Dr. Livingstone, I Presume WELDWISE 2400 - Manual (Page 130)

2. TROUBLE WITH FORCE SENSOR, READINGS OR CHANNEL
PROBLEM POSSIBLE CAUSE OR
SYMPTOM
POSSIBLE FIX
CALIBRATED FORCE
SIGNAL IS READINGS
HIGHER OR LOWER
THAN NORMAL Calibration has changed or is incorrect. Inspect and recalibrate sensor if necessary (Refer to Chapter 8,
Calibrating the Sensors). Note: If an Export Setup was
performed the last time this sensor was properly calibrated, an
Import Setup may be performed to reload the saved calibration
settings. Refer to Chapter 6, WMS Reference Guide.
The force sensor is not connected properly. Inspect electrical connections for poor connections or corrosion.
Use the Input Monitor to observe the force channel readings.
With the sensor disconnected an A/D value of +/-32767 may
indicate a failed sensor cable or weld monitor hardware
problem. Refer to Section 8 of this chapter, Trouble With
Hardware.
Use the Input Monitor to observe the force channel readings.
Apply and remove pressure. If the A/D value does not change,
this may indicate a failed sensor, sensor cable (see below) or
weld monitor hardware problem. Refer to Section 8 of this
chapter, Trouble With Hardware.
Use the Input Monitor to observe the force channel readings
and compare the readings to those of another similar weld head
adjusted to the same pressure. Apply and remove pressure. If
the A/D values are not similar to those displayed on a different
weld monitor that is functioning properly, this may indicate a
failed sensor, sensor cable or weld monitor hardware problem.
CALIBRATED FORCE
SIGNAL IS INDICATING
A “FROZEN” (static)
READING
The force sensor, sensor cable, or weld
monitor is malfunctioning.
Use the Input Monitor to observe the force channel readings.
Apply and remove pressure. If the A/D values are not close to
expected values, this may indicate a failed sensor, sensor cable
(see below) or weld monitor problem. If sensor and cable are ok
refer to Section 8 of this chapter, Trouble With Hardware.
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