APPENDIX B: ELECTRICAL AND DATA CONNECTIONS
HF25D DC RESISTANCE WELDING SYSTEM
B-4
990-333
Connections
Connect an approved, normally closed emergency stop switch across the 2-foot (61 cm) operator
emergency stop switch cable. The cable is routed through the side of the connector box on the rear
panel. When the switch is operated (opened), it de-energizes the main power contactor, removing three-
phase input power to the Control.
Operator Emergency Stop Switch Cable Pin Assignment Summary
Signal
TB5
Pin No.
Name Type
Control
Board
J3
Max
Voltage
Max
Current
I/O Comments
41 CONTRET AC 1 24
VAC
GND
10mA O
Contactor
Return
42
24VAC
AC
2
24VAC
10mA
I
Emergency stop switch
normally closed contact
Force Firing Switch Input
Function
The force-firing switch input to the Control from the weld head signals that the selected pressure has
been applied to the weld pieces. Note that a mechanical firing switch is subject to contact bounce,
which can cause false weld starts. The effects of switch bounce can be avoided at low weld speeds by
using the switch debounce function on the Control main menu. If welding speeds are to exceed 1.5
welds per second, use an optical firing switch.
Connections
The firing switch cable is a Type 2/C, 600-volt cable containing two shielded, twisted pair 22 AWG
stranded leads. It is 5 feet long.
The firing switch cable connector is a 2-pin Amphenol Type 80-MC2FI. It mates with the weld head
firing switch connector, which is a 2-Pin Amphenol Type 80-MC2M.
If the weld head uses an opto coupler instead of a mechanical switch, its emitter is connected to digital
ground (Pin 1).
If the firing switch is from a PLC (with a positive-voltage input), the factory-installed jumper between
pins 19 and 20, are moved between 19 and 18 (ground).
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