Dr. Livingstone, I Presume WELDWISE 2400 - Manual (Page 99)

0434-INS-400 Rev. C
7-5
Installing the Voltage Leads
Voltage leads should be as short as possible; do not be afraid to cut them. They should be connected as
close as possible to the electrodes, ideally on a permanent fixture so that the leads will not have to be
re-attached during electrode maintenance. Typically a small hole (10-32 is recommended) is drilled
and tapped near the electrode tip and a ring terminal installed on the voltage lead.
Affixing the voltage leads is a process that requires
working both from front to back, as well as back to
front. It is a balance between keeping the cable
connector as close to the leads as possible while
leaving sufficient excess to accommodate head
motion. Keeping the leads short and twisting the wire
whenever possible will greatly reduce unwanted noise
and help ensure the integrity of the sensor readings.
You may also choose to protect the leads with a flame
resistant spiral wrap, or a miniature flexible conduit to
protect wires from damage. If you are installing on a
Servo Gun or have reason to believe you may have
noise from a Servo motor, you should install a
Voltage Lead Noise Suppression Filter.
Make sure that the contact surfaces on the ring
terminals and the electrodes are free of dirt, grease
or corrosion.
The cable connector should be out of the way of moving parts or current carrying pieces. The leads
should be attached as close to the tips of the electrodes as possible, without interfering with the
weld process. Ideally, you will want to select a location on a permanent piece of tooling to prevent
re-mounting the leads.
Once you have selected a location, drill and tap a hole for a 10-32 screw, taking care not to tap into
an area where the electrode's cooling channels are located.
The Noise Suppression Filter should be attached close to the connector, and should be wrapped 13
times with the leads. Do not twist the leads while wrapping them around the filter. The filter itself
should then be secured using cable ties.
Run the voltage lead wire from the connector up to the point of connection near the electrode tips.
Open and close the tips to see exactly how much excess lead wire is needed to accommodate the
motion.
Secure the voltage wires back along the bus using cable ties or some type of hold-down clamps.
Attach # 10 ring terminals to the ends of the voltage leads.
Figure 7-4 Mounting the Voltage leads