. Be sure the bond clip is in good condition
and properly positions terminal under center of tap hole as
shown.
See Figure 7.
2. Position the welder with attached molds on the rail head.
The bottom edge of the mold should be aligned with the
lower edge of the rail head. Use the mold height adjusting
screws to properly align the mold. See Figure 8.
3. Close clamp to lock welder on rail. Clamp is adjustable for
rail sizes. Check that mold face fi ts against rail and bond
terminal is held against rail by clevis. See Figure 8.
WARNING: Correctly positioning the mold against the rail
with the welder device is critical for safety and success in
making a bond. There must be no gaps between the lower part
of the mold that contains the weld cavity and the rail surface;
if a gap is present, the mold should be discarded and a new
one used. See Figure 9. (Molds can generally be used for up
to 50 welds.) The exothermic reaction reaches a temperature in
excess of 4000°F, therefore great care must be exercised to avoid
spillage of the molten metal. Failure to observe this warning
may result in molten metal leakage onto the rail with immediate
risk of personal injury, and potentially serious structural damage
to the rail that could result in a rail break leading to property
damage, injury or death to others.
FIGURE
7
FIGURE
8
FIGURE
9
CADWELD ® PLUS Rail Joint Head Bonds
Refer to the mold tag for applicable instruction sheets. IPRSJCP_C
Bond Clip
CADWELD ® PLUS
Mold Cover
Mold Height Adjusting Screw
Clamp Adjustment Screw
Splice Bar
Tap Hole
Bond
Terminal
Bond Clip
4. Insert CADWELD PLUS welding material cup into mold.
See Figure 10.
5. Attach Control Unit termination clip to ignition strip,
align the strip and close the cover. See Figure 11.
FIGURE
11
CAUTION: Install only the specifi ed CADWELD PLUS
welding material cup in the mold crucible. Use only the
welding material size that is specifi ed on the mold. ERICO
®
brand of welding material (F80) is formulated specifi cally for
use with rail steel.