Problem possible cause or symptom possible fix – Dr. Livingstone, I Presume WELDWISE 2400 User Manual

Page 131

PROBLEM

POSSIBLE CAUSE OR

SYMPTOM

POSSIBLE FIX

The air pressure was adjusted or system
pressure has changed.

Check air pressure setting. Check the force at the electrodes.

Process timing has changed. Weld head is
extending later or retracting sooner than it
was when Master or tolerance limits were
set. Intensification timing has changed.

Check for mechanical binding. Check for PLC program
changes.

WHEN A WELD IS
MADE, THERE IS
LITTLE OR NO FORCE
REPORTED.

Mechanical binding.

Check for mechanical binding of the weld head.

”FROZEN” A/D
READING: The Input
Monitor indicates a
constant (static) A/D
reading for the force sensor.
This value never changes;
the other sensor channels do
not change or update either.

Problem with Weld monitor.

If other channel readings are not changing, the data may not be
updating. Shutdown and Restart the weld monitor. If problem
persists contact Livingston Service.

Sensor failure.

A reading of +/-32767 indicates that the input channel is
reading its maximum value and is saturated. There may be
problem with the sensor, sensor cable, or weld monitor
hardware. Disconnect the sensor from the sensor cable. If the
A/D reading changes to a value within +/- 100 from 0, the
sensor may be malfunctioning. Repair or replace the sensor. If
the A/D reading remains at maximum value then the sensor
may be OK and the sensor cable may be malfunctioning. Refer
to Section 6, Possible Sensor Cable Failure.

“PEGGED” A/D
READING: The Input
Monitor indicates a force
channel A/D reading of +/-
32767. This value never
changes; the other sensor
channels appear to be
working and the A/D values
for these channels are
changing/updating.

Sensor cable failure.

Disconnect the sensor from the cable, if still pegged.
Disconnect cable from the weld monitor. If the A/D reading
changes to a value within +/- 100 from 0, the sensor cable
should be repaired or replaced. If the A/D reading remains at
maximum value, refer to Section 8, Trouble With Hardware.

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