Harger US115, US300, USCONTROLLER, NUWTUBE65, US400 Installation Manual

Instructions

• Always follow the Welding and General Safety Instructions included with this mold.

• Always follow the Conductor Preparation Instructions included with this mold specifi c to the connection to be made.

Ultraweld® UltraShot® Welding Procedures

1. Check mold tag for conductors to be welded and proper
weld metal cartridge size to use.

2. Make sure all surfaces and conductors are clean, dry and are
the proper sizes for the mold’s application per mold tag.

3. For the initial connection, torch dry the mold with a hand
operated propane torch.

4. Position mold onto conductor(s). See front of the other
instruction sheet included with this mold for positioning
of conductors into mold. Lock mold with handle clamps
or frame, which ever is the case. Note that Handle Clamp
adjustments may be made by removing adjusting screw and
turning eye bolt 180° clockwise to tighten or 180° counter
clockwise to loosen.

5. If using UltraShot
mold with the igniter exiting the mold through the slot in the
top of the mold. Ensure the lid is closed tightly.

Note: UltraShot® weld metal US500, US750, US1000 and

US1500 are made up of two or three cartridges. To use,
cartridge(s) without an igniter should be dropped into the
mold fi rst. The cartridge with an igniter should be on top
and should be exiting the mold through the slot in the top of
the mold. Ensure the lid is closed tightly.

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, drop the weld metal cartridge into the

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UltraShot

6a. Before igniting, verify conductor positioning and that mold is

closed completely.

6b. Slide the igniter lead connecter over the end of the igniter.

Push connector until the igniter bottoms out inside the
connector.

6c. Simultaneously push and hold both buttons on the side of

the USCONTROLLER until the reaction is initiated and then
release the buttons. Note that the LED light on the side
of the USCONTROLLER will illuminate while both buttons
are pressed. Do not hold buttons for more than 5 seconds.
Should the reaction not occur, wait 30 seconds and remove
the UltraShot
fails to ignite again, it is likely that the controller needs to be
recharged.

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cartridge and insert another cartridge. If it

Revised 7.9.12

6d. After ignition, remove igniter lead immediately.

Step 5

Step 5 Notes

301 Ziegler Drive, Grayslake, IL 60030
Phone: [phone]
Fax: [phone]
Website: www.harger.com

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Ultraweld® UltraShot® Welding Procedures

Continued

7a. If using Ultraweld tubes, insert disk in the bottom of the

mold crucible, concave side up.

7b. Pour the weldmetal (clear cap side) into the mold crucible

on top of the disk.

7c. Open starting powder side (orange cap) and put approxi-

mately two-thirds of the starting material on top of the weld
metal. Close the lid and put the remaining material on top of
the lid near the hole.

9. To clean the mold, use a MCBRSH1 natural bristle brush be­fore making next weld. On horizontally split molds, use end
of mold cleaning spade, a small diameter rod or screw driver
to remove slag from tap hole. Caution should be used when
cleaning molds to avoid burns from contact with hot mold.

Do Not Use Wire Brush to Clean Mold!

USCONTROLLER

7d. Ignite starting material with a fl int igniter.

8. Wait approximately 30 seconds before opening mold to
permit metal to solidify.

Flint Igniter

Ultraweld-UltraShot Welding Procedure Instructions

Battery Type:

• This ignition unit contains a lead-acid battery which is
sealed and maintenance free.

Battery Charging:

• To properly charge this Deep Cycle AGM battery only use

the dual stage charger provided with the USCONTROLLER
unit.

• Never run the battery to a point where it is completely

discharged.

• The dual stage charger provides a trickle charge so it is

impossible to over-charge and damage the battery.

• Charge before each use to achieve optimum performance.

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