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Not only can the probe qual ball have the wrong diameter, but the probe tip diameter itself may have the wrong diameter. For the probe tip diameter, go to the probe qual window, click on a probe angle in the file, then click on the 'edit' button. Confirm that the probe ball diameter is correct. I've had people change that (unknown to the rest of us) diameter and it can screw things up for quite a while. There is also an error that will pop up if the probe ball DIA is too far from the value entered --- so if it is NOT too far from the value entered (but still not correct) PC-DMIS will not give you an error. If the DIA is not correct, you can change it there, but you should then check the DIA in all probe angles after that.
Recalibrating the tips will update this value based on the ref sphere size anyway.
Does sound like maybe they altered the ref sphere size (possibly to used their own calibrated/traceable one) during the machine calibration, and didn't change it back.
Thanks for the input. The reference sphere used in calibration was verified on our FARO arm and came very close(realizing there is some error in FARO arm readings) to what it says on the side of it.
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