Dr. Livingstone, I Presume WELDWISE 2400 - Manual (Page 101)

0434-INS-400 Rev. C
7-7
Installing the Displacement Sensor
Livingston recommends the use of a double rod end displacement sensor. The size of this sensor will
depend on the stroke of weld cylinder: the sensor's stroke must always be greater than the full stroke of
the cylinder to prevent over-travel of the sensor.
It is important to leave at least ¼" of travel on either end of the sensor stroke as the resistive element
inside the sensor has a small dead band on each end. Try to position the sensor so readings are being
taken in the middle range of the full stroke, because scaling resistors are tuned to work best with
readings being taken in the area that is centered between 25% of travel on each end. The sensor itself
should be mounted on a non-flexible aluminum (or other non-magnetic) bracket. It is essential that the
mounting be extremely stiff, since any mounting bracket that can be deflected a few thousandths of an
inch can result in erratic and inaccurate displacement readings.
The displacement sensor window is approximately 9% of the range of the stroke of the displacement
sensor. For example, a 4-inch sensor has a .354-inch range (+/- 0.177 inches from the zero point). For
additional info on displacement window and sensor sizing, please contact your Livingston
representative. The displacement sensor can be zeroed electronically at any point on its stroke. For
more information on zeroing the displacement sensor, please refer to Chapter 8, Calibrating the
Sensors.
General mounting guidelines:
Affix the mounting bracket to the welder. If possible, avoid locating the mounting on an electrical
bus, especially the transformer secondary bus;
Mount the sensor to the bracket; use a service removable thread locking compound on rod end
bolts and all other bracket fasteners to keep parts from loosening.
Locate the blue displacement cable and plug it into the sensor.
The Livingston Monitor-Sensor cable may be modified to work with qualified third-party sensors.
Please contact your Livingston representative for further information.