Dr. Livingstone, I Presume WELDWISE 2400 - Manual (Page 120)

cable are shorted or open, an inaccurate calibration will result. Check for “frozen” or “pegged”
A/D readings.
Plug in a known good sensor and cable check the A/D values and compare them with the
suspect sensor and cable.
As an example a properly sized force sensor with no load on it will have an A/D reading of
approximately 0 to 40. When full force is applied the reading should be from 50% to 75% of
full scale. 50% of 32767 = 16383 A/D counts.
These numbers will vary based on sensor millivolt per volt output and load range verses actual
load. The point is that if A/D readings with sensor loaded are similar to the sensor with no load
this generally indicates a failure of the sensor or sensor cable.
Remember when checking a displacement sensor you must be within the measurement window
to get meaningful A/D readings. If you are not within (e.g. gun is retracted) the reading will be
“pegged”(+/- 32767, channel input range has been exceeded). Refer to Chapter, 8 Calibrating
the sensors, Chapter 9, FAQ and the Displacement Channel Over view Section of Chapter 11
for additional Information on displacement.
0455-INS-400 Rev. C
10-4