Dr. Livingstone, I Presume WELDWISE 2400 - Manual (Page 125)

PROBLEM POSSIBLE CAUSE OR
SYMPTOM
POSSIBLE FIX
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 new
cable to avoid recurring damage. Spiral wrap or guards will also
help to protect cable. Refer to Section 6, Possible Sensor Cable
Failure.
Inspect electrical connections for damage, poor connections
and/or corrosion. Replace connectors and/or cable.
Use the Input Monitor screen to observe the force channel
readings. Try flexing different areas of the sensor cable looking
for any area that causes the readings on the Input Monitor to
"jump". Replace the cable if flexing any part of it causes
intermittent readings.
EVERY WELD IS
REJECTED: The Weld
Summary screen indicates
that Force Parameters are
out of tolerance.
CONT'D
Sensor cable failure.
Disconnect the sensor cable from the weld monitor & sensor
and then using Livingston sensor cable documentation, check
continuity of all connections within the cable. Repair or replace
cable as necessary.
Calibration has changed. Inspect and re-enter toroid calibration factor if necessary (Refer
to Chapter 8, Calibrating the Sensors).
Tolerances are set improperly. Adjust the tolerances.
Voltage lead failure or poor connections. Inspect the voltage leads for severed or abraded wires, or poor
connections and repair as necessary.
EVERY WELD IS
REJECTED: The Weld
Summary screen indicates
that Current, Voltage,
Energy, Resistance or
Conduction Angle
Parameters are out of
tolerance.
Weld process has changed due to shunt,
tooling change or tooling failure. Check welded parts for missing parts, nuts, etc. Check nut
feeder. Inspect the shunts and tooling.
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