Dr. Livingstone, I Presume WELDWISE 2400 - Manual (Page 123)

PROBLEM POSSIBLE CAUSE OR
SYMPTOM
POSSIBLE FIX
Sensor is reading outside of usable range
(window). Zero the displacement. (Refer to Chapter 8, Calibrating the
Sensors or Supplementary Procedure, if applicable). If
monitoring more than 1 specific weld with the weld monitor
(e.g., weld gun shuttles or moves to multiple locations when
welding), verify that the initial and final stack-ups are within
the displacement window for each weld being made. (Refer to
the FAQ for more information about the displacement window).
Mechanical problems: loose displacement
brackets or loose tooling. Check the tooling and brackets for looseness or mechanical
slop. Check for loose electrodes. Repair as necessary.
Welds are being made with missing parts. Check welded parts for missing parts, nuts, etc. Check nut
feeder.
Mechanical binding. Check for mechanical binding.
Process timing has changed. Weld head is
extending too late or retracting too soon. Check for mechanical binding. Check for PLC program
changes.
Sensor failure. Refer to Section 3, Trouble With Displacement Sensor,
Readings or Channel.
Inspect sensor cable for physical damage. A cable that is
deformed, severed, partially severed, shredded, abraded and/or
has bare wires showing may be suspect. Disconnect sensor
cable from the weld monitor and replace. Try to reposition
cable new to avoid recurring damage. Spiral wrap or guards will
also help to protect cable. Refer to Section 6, Possible Sensor
Cable Failure.
EVERY WELD IS
REJECTED: The Weld
Summary screen indicates
that any or all Displacement
parameters (Initial
Thickness, Final Thickness,
Setdown, Expansion) are
out of tolerance.
CONT’D
Sensor cable failure.
Inspect electrical connections for damage, poor connections
and/or corrosion. Replace connectors and/or cable.
10-7
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