INSTALLATION FOR GROUNDING SYSTEM
• Measure 600 to 1000mm from the base of the foundation as shown in Fig. 1. This will be the
minimum distance of terminal rod from the base.
• In preparation for grounding, dig 500 mm(H) x 500 mm(W) in a form of delta as
shown in the figure. Provide a distance of 3000mmL for the three sides.
• Drive ground rod on each corner of the delta. Make sure that there is a 200mm
allowance left from the top as shown in the figure.
• Join all ground rods using 100mm² bare copper wire with the use of
exothermic welding. See figure below for exothermic welding.
Exothermic Welding
- Permanent Bonding
- IEEE 837 Compliant
- UL 467 Certified
- Cost Effective Solution
EXOTHERMIC WELDING PROCEDURE
The Exothermic Weld process is a method of making electrical connections of
copper-to-copper or copper-to-steel in which no outside source of heat or
power is required. In this process, conductors are prepared, placed in a purpose
designed graphite mould, and exothermically welded to produce a permanent
molecularly bonded electrical connection.
Note: Before performing Exothermic Welding, make sure that the ground clamp
is inserted in the ground rod
• Always wear protective safety glasses and gloves while working with
exothermic welding products.
• Gather all the proper material and equipment/accessories for the type of
connection you are making. Check to ensure the graphite Mould is not worn or
broken, which could cause leakage of molten weld metal.
• Slide the handle clamp into the pre-drilled holes with the proper orientation
for the thumbscrews.
• Tighten the clamp thumbscrews onto the mould.
• The material to be welded (cable, rod, tape etc.) must be clean using the wire
Brush and dry using the Flame Torch included in the set of accessories. Thus
the oxide layer and superficial impurity is eliminated. Given that the graphite
mould also absorbs moisture, this should be removed by preheating with a gas
welding torch again to avoid a porous welding.
• P.N - After the first welding is done, it is not necessary to re-heat the mould if
the next welding is done within 15 minutes as it conserves the previously
generated heat.
• Place the conductors in the mould and close the handle clamp to avoid
material leakages during the reaction.
Please Note – You can apply Sealing Compound at the places where the
conductors is passing from the mould else at the time of Welding, the
Exothermic Liquid will spread out as a flame resulting in improper joint
• Place the metallic disk inside the mould and ensure that Powder should not
enter into Weld Cavity.
• Pour Exothermic Weld Powder into Graphite Mould. (Pour the Powder
recommended and supplied by us)
• Empty 50% of the starting powder above Exothermic Weld Powder (Don’t Mix,
just scatter) and then Close the Mould Mouth and then the rest 50% Starting
Powder, sprinkle it on the Mould Mouth nearby the small hole given on the
top of the Mould Mouth.
• Close the lid of the mould then ignite the starting powder extended on the
top/side of the mould using flint igniter.
• Once started, the reaction will take 8-20 seconds during which it is
recommended to stand clear of the mould.
• After at least 10 seconds of the Mould cooling down, open the mold by
undoing the handle grip. Remove the mould from the joint and clean the joint
by removing slag with help of Slag Removal Tool and hard brush. Then clean
the weld cavity with soft brush gently. The mould will be ready now to use
again without having to reheat it as it is already warm.
• Interconnect down-conductor to ground rods via ground clamp.
Note: Before Connecting the downconductor to grounding system, make sure
that cable pulling operation were performed correctly
Actual Grounding System