Model WP9000 WeldProbe Force Gage

Model WP9000
WeldProbe Force Gage
2080 Arlingate Lane, Columbus, Ohio 43228 USA • (614)850-5000
Sensotec, Inc.
2080 Arlingate Lane
Columbus, Ohio 43228 USA
Copyright © 1999 by Sensotec, Inc. all rights reserved
Telephone: (614)850-5000
FAX: (614)850-1111
Toll Free: 1-800-848-6564
E-mail: [email protected]
WWW: http://www.sensotec.com
Model WP9000 WeldProbe Force Gage
Sensotec Part Number: 008-0548-00
Rev. D: March, 2003
IMPORTANT! IT IS RECOMMENDED THAT YOU READ
THIS DOCUMENT THOROUGHLY BEFORE APPLYING
POWER TO THIS UNIT. THIS DOCUMENT CONTAINS
INFORMATION ON WIRING, CALIBRATION, AND USE
OF FEATURES.
Sensotec continually improves its products, and thus the
information herein is subject to change without notice.
TABLE OF CONTENTS
Chapter 1
INTRODUCTION
1.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Quick Operation Guide . . . . . . . . . . . . . . . . . . . . . 6
1.3 Instrument Layout. . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.4
1.5
1.6
1.7
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Battery Indicator . . . . . . . . . . . . . . . . . . . . . .
Decimal Point Position . . . . . . . . . . . . . . . . . . . . .
Incremental Display Step . . . . . . . . . . . . . . . . . . .
Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
......
......
......
......
......
.7
.7
.8
.8
.8
Maximum Safe Overload . . . . . . . . . . . . . . . . . . . 9
Front and Side Views . . . . . . . . . . . . . . . . . . . . . 10
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
OPERATION
2.1 Battery Replacement . . . . . . . . . . . . . . . . . . . . . 13
2.2 Turning the Instrument On and Off. . . . . . . . . . . 14
2.3 Zeroing the Display. . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Restoring the Calibrated Zero . . . . . . . . . . . . . . 15
2.5 Reading the High/Low Values . . . . . . . . . . . . . . 15
2.6 Clearing the High/Low Values . . . . . . . . . . . . . . 16
Chapter 3
FIELD SELECTABLE FEATURES
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2
3.3
Setup Menu Operation. . . . . . . . . . . . . . . . . . . . 17
Enable Options (“(”) Description . . . . . . . . . . . 19
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.4
3.5
3.6
3.7
3.8
Auto-off Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Always-On Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
[Zero] Button Disable Feature . . . . . . . . . . . . . . . . . . . . . .20
[Hi/Lo] Button Disable Feature . . . . . . . . . . . . . . . . . . . . .20
[Clear] Button Disable Feature . . . . . . . . . . . . . . . . . . . . .20
Enable Options (“(”) Menu Item . . . . . . . . . . . .
Engineering Units (“81,W”) Menu Item . . . . . . . . .
Auto-off time (“$R))”) Menu Item . . . . . . . . . . . .
Update Rate (“U$W(”) Menu Item . . . . . . . . . . . .
Internal Software Version (“Y(U”) Menu Item . . .
21
22
23
23
24
Chapter 4
CALIBRATION
4.1 Calibration Considerations. . . . . . . . . . . . . . . . . 25
4.2 Required Forces . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Calibration Procedure . . . . . . . . . . . . . . . . . . . . 27
4.3.1 Enter Forces to be Applied . . . . . . . . . . . . . . . . . . . . . . . .27
4.3.2 Apply Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.4
4.5
Rear View of Front Face Panel . . . . . . . . . . . . . 31
Calibration Error Messages . . . . . . . . . . . . . . . . 32
Chapter 5
TROUBLESHOOTING
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Help Message Codes. . . . . . . . . . . . . . . . . . . . . 33
5.3 Troubleshooting Hints . . . . . . . . . . . . . . . . . . . . 34
Chapter 1
INTRODUCTION
1.1 Overview
The WeldProbe is a rugged, hand-held instrument for
accurately calibrating weld electrode force on resistance
welding machines. This device helps ensure compliance
with ISO 9000 or QS 9000 quality requirements by taking
the guesswork out of setup. Measuring accurate force
levels at the electrode tips helps eliminate inaccuracies of
the line-pressure readings, air cylinder friction, and
mechanical wear.
The WeldProbe is designed for long life in the harsh welding environment by using Sensotec’s standard fullywelded load cell construction and NEMA 4 electronics
packaging. The easy-to-use design includes a simple
push-button format and a large LCD display that provides
both continuous and peak (maximum) force values in keypad-selectable engineering units.
High-speed digital electronics sample readings during the
squeeze-weld-hold sequence and capture the peak force
for display. A simple, one-button CLEAR prepares the
instrument for the next reading. Two standard 9-volt alkaline batteries provide 80 hours of continuous use. Battery
life is maximized with a programmable power-off feature.
Model WP9000 WeldProbe Force Gage
page 5
1.2 Quick Operation Guide
1. Depress the [On/Off] button to power up the instrument.
Wait about 5 seconds for the instrument to warm up.
2. If a non-zero value appears on the display, press and
hold the [Zero] button until the display reads “”
(this takes about three seconds).
3. Insert probe, initiate welder, and take reading.
4. Press and hold the [Hi/Lo] button until the display reads
“+, ” to read the maximum (or peak) force value.
5. Press [Clear] to clear the maximum value in preparation for the next reading.
6. As shipped from the factory, the instrument will automatically shut itself off if no buttons have been
pressed in four minutes.
Note: The WP9000 is a force calibration device designed
to measure the force between electrodes on resistance
welders. It can withstand passing current through the
force transducer.
It is recommended for the saftey of
the operator and the WP9000 to disable current before operation. Many
repeated current firings may damage
the weld force indicator.
page 6
Introduction
1.3 Instrument Layout
1.3.1 LCD Display
The 4½-digit liquid crystal display (LCD) readout displays
the load applied to the instrument, interacts with the user
when the instrument is being set up or calibrated, and
indicates if there is a problem with the instrument.
When a WP9000 instrument is turned on, it illuminates all
LCD segments. Then, the engineering units the gauge will
be using appears on the display. Most WP9000 instruments are calibrated in pounds (“/E
/E6
6”) and the instrument
has conversion factors for many standard engineering
units built in. However, if the instrument displays 63& /
(special) it has been specially calibrated to another engineering unit at the factory. In that case, the serial number
tag on the top of the instrument will indicate the engineering units being used and the capability to select other
engineering units should not be used.
After the display of the engineering units, the force
applied to the load cell is shown on the display. If the load
applied to the load cell is above the instrument's ability to
measure, the display will indicate this overrange condition
by showing a " " on the far left hand side of the display.
The display will read " " if the instrument is underranged.
1.3.2 Low Battery Indicator
On the left side of the display, just above the minus sign,
is the low battery indicator (in the shape of an arrow).
When the battery voltage is less than 5 volts, the display
will be blanked and the low battery indicator will illuminate
to indicate that the batteries should be replaced. The low
battery indicator can be seen when the instrument is
turned on and all segments of the display are momentarily
lighted.
Model WP9000 WeldProbe Force Gage
page 7
When the low battery indicator is illuminated, change the
batteries as soon as possible. The instrument will not
function if the battery voltage falls below approximately 4
volts.
1.3.3 Decimal Point Position
The decimal point position automatically
depending upon:
• the user selected engineering units
•
changes
the load range of the instrument
The decimal point position cannot be changed manually.
1.3.4 Incremental Display Step
The incremental display step is the value by which the last
digit of the display will change. This value will be either 1,
2, or 5 display counts. It automatically changes depending
upon:
• the user selected engineering units
•
the load range of the instrument
The incremental display step cannot be changed manually.
1.3.5 Load Cell
The WP9000 instrument can be ordered with one of two
types of load cells: those with a load sensing button, and
those with a load sensing indentation. The load sensing
button is useful when the WeldProbe is used with projection welders. The load sensing indentation is useful for
most spot welding applications.
page 8
Introduction
1.4 Maximum Safe Overload
Maximum safe overload is the force which the instrument
can experience occasionally without loss of accuracy or
permanent damage.
Table 1: Maximum Safe Overload
Force Range (lbs.)
Maximum Safe Overload
(lbs.)
0 - 500 = 500
750
0 - 1000 = 1K
1500
0 - 2000 = 2K
3000
0 - 5000 = 5K
7500
0 - 10000 = 10K
15000
Model WP9000 WeldProbe Force Gage
page 9
1.5 Front and Side Views
Figure 1-1: Model WP9000 Front View
Figure 1-2: Model WP9000 Display Side View
page 10
Introduction
1.6 Dimensions
Figure 1-3: Model WP9000 Display Dimensions
Figure 1-4: Model WP9000 Load Cell Dimensions (2000 lbs.
Range with Sensing Indentation)
Model WP9000 WeldProbe Force Gage
page 11
1.7 Specifications
Sensotec continually improves its products, and thus
these specifications are subject to change without notice.
Display Diameter:
3.7 inches
Accuracy:
0.5%
Operating Temperature:
30 to 180 ºF
Force Ranges 0 to:
1000, 2000, 5000, 10000 lbs.
Overload Capability:
150% of full-scale range
Calibration Engineering
Units:
lbs
Built-in Engineering Unit
Conversion:
lbs, Kg, kN, N, g (field selectable)
Sampling Rate:
19.2kHz internal; 24Hz display update
Power Requirements:
two 9 Volt alkaline batteries provide
approximately 80 hrs continous life
Load Cell Material:
BeCu
Housing Material:
Stainless steel
High and Low Capture:
Standard, same update rate as display
Zero and Span Adjustment:
Standard
Front Panel Membrane
Tactile feedback, raised buttons
Calibration Data:
Stored on non-volatile memory chip
Package:
All-welded load cell; NEMA 4 rated
display unit
Weld Current:
Survives accidental current discharge
page 12
Introduction
Chapter 2
OPERATION
2.1 Battery Replacement
Two nine-volt alkaline batteries (NEDA 1604) are recommended for use in the Model WP9000. This is a common
type of battery which is available at many stores. With
two alkaline batteries, a Model WP9000 instrument will
operate continuously on for approximately 80 hours. Carbon-zinc batteries (sometimes labeled as “general purpose” or “heavy duty”) should not be used. Please note
that the temperature specifications of the batteries you
purchase may not be the same as those of the Model
WP9000.
If two batteries are not available, the instrument will operate with only one alkaline battery installed in either clip.
However, this will reduce the continuous operation time to
approximately 40 hours.
The use of two lithium batteries will allow your Model
WP9000 instrument to operate continuously for over 160
hours.
To install the batteries:
1) Remove the center screw on the back of the instrument.
2) Remove the front face panel from the case.
3) The colored ribbon cable extending from the sensor to
the electronics may be disconnected to make the
battery installation more convenient.
Model WP9000 WeldProbe Force Gage
page 13
4) Replace the batteries one at a time, making sure of the
correct polarity.
5) Reconnect the sensor cable to the electronics.
Important note: The correct orientation of the
sensor cable is shown on page 31. If you connect the sensor cable backwards, the instrument will not operate correctly.
6) Replace the front face panel.
7) Carefully replace the rear center screw.
Note: Calibration and setup values are stored in a nonvolatile memory, and are not lost during battery replacement.
2.2 Turning the Instrument On and Off
Push the [On/Off] button to turn
the instrument on or off.
As the instrument turns on, every segment on the display
is momentarily lighted. The high/low data values are
cleared.
2.3 Zeroing the Display
Hold the [Zero] button until the
the display shows “” (about
5 seconds).
The instrument will retain this zero value even after the
instrument has been turned off.
page 14
Operation
2.4 Restoring the Calibrated Zero
To restore the zero, first press
and hold the [Clear] button,
and while holding [Clear]...
... press the [Zero] button. Hold
both buttons until the display
shows “ 3
3”, then release.
The "calibrated zero" is the zero value of the instrument at
the time it was last calibrated. Restoring the calibrated
zero can be used to “undo” an inadvertent press of the
[Zero] button.
2.5 Reading the High/Low Values
The high and low values are updated at the same rate as
the tracking value.
Press the [Hi/Lo] button once to
read the highest value since the
last time the data was cleared.
The word "+," and the corresponding value will flash intermittently on the display. This flashing indicates that the
instrument is not displaying the "live" tracking value of the
applied force. However, the instrument is still monitoring
the applied force and updating the high and low values.
Press the [Hi/Lo] button a
second time to read the lowest
value since the last time the data
was cleared.
The word "/R" and the corresponding value will flash intermittently on the display. This flashing indicates that the
instrument is not displaying the "live" tracking value of the
applied force. However, the instrument is still monitoring
Model WP9000 WeldProbe Force Gage
page 15
the applied force and updating the high and low values.
Press the [Hi/Lo] button a third
time to return to the “live” tracking
mode. The display will show “---”
to indicate tha the instrument has
returned to the “live” tracking mode.
2.6 Clearing the High/Low Values
Press the [Clear] button to erase
the high and low data values.
The high and low data values are also cleared when the
instrument is turned off.
page 16
Operation
Chapter 3
FIELD SELECTABLE FEATURES
3.1 Introduction
This Chapter discusses the field selectable features available on the model WP9000 WeldProbe Force Gage.
These features can be activated, deactivated and modified via the Setup Menu accessed by the front panel.
These field selectable features include:
• Enabling the automatic power off feature to conserve
battery life
•
Disabling the front panel buttons
•
Changing the engineering units used to display the
applied force.
•
Adjusting the automatic power off time
•
Changing the update rate
3.2 Setup Menu Operation
All of the field selectable features are accessed via the
Setup Menu. This section discusses its operation.
To change a feature with the Setup Menu:
Make sure the instrument is turned
off. Then, press the [On/Off] button.
Model WP9000 WeldProbe Force Gage
page 17
While unit is checking the display
(lighting all LCD segments simultaneously) press and hold down
the [Zero] button.
The display now reads “//
/R
R”, which is the first item of the
Setup Menu. Release the [Zero] button.
Pressing and releasing the [Zero]
button will scroll down through the
available Setup Menu items.
The table below provides a list of the items available in
the Setup Menu and a brief description of each.
Table 2: Setup Menu Items
Display
Menu Item
Purpose
//R
Low Limit
setpoint
N/A
/+,
High Limit
setpoint
N/A
(2
Enable
Options
Enable Auto-Off feature;
Disable front panel buttons
8 1, W
Engineering
units
Change engineering units used to
display force
$R)
R))
)
Auto-off time
Change Auto-Off power down time
U $W(
Update rate
Change update rate of force readings
Internal software revision
Display internal software part number and revision
Y(U
page 18
Field Selectable Features
When the menu item you wish to
change is displayed, press
[Clear].
The display now shows the present setting of that menu
item. If you only wish to examine the present setting of
the menu item, you can use the [On/Off] button to turn the
instrument off. Otherwise...
Use the [Hi/Lo] and [Clear]
buttons to scroll up and down,
respectively.
If you wish to abandon the changes you made to this setting, you can use the [On/Off] button to turn the instrument
off. Otherwise...
Once the setting you want is displayed, press the [Zero] button to
store this setting into memory.
The next menu item will be displayed after the instrument
stores the setting into memory.
3.3 Enable Options (“(”) Description
The Enable Options (“(”) menu item controls the features
described in the sub-sections below.
3.3.1 Auto-off Feature
The unit will shut itself off if no buttons are pressed for the
time duration specified with the Auto-off time (“$R)
R)))”)
menu item. The unit can also be shut off with the [On/Off]
button.
This feature is useful for conserving battery life.
instrument is shipped with this feature enabled.
Model WP9000 WeldProbe Force Gage
The
page 19
3.3.2 Always-On Feature
The [On/Off] button is disabled and will not shut the unit
off. This mode is used so that the high and low capture
values, output signals, or limit alarms are not interrupted if
an operator tries to shut the unit off during testing or monitoring.
3.3.3 [Zero] Button Disable Feature
This feature disables the ability to zero the display of the
instrument. The ability to restore the calibrated zero is
also disabled. When the [Zero] button is pressed, the display momentarily reads “( ” which indicates that the button has been disabled via the Enable Options menu item.
3.3.4 [Hi/Lo] Button Disable Feature
This feature disables the ability to read the stored high
and low values on the display. The display will always
read the “live” tracking value of the applied force. When
the [Hi/Lo] button is pressed, the display will momentarily
read “(” which indicates that the button has been disabled via the Enable Options menu item.
3.3.5 [Clear] Button Disable Feature
This feature disables the ability to clear the high and low
data values with the [Clear] button. The ability to restore
the calibrated zero is also disabled. When the [Clear] button is pressed, the display momentarily reads “(
(” which
page 20
Field Selectable Features
indicates that the button has been disabled via the Enable
Options menu item. NOTE: The high and low data values
may also be cleared by turning the unit off and back on,
unless the Always-on feature is used.
3.4 Enable Options (“(”) Menu Item
To activate or deactivate the features described in the previous section, the setting of the Enable Options (“( ”)
menu item must be changed. The procedure to change
the setting of a menu item is described in the “Setup
Menu Operation” section earlier in this Chapter.
The setting value of the Enable Options (“( ”) menu item
is obtained by adding together the values of the desired
options according to the table below.
Table 3: Enable Options (“(”) settings
Feature
Disabled
Enabled
Auto-off
0
1
Always-on
0
2
[Zero] button
4
0
[Clear] button
16
0
[Hi/Lo] button
32
0
For example, to enable the Auto-off feature and disable
the [Zero] button enter a setting value of “0005”. As
another example, to disable both the [Zero] and the
[Clear] buttons enter a setting value of “0020”.
If the Auto-off and Always-on features are both activated,
the unit will behave as follows: The [On/Off] button can
Model WP9000 WeldProbe Force Gage
page 21
turn the instrument on but it cannot turn the instrument off.
The only way to turn the instrument off is not to press any
buttons for the duration specified in the Auto-off time
(“$R) )”) menu item. Note that the Auto-off time (“$R)
R)))”)
setting can be several hours.
3.5 Engineering Units (“81, W”) Menu Item
The Engineering Units (“81,W”) menu item determines
which units-of-measure are used to display the force
readings. Most WP9000 instruments are calibrated in lbs.
and the instrument has conversion factors for many standard engineering units built in. The procedure to change
the setting of a menu item is described in the “Setup
Menu Operation” section earlier in this Chapter.
Note: If the instrument displays “63&/” (special) when
powering up, it has been specially calibrated to another
engineering unit. The ability to change the engineering
units is not available.
The table below gives a list of the engineering units built
into the instrument.
Table 4: Engineering Units (“81, W”) Available Settings
Setting
page 22
Engineering Unit / Comment
$G&
for factory use only
/E6
lbs
1
N
N1
kN
J
g
NJ
kg
Field Selectable Features
3.6 Auto-off time (“$R) )”) Menu Item
The Auto-off time (“$R) )”) menu item is only meaningful if
the Auto-off feature is enabled in the Enable Options (“( 2”)
menu item. The procedure to change the setting of a
menu item is described in the “Setup Menu Operation”
section earlier in this Chapter.
The table below gives a list of the available settings for
the Auto-off time (“$R) )”).
Table 5: Auto-off time (“$R)
R)))”) Available Settings
Setting
Time
0
4 minutes
1
1 hour
2
2 hours
3
3 hours
4
4 hours
5
5 hours
6
6 hours
7
7 hours
8
8 hours
3.7 Update Rate (“U$W(”) Menu Item
The Update Rate (“U$W(”) menu item determines the number of times the force readings are updated per second.
The track, high and low values are all updated at this rate.
The update rate can be varied from 5 to 24 updates per
second. As shipped from the factory, the update rate is
set to 24 per second.
Model WP9000 WeldProbe Force Gage
page 23
Important Note: To receive maximum accuracy in resistance welding applications, it is
important to leave the update rate set at 24 per
second.
3.8 Internal Software Version (“Y(U”) Menu Item
The Internal Software Version (“Y( U”) menu item displays
the part number and version number of instrument’s operating software. The software part number and version
number are of the form:
084-1087-02 1.19
Where the “084-1087-02” is the part number, and the
“1.19” is the version number.
Since this string is too long to fit on the 4½ digit-display,
pressing either the [Hi/Lo] or [Clear] buttons will scroll
through this string 4 characters at a time.
page 24
Field Selectable Features
Chapter 4
CALIBRATION
4.1 Calibration Considerations
In order to obtain optimum performance from the model
WP9000 instrument when testing or re-calibrating, Sensotec recommends the following:
• Allow a 5-minute warm-up period before testing or calibration.
•
The force standard you use should be at least 4 times
more accurate than the specification of the WP9000
instrument.
4.2 Required Forces
In order to re-calibrate the instrument, you must have a
precision force standard that can produce the zero-scale,
half-scale and full-scale forces for the instrument's range.
For example, if your WP9000 instrument has a range of
500 lbs, your force standard must be able to accurately
produce forces of 0 lbs, 250 lbs, and 500 lbs.
If your force standard cannot produce these exact values,
the instrument can be programmed in the field to expect
slightly different values during the re-calibration process.
For example, if your calibrated weights are equal to 0 lbs,
251 lbs and 498 lbs, you can program the instrument to
expect these weights during the re-calibration process.
All WP9000 instruments are calibrated in lbs regardless of
the field-selected engineering units. However, if the
instrument displays the word ”63&/” (special) when it powers up, it has been specially calibrated to another engineering unit. In that case, the serial number tag on the top
Model WP9000 WeldProbe Force Gage
page 25
of the instrument will indicate the engineering units that
will be used for re-calibration.
To maintain NIST traceability, Sensotec can re-calibrate a
WP9000 instrument for you. NIST certificates may be
ordered as a separate accessory for a nominal fee.
Table 6: Required Forces (all in lbs)
Force
Range
Calibration
Point 0
(zero-scale
force)
Calibration
Point 1
(half-scale
force)
Calibration
Point 2
(full-scale
force)
500
0
250
500
1K
0
500
1000
2K
0
1000
2000
5K
0
2500
5000
10K
0
5000
10000
page 26
Calibration
4.3 Calibration Procedure
The calibration procedure consists of two parts, the first of
which may not be necessary in all applications.
• First, the instrument is told exactly what zero-scale,
half-scale and full-scale forces are to be applied during
the calibration procedure.
•
Second, the forces are applied to the instrument.
The following two sections explain this procedure.
4.3.1 Enter Forces to be Applied
The expected force values to be applied during calibration
are accessed via the Factory Configuration Menu. This
section discusses its operation.
To change a value with the Factory Configuration Menu:
Make certain the instrument
is turned off.
Open up the instrument by removing the center screw on
the back. Next, remove the front face panel. Take care
not to break the wires extending from the sensor to the
electronics. As indicated on Figure 4-1, move the mode
jumper from the "park" position to the "configure" position.
Hold the [On/Off] button,
then press the [Hi/Lo] button. The display will momentarily read “R 3”.
Release the [Hi/Lo] button, and the display will read “G3”
which is the first item of the Factory Configuration Menu.
Model WP9000 WeldProbe Force Gage
page 27
Pressing and releasing the [Zero]
button will scroll down through the
available Factory Configuration
Menu items.
The table below provides a list of the items available in
the Factory Configuration Menu and a brief description of
each.
Table 7: Factory Configuration Menu Items
Display
Menu Item
Purpose
G3
Decimal Point
How many decimal points are
used to edit the “32”, “3” and “3”
Factory Configuration Menu items.
3
Zero-Scale
Point
The expected value in lbs of the
force to be applied at zero scale.
3
Half-Scale
Point
The expected value in lbs of the
force to be applied at half scale.
3
Full-Scale
Point
The expected value in lbs of the
force to be applied at full scale.
,13
Input Range
For factory use only. Do not
change this setting.
When the menu item you wish to
change is displayed, press
[Clear].
The display now shows the present setting of that menu
item. If you only wish to examine the present setting of
the menu item, you can use the [On/Off] button to turn the
instrument off. Otherwise...
page 28
Calibration
Use the [Hi/Lo] and [Clear]
buttons to scroll up and down,
respectively.
If you wish to abandon the changes you made to this setting, you can use the [On/Off] button to turn the instrument
off. Otherwise...
Once the setting you want is displayed, press the [Zero] button to
store this setting into memory.
The next menu item will be displayed after the instrument
stores the setting into memory.
After you have finished using the Factory Configuration
Menu, the mode jumper must be moved from its "configure" position to its "park" position as indicated in Figure
4-1. Close the unit up and replace the center screw.
4.3.2 Apply Forces
Make certain the instrument
is turned off.
Open up the instrument by removing the center screw on
the back. Next, remove the front face panel. Take care
not to break the wires extending from the sensor to the
electronics. As indicated on Figure 4-1, move the mode
jumper from the "park" position to the "calibration" position.
Hold the [On/Off] button,
then press the [Clear] button. The display will momentarily read “R 3”.
The display will begin to alternately flash between the
force required for calibration point #0 (for example "
"
Model WP9000 WeldProbe Force Gage
page 29
and "
"). If you wish to abandon the calibration procedure, press the [On/Off] button to turn the unit off. Otherwise...
Apply the indicated force to
the instrument. Press [Clear]
until “3” is displayed, indicating that the reading is
being stored.
Next, the display will begin to alternately flash between
the force required for calibration point #1 (for example,
" ") and "
".
Apply the indicated force to
the instrument. Press [Clear]
until “3” is displayed, indicating that the reading is
being stored.
Finally, the display will begin to alternately flash between
the force required for calibration point #2 (for example,
"
" and " ").
Apply the indicated force to
the instrument. Press [Clear]
until “3” is displayed, indicating that the reading is
being stored.
When the last force point has been entered, the instrument will turn itself off. At this time, the mode jumper
must be moved from its "calibration" position to its "park"
position as indicated in Figure 4-1. Close the unit up and
replace the center screw.
Check that the instrument has been calibrated properly by
turning it back on and using the force standard.
page 30
Calibration
4.4 Rear View of Front Face Panel
O ption s C ircu it B o ard
(A rra ng em en t va rie s a ccordin g to m od el)
P ro pe r o rie nta tion o f
sen so r cable
or
RED
BL A C K
W H IT E
GR E E N
BR O W N
RED
OR A NG E
YE LL O W
M od e jum p er p ositio ns
"PA R K"
"CA LIB RATION "
"CON FIGU RE "
Jum pe r sho uld be
lo cate d h ere d uring
no rm al op era tio n.
P lace jum p er in this
po sitio n to reca lib rate
in strum e nt.
T his ju m per p ositio n
is n orm a lly n ot
use d b y the custom e r.
Figure 4-1: Front face panel (rear view), showing mode jumper
positions and orientation of sensor cable
Model WP9000 WeldProbe Force Gage
page 31
4.5 Calibration Error Messages
If unexpected forces are encountered during the calibration procedure, the WP9000 instrument will alert the user
by flashing the word "+( /3" and a message number on the
display. This indicates that the calibration process cannot
continue, and that you must turn the instrument off and recalibrate again when the error has been corrected. A list
of error message numbers and their causes is given in
“TROUBLESHOOTING” on page 33.
page 32
Calibration
Chapter 5
TROUBLESHOOTING
5.1 Introduction
This chapter provides information on correcting common
problems that may be encountered operating and calibrating the instrument.
5.2 Help Message Codes
If the instrument detects a problem during its power-on
self-test, operation, or calibration, it will alert the user by
flashing the word “+( /3 ” and an error message code number on the display. The instrument cannot continue operation and you must turn the instrument off and correct the
error.
•
“+(
+(//3 ”: Calibration error.
Analog to digital converter overrange.
One of the force points is above the calibration range
of the instrument. Or, the sensor cable is not connected properly.
•
“+(
+(//3 ”: Calibration error.
Analog to digital converter underrange.
One of the force points is below the calibration range
of the instrument. Or, the sensor cable is not connected properly.
•
“+(
+(//3 ”: Calibration error.
The applied forces at any two calibration points did not
differ enough.
•
“+(
+(//3 ”: Self-test error.
The engineering unit conversion that you selected
cannot be rendered on a 4½-digit display. For example, consider the case of an instrument with a range of
Model WP9000 WeldProbe Force Gage
page 33
2000 lbs. If you were to select grams (“J ”) in the Engineering Units (“81,W ”) menu item the instrument would
signal this error. This is because 2000 lbs equals
907184 grams which cannot be shown on a 4½-digit
display.
•
“+(
+(//3 ”: Non-volatile memory write error.
“+(
+(//3 ”: Non-volatile memory read error.
“+(
+(//3 ”: Non-volatile memory verify error.
“+(
+(//3 ”: Non-volatile memory version mismatch.
“+(
+(//3 ”: Analog-to-digital converter not ready.
Turn the instrument off and on again. If these problems persist, contact Sensotec.
5.3 Troubleshooting Hints
•
Verify that the power source is operating correctly.
Make sure the batteries are fresh or that the external
supply is wired correctly.
•
Verify that you have set the instrument to read in the
desired units-of-measure.
•
Verify that the sensor cable is connected correctly.
The figure on page 31 shows the correct orientation of
the sensor cable.
•
If you have changed the display update rate from the
factory default of 24 per second, it may now be set too
low for your application and this may be interpreted as
the peak readings being too low. Try increasing the
display update rate.
•
The sensor and the electronics are a matched set. Do
not, under any circumstances, exchange sensor and
electronics on two different instruments.
•
The [Zero] button must be held down for 5 seconds
before the display will be zeroed. This is in order to
prevent unintentional zeroing of the display.
page 34
Troubleshooting
•
As shipped from the factory, the instrument will shut
itself off after four minutes unless any button is
pressed. You can adjust this Auto-off feature if you
wish.
•
Inspect the instrument for physical damage. If the
instrument is physically damaged, consult the factory
for repair. Do not attempt repairs as this may void the
warranty.
•
When all else fails, disconnect the batteries for 5 seconds, then reinstall.
Model WP9000 WeldProbe Force Gage
page 35
page 36
Troubleshooting
WARRANTY
Limitation of Remedy and Disclaimer of Warranty
Any of our products which, under normal operating conditions, proves defective in
material in workmanship within one year from the date of shipment by Sensotec, Inc.,
will be repaired or replaced free of charge, provided that the buyer (1) promptly notifies
Sensotec, Inc. of any such defect; (2) provides Sensotec, Inc. with satisfactory proof of
the defect and that the product was properly installed, maintained, and operated within
the limits of rated and normal usage; and (3) obtains from Sensotec, Inc. authorization
to return the product. Any such product shall be returned with transportation charges
prepaid. The replacement product will be shipped F.O.B. our plant.
The remedy set forth herein does not extend to any product or part thereof which,
under normal usage, has an inherently shorter useful life than one year. The remedy
set forth herein does not apply to damage or to defects in any product caused by the
buyer’s misuse or neglect, nor does it apply to any product which has been repaired or
disassembled which, in the sole judgement of Sensotec, Inc. affects the performance
of the product.
The remedy set forth herein is the buyer's exclusive remedy, and will satisfy all obligations of Sensotec, Inc. whether based on contract, negligence, or otherwise. Sensotec,
Inc. is not responsible for any incidental or consequential loss or damage which might
result from a failure of any Sensotec, Inc. product.
THIS EXPRESS WARRANTY IS MADE IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
Obtaining Service Under Warranty
Advanced authorization is required prior to the return to Sensotec, Inc. Before returning the items, either write to the Repair Department c/o Sensotec, Inc., 2080 Arlingate
Lane, Columbus, Ohio 43228, or call (800) 848-6564 with: 1) a part number; 2) a serial
number of the defective product; 3) a technical description* of the defect; 4) a nocharge purchase order number (so products can be returned to you correctly); and 5)
ship and bill addresses. Shipment to Sensotec, Inc. shall be at Buyer's expense and
repaired or replacement items will be shipped F.O.B. our plant in Columbus, Ohio.
Non-verified problems or defects may be subject to an evaluation charge. Please
return the original calibration data with the unit.
Obtaining Non-warranty Service
Advance authorization is required prior to the return to Sensotec, Inc. Before returning
the item, either write to the Repair Department c/o Sensotec, Inc., 2080 Arlingate Lane,
Columbus, Ohio 43228, or call (800) 848-6564 with: 1) a part number; 2) a serial number of the defective product; 3) a technical description* of the malfunction; 4) a purchase order number to cover Sensotec, Inc.'s repair cost; and 5) ship and bill
addresses. After the product is evaluated by Sensotec, Inc., we will contact you to provide the estimated repair costs before proceeding. The minimum evaluation charge is
$95. Shipment to Sensotec, Inc. shall be at Buyer's expense and repaired items will be
shipped to you F.O.B., our plant in Columbus, Ohio. Please return the original calibration data with the unit.
Repair Warranty
All repairs of Sensotec, Inc. products are warranted for a period of 90 days from date of
shipment. This warranty applies only to those items which were found defective and
repaired. It does not apply to products in which no defect was found and returned as is
or merely re-calibrated. Out of warranty products may not be capable of being returned
to the exact original specifications or dimensions.
*Technical description of the defect: In order to properly repair a product, it is necessary for Sensotec, Inc. to receive information specifying the reason the product is being
returned. Specific test data, written observations on the failure and specific corrective
action you require is needed.
(800)848-6564
2080 Arlingate Lane
Columbus, Ohio 43228
Tel: (614)850-5000
Fax: (614)850-1111
E-mail: [email protected]
http://www.sensotec.com