Triton electronics Amv3500 User manual

AMV3500 Operating Manual

 
© Triton Electronics Ltd 2022 Doc. AMV35003_1.doc v1.04 PAGE 2 OF 52 
Contents 
Starting and connecting the AMV3500...........................................................................................4 
1 Connecting the sensors...........................................................................................................4 
1.1 Current sensor.................................................................................................................4 
1.2 Voltage connections........................................................................................................5 
1.3 Wire Feed Sensor............................................................................................................5 
1.4 Temperature Sensor .......................................................................................................5 
1.5 Gas Flow Sensor..............................................................................................................6 
1.6 Travel Speed Sensor........................................................................................................6 
1.7 Voltage breakout box (P316) ..........................................................................................6 
1.8 4-20mA Breakout box (P362)..........................................................................................6 
2 Charging the AMV3500...........................................................................................................7 
3 Starting the AMV3500.............................................................................................................7 
Main Operating Screens and Menus...............................................................................................7 
1 AMV3500 configuration menu................................................................................................7 
2 Set Alarms ...............................................................................................................................8 
3 Calibrate..................................................................................................................................8 
4 Configure.................................................................................................................................9 
4.1 Main ................................................................................................................................9 
4.2 Heat Input .....................................................................................................................10 
4.3 Trigger ...........................................................................................................................11 
4.4 Maintenance .................................................................................................................12 
5 Additional..............................................................................................................................12 
6 Resume..................................................................................................................................13 
7 New Procedure .....................................................................................................................13 
8 About.....................................................................................................................................14 
9 Stud Welding.........................................................................................................................15 
10 Load Configuration................................................................................................................15 
11 Save Configuration................................................................................................................15 
12 Data export ...........................................................................................................................16 
13 Monitor Screen .....................................................................................................................17 
13.1 Oscilloscope Mode........................................................................................................18 
13.2 Printer options ..............................................................................................................19 
14 Pass Complete.......................................................................................................................21 
14.1 Arc values......................................................................................................................21 
14.2 Enter Pass Length..........................................................................................................22 

 
© Triton Electronics Ltd 2022 Doc. AMV35003_1.doc v1.04 PAGE 3 OF 52 
14.3 Pass summary values ....................................................................................................22 
14.4 Graph.............................................................................................................................23 
14.5 Procedure......................................................................................................................23 
14.6 Summary PDF................................................................................................................23 
15 Procedure Complete .............................................................................................................25 
16 Printer Controls.....................................................................................................................26 
16.1 Configure Screen...........................................................................................................26 
16.2 Monitor screen..............................................................................................................27 
16.3 To print an average at a specific second interval..........................................................28 
16.4 Saving the values...........................................................................................................29 
16.5 Suggested setting..........................................................................................................29 
17 AMV Final File Uploader .......................................................................................................30 
How to guides ...............................................................................................................................32 
1 Monitor a GTAW, GMAW or MMAW procedure..................................................................32 
2 Setup to monitor an AC SAW procedure ..............................................................................40 
3 Use F1 and F2 Function buttons. ..........................................................................................48 
3.1 Start a new procedure: .................................................................................................48 
3.2 Record Welding –F1 .....................................................................................................49 
3.3 Record Welding F2........................................................................................................50 
3.4 Summary .......................................................................................................................52 
 
 
 

1. Starting and connecting the AMV3500

1.1 Connecting the sensors

1.1.1 Current sensor

There are two current sensing devices for the AMV3500. A clamp system is mostly used as it is a

convenient and simple way to attach to the welding cable. Secondly an inline sensor, this offers

greater accuracy and repeatability but is less flexible.

1.1.1.1 Clamp Sensor

The current sensor (P332) is clamped around either the torch

or earth return. Practically both sides should measure the

same values.

The clamp will determine a positive and negative flow of

current. The AMV3500 will show only the magnitude of

current on the digital display the direction is shown in the

OSCILLOSCOPE mode.

The clamp meters are iron based and will take an offset as

they become magnetised. Check that the current channel

reads zero, or close to, before monitoring a weld.

Check the clamp has not been mechanically damaged, the

clamp arms should be fully closed and aligned with each

other.

1.1.1.2 Inline sensor

The inline current sensor (P360) fits inline

with the welding cables, either torch or

earth return. The inline sensor uses Dinse

connectors.

1.1.2 Voltage connections

It is important to remember that unless measuring the voltage at the welding head or torch, all

measured voltage will include the voltage drop across the cables. So, if a procedure is qualified using

3m cables but in production uses 6m cables the voltage measured at the power source will be

different.

AMV3500 will display the voltage magnitude when displaying digital values, it is only in

OSCILLOSCOPE mode that polarity of voltage is shown. For all calculations the magnitude is used.

1.1.2.1 Voltage clips

These are the simplest way to connect to any power source. Generally, one side on the earth clamp

and, if MIG/ MAG welding the other on the wire feed unit.

1.1.2.2 Dinse connectors

Dinse connectors provide a convenient way to measure

welding voltage. These are particularly applicable to TIG and

MMAW welding.

1.1.3 Wire Feed Sensor

Clip the wire feed sensor around the welding wire and

connect to the AMV3500.

1.1.4 Temperature Sensor

1.1.5 Gas Flow Sensor

The gas flow sensor is plumbed into the gas flow line. The

direction of flow is marked on the sensor.

1.1.6 Travel Speed Sensor

The travel sensor is a surface contact sensor for monitoring table or

welding torch speeds. The mounting of the sensor is dependent on the

application, it can be by surface wheel or through the gear train. Output

pulses are calibrated by the AMV to give results in speed (units can be

specified at calibration) or RPM as the application dictates.

1.1.7 Voltage breakout box (P316)

The voltage breakout board provides an easy way to integrate additional sensors to the AMV weld

monitors. The P316 is intended for a device that outputs voltage that can feed into the +/- 3V input

stage on the AMV.

In addition, it can also power device from the internal 12V AMV power bus. Max drain 20mA.

Connections are made by screw terminal.

1.1.8 4-20mA Breakout box (P362)

The voltage breakout board provides an easy way to integrate additional sensors to the AMV weld

monitors. The P362 is intended for a device that outputs a 4-20mA signal that can feed into the +/-

3V input stage on the AMV.

In addition, it can also power device from the internal 12V AMV power bus. Max drain 20mA.

Connections are made by screw terminal.

1.2 Charging the AMV3500

The AMV3500 is charged using the 18V 3.3A DC Jack at the back of the unit. The bayonet is centre

positive. The charger will time out after approximately 4 hours, to ensure the battery is fully charged

from empty two 4 hours cycles are required.

A full charge should run the AMV3500 for 3-4 hours depending on the printer setting. When the low

battery alarm goes off there is about 15 minutes of charge left.

With regular charging cycles the battery will last for a few years.

1.3 Starting the AMV3500

To start the AMV press the ON/OFF button at the back of the unit. It takes 2 minutes to boot to the

AMV3500 Configuration menu

2Main Operating Screens and Menus

2.1 AMV3500 configuration menu

This is the main screen to setup and record a new procedure. The main sections are:

1. Procedure information –this section displays the current procedure name and details. To

change the entries, press NEW PROCEDURE or EDIT

2. Channels to monitor, select the channels Voltage and Current these must be selected.

Temperature can be set to IP (InterPass). In this mode the temperature is taken at the start

of the weld.

3. Select the welding process. This has most effect when calculating heat input using process

efficiency –see CONFIGURE.

4. These are the main control features and are discussed in more detail later.

5. Options for saving configuration files and exporting the recorded data.

The next sections go through the individual screens and options, there are also examples for how to

run through a setup in the How to Guides.

2.2 Set Alarms

The alarms show on the main screen. There are two levels an amber warning level and a red out of

tolerance level. To turn on the channel’s alarm press the channel button and the state changes to

ENABLED:

To set the values, enter the target values in the central column. Click in the box and a numeric entry

pad will be displayed. Once the values have been entered press the Set AMBER and Set RED buttons

to automatically set the limits. By default these are 10% and 12.5% respectively, but this can be

changed, by clicking inside the red and amber value boxes. Individual boxes can also be changed as

required.

The alarms are saved with the configuration file.

2.3 Calibrate

To access the calibration menu please contact Triton Electronics Ltd.

2.4 Configure

There are 4 main tabs of configurations

•Main –these are most of the user configurations

•Heat Input –special options for heat input calculation

•Trigger –where to set the arc on / arc off condition

•Maintenance –mainly for Triton engineers to help diagnose any system issues

Company name can be set (needs a USB keyboard to be used) –this is printed at the top of all

reports.

CLOSE returns the programme to the main AMV3500 Configuration Screen and saves the values.

2.4.1 Main

2.4.1.1 Store Transient Data

This will store the welding waveform data. The data can be analysed using our AMV_Desktop

software. This is available to all purchasers of the AMV3500.

Generally, this is not set as transient data files can be large.

2.4.1.2 WFS pulse

Sets the wire feed speed sensor to a frequency type. The option to use a voltage input sensor is for

legacy compatibility –all new sensors are frequency base.

2.4.1.3 RMS Values

If RMS values are preferred this should be turned on. By default if the process is set to AC the RMS

option is activated, otherwise it is off.

2.4.1.4 PICO temp

For compatibility with a TC-08 Pico Data logger, please ask if you are interested in using this option.

2.4.1.5 AutoPassUp

This is for surfacing type applications. In normal operation the pass complete button is blocked

when an arc is recording. This stops an operator accidentally completing a recording before the weld

has completed. However, for a surfacing application the welding arc is maintained during the

completion of the pass. Activating this function allows a pass up to be completed while the AMV

continues to “see” a welding arc. It can result in a few seconds of data loss (approx. 5 seconds) as

the files are saved and the next pass started.

2.4.1.6 Multi-power source

Voltage and current are set as data channels 1 and 2, but the remaining channels can be configured

as needed. In this case up to 4 current channels can be summed for heat input. For instance, a SAW

system with 4 wires feeding the same weld pool, the assumption is that the voltage is common. Of

course, this is rarely the case, but it can be used as an approximate control.

2.4.1.7 Arc Cancel Option

If this is selected the user has an option to cancel the last recorded arc.

2.4.2 Heat Input

2.4.2.1 Heat Input Calculation

Changes calculation from instantaneous to average.

2.4.2.2 Use BS EN Process Efficiency

Adds the process efficiency to the overall heat input calculation

2.4.2.3 Arc Heat Input

If turned on a weld length is entered at the end of an arc so heat input can be calculated, this is

aimed at automated applications.

2.4.2.4 Use Segment Control

If you are using the strip welding technique you can use segment control to calculate heat input as

the pipe is welded. At the completion of an arc you can complete a section, enter a weld length so

the heat input is calculated. Once the last segment is welded all segments are included in the pass

data.

2.4.2.5 Resistance

Practically it is not possible to monitor the welding voltage across the welding arc. This allows for an

adjustment to be made if the resistance of the power cables is known.

2.4.3 Trigger

2.4.3.1 Trigger values

Once the voltage and current values are ‘seen’ by the AMV it considers a welding arc is on. If either

drops below the value the arc is considered off. One or both can be set to zero (if both are set to

zero the AMV will always see a welding arc –this condition is to be avoided)

Slope up and Slope down times can be set –these are removed from the arc time and heat input

calculations. If the welding arc is shorter than both the slope up plus slope down value an error is

detected, and the arc discarded.

Min arc time is the shortest arc time needed for an arc to be considered “real”. Particularly for

manual metal arc welding if the electrode is struck to just prove there is contact or “warm” the

electrode this is ignored if below the min arc time.

2.4.4 Maintenance

These settings are just for basic setup or fault finding only and should not be altered.

2.5 Additional

This screen can be used to store additional procedure information. Please speak to Triton Electronics

Ltd.

2.6 Resume

The resume screen shows the available data files that can be resumed. Press the file name and the

data should be loaded into the display boxes along with the next pass number.

Press LOAD to return to the configuration screen. This returns to the Configuration Screen.

2.7 New Procedure

To clear the current flashing text box press the CLEAR button. Then start to type in the new

information.

The other buttons on the screen are:

NEXT –use this button to move to the next text box.

DELETE –deletes the last entry in the current box being edited.

UPDATE –When the new data has been entered press the UPDATE button to return to the

configuration screen. This will return to the Configuration Screen.

2.8 About

The about screen shows the current software version. When connected to a network the IP address

is also displayed.

2.9 Stud Welding

2.10 Load Configuration

To use this screen, select the configuration name and press LOAD. Configurations include alarms

settings, welding process and logging channels.

Return the configuration details to the Configuration Screen.

2.11 Save Configuration

To store the current configuration use the Save Configuration screen. Use the screen keypad to

enter a file name and description.

Press UPDATE to save the configuration and return to Configuration Screen

2.12 Data export

1. Select the procedure to be either copied or moved to a USB.

2. Make sure the USB has been detected and that the correct drive letter is selected.

3. Decide if TEXT or ALL data is required

4. Select to wither MOVE files or SAVE files. SAVE files copies the files to the USB stick,

MOVE removes them from the AMV and onto the USB stick.

5. To DELETE a folder ALL files must first have been moved to the USB stick.

6. Press CLOSE to complete and return to the Configuration Screen.

2.13 Monitor Screen

The main monitoring screen shows the values recorded during welding. If a pulse process has been

chosen the pulse values are displayed along the bottom of the screen.

The options are:

•CONFIGURE –takes the software back to the Configuration Screen.

•PASS COMPLETE –finishes this pass (collection of arcs) and moves to the PASS COMPLETE

screen

•OSCILLOSCOPE –changes the display to a graph of the welding waveforms.

•PRINTER –sets the printer options.

•QUIT –close the software and the AMV3500

2.13.1 Oscilloscope Mode

This changes the main display so that the welding waveform can be analysed. Use the button at the

top right-hand side of the screen to view current and voltage values:

If the transient file option has been set in the CONFIGURE screen the transient file will be recorded

for future examination. However, please note these files will become large very quickly.

2.13.2 Printer options

The AMV prints out the recorded data as the weld progresses. It simultaneously saves a text file

containing the same information.

The options are:

OFF turns the printer off completely

for this run only. Resets to ON after

pass complete. This also stops a text

file being saved.

ARC/PASS prints out the averages of

the pass and every arc.

If a time is selected the AMV prints

out averages at these second

intervals and the average arc and

pass values

PRINTER OFF turns the printer off

but allows a printer text file to be

generated as if the printer was on.

This option is remembered and once

set it is the default value.

Print Arc. If this option is selected

the AMV prints Arc averages, if

unticked they are stored in the text

file, similarly second averages are

saved but not physically printed

(need to select the period).

For example, this setting:

Means a text file will be generated, producing averages every second of the weld and at the end of

an arc and pass. However, physically all that will be printed is the pass summary.

This is a good starting point as the paper generated acts as a good physical summary of the welding

and the text file contains more detail, that if printed would use much of the paper roll.

For more information see the section on PRINTER CONTROLS

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