Alxii Manual v1 - 4 Data Logger

ALX II Portable Operators Manual
TVC
The Validation Centre (TVC) Ltd
ALX II
PORTABLE
&
ALX II RS
OPERATION MANUAL
ALXII MANUAL Page 1 of 119

I N D E X
SECTION 1 ....................................................................................... / Introduction
1.1 ........................................................................................ / Revision

1.2........................................................................................ / Purpose
1.3 ....................................................................................... / Overview
1.4 ................................................................... / Warnings/Precautions
1.5...................................................................... / Primary Parameters
1.6................................................................../ Secondary Parameters
1.7 ............................................... / Averaged and Totalled Parameters
1.8............................................................./ Unit Layout and Functions
Fig 1/2/3 ............................................................. / Unit Layout Pictures
SECTION 2 ................................................ / Operating Instructions – Basic ALX II
2.1 ................................................................................... / Introduction

2.2 ................................................. / Basic Logging Software Overview
2.3 ......................................... / Pipeline Procedure Software Overview
2.4 ....................................... / Standard Procedure Software Overview
2.5 ........................................ / Pulse Measurement Software Overview
2.6 ........................................................... / Robotic Software Overview
2.7 ........................................../ Equipment Pre-checks and installation
2.8 ...................................................................... / Connection Drawing
2.9 ................................................................................ / Switch On/Off
2.10 .............................................. / Basic Logging Software Operation
SECTION 3 ............................................................. / Pipeline Procedure Software
3.1 ........................................................................................... / Set Up

3.2 ................................................................................ / Data-Logging
3.3 ..................................................................................... / Weld Data
SECTION 4 ........................................................... / Standard Procedure Software
4.1 ........................................................................................... / Set Up

4.2 ................................................................................ / Data-Logging
4.3 ..................................................................................... / Weld Data
SECTION 5 ........................................................... / Pulse Measurement Software
5.1 ................................................................................... / Introduction

5.2 .......................................................... / Running the Pulse Software

5.3 ................................................................... / Pulse Scope Software
5.4 ...................................................................................... / Reporting
5.5 .................................................................... / Pulse Scope Controls
5.6 ............................................................................................ / Q & A
SECTION 6 ............................................................................... / Robotic Software
SECTION 7 ........................................................................... / Reporting Software
7.1 .................................................. / Tile Screen and Report Selection

7.2 ......................................................... / Selecting Weld Files to View
7.3 ............................................. / Viewed Files – Editing Welds in Grid
7.4 ............................................................................... / Deleting Rows
7.5 ................................................................................. / Editing a Cell
7.6 ......................................................... / Selecting an Excel Template
7.7 .......................................... / Exporting Weld Data to Excel Reports
7.8 ......................................................... /Creating a New Excel Report
7.9 ....................................................................../ Creating a Template
7.10 .......................................................................... / Example Set Up
SECTION 8 ........................................................................................... / Servicing
8.1 ................................................................... / Printer Paper Change

8.2 ....................................................................... / Ink Ribbon Change
8.3 ...................................................................................../ Printer Life
8.4 ....................................................................... / Current Probe Zero
8.5 ...................................................................... / Wire Feed Servicing
8.6 ................................................. / Battery Pack Installation/Removal
8.7 ............................................................................... / Battery Status
8.8 ........................................................................... / Battery Charging
8.9 ............................................................. / Battery – Additional Notes
SECTION 9 ..................................................................... / Fault Finding/Diagnosis
9.1 ......................................................................... / Fault Descriptions

9.2 ................................................................. / Recommended Spares
SECTION 10 ............................................................. / Additional User Information
10.1 ................................................................................... / Calibration

10.2.................................................................... / Equipment Disposal
SECTION 11………………………………………………………/ ALXII RS
11.1……………………………………………………/ General Description
ANNEXE
A1………………………................ALX II RS Software Setup For Win.XP
A2………………………................ALX II RS Software Setup For Win.7
1 Introduction
The ALX II should only be operated by trained personnel who have first read
this operation manual. Connection of the ALX II to a welding power source
should only be carried out by trained, experienced personnel observing the
required level of electrical safety.
The Validation Centre (TVC) Ltd accept no responsibility for the incorrect
usage or connection of the ALX II.
Revision No: Details: Author: Date:

1.1 Draft issue CJC/MP/JP Dec 2007
1.2 Add ALXII RS and Annexe KPH June 2013
1.3 Add NFM warning KPH October 2013

1.2 PURPOSE
This manual describes the user interface and operation of ALXII Welding Monitor
PLEASE NOTE: if you have an operational problem, PLEASE read the “fault diagnosis” at
the end of the manual. Hopefully this will save you time and avoid telephone calls.
Some statements in this manual are tagged “optional” and could be in current
development

1.3 Overview
The ALXII may best be described as a versatile, instrumentation package dedicated

to the monitoring of arc welding processes. An accurate and comprehensive display
of welding information makes the ALXII eminently suitable for use both in the field of
welding trials, and in the laboratory for pure research. The fact that it is both
portable and easy to operate allows efficient transfer of laboratory techniques into
practical shop floor procedures.
The use of the ALXII during the setting up of welding conditions helps eliminate time-
consuming trials and error and reduces costly rejects or repairs. In-process
monitoring allows rapid and reliable diagnosis of intermittent equipment malfunctions
and process deviations, which in turn may indicate equipment deterioration allowing
preventative maintenance to be quickly and efficiently applies to avoid expensive
„down-time‟ and lost production.
The ALXII can be used single handily by the welder, providing an independent,
permanent record for future analysis by others or by the welder himself. The
operator entered headings on the printout provide the central core of information to
allow the weld information collected by the ALXII to be included as part of a
comprehensive Quality Assurance Quality Control system.
The provision of on-board data storage as standard in the ALXII allows the user the
additional option of down-loading the collected weld data into a PC for further
processing or incorporation into a weld data-base/computerised archiving.
The instrument is intended for use with manual, semi-automatic and fully automatic
processes, namely:- Covered Electrode (MMA/SMAW), Metal Inert Gas
(MIG/MAG/CO2/GMAW), Submerged Arc (SAW), Tungsten Inert Gas (TIG) and
Plasma (PAW) including pulsed processes.
1.4 WARNINGS/PRECAUTIONS – The following must be read before

attempting to use the ALX.
1. The monitor must not be connected to or disconnected from a welding

set whilst welding is in progress.
2. Do not use ALXII or its gas transducer with fuel gases of any kind or
Oxygen. The gas options are for measuring inert shielding gases
only.
3. The unit must not be powered up or reset whilst weld monitoring is in

progress.
4. Do no allow the unit to become heavily contaminated with weld dust.
5. All fuses must be replaced with correct type and rating.
6. Do not use damaged probes (especially applicable to TIG Voltage

leads.)
7. Do not allow the metal case of the unit to come into contact with the
work piece or welding set during welding.
8. No user serviceable parts are in the main ALXII unit.

1.5 ALXII Primary Parameters
The main parameters of primary importance are displayed on the large LCD
style meters on the main page of the ALX II Logging software, these are:-
Welding Current (AMPS)
This is the main parameter controlling heat input and weld penetration in all
processes and is closely related to weld metal deposition rate for consumable
electrode systems.
The current is measured by using a „hall effect‟ current probe clamped

around the cable carrying the total weld current.
The display reads a true representation of the current drawn by the welding
station (either average AC to 1280 Amperes or DC up to 2000 Amperes).
Arc Voltage (VOLTS)
Arc voltage, the electrical representation of arc length, is particularly

important in controlling weld bead surface profile and has a significant effect
on heat input. It is measured by connecting the sensing leads across the arc
gap as close to the arc as possible. Capable of measuring either average AC
up to 64.1 volts or DC upto 99.9 volts.
Note: When measuring AC voltage and current the ALXII will display and
print the mean average value. To convert to RMS multiply by a factor
of 1.1.
Wire Feed Speed (WIRE) – (Optional).
Changes in wire feed speed during a weld process can critically affect weld
heat input. To measure this a tachogenerator is used whose voltage output
is directly proportional to rotation.
The tachogenerator is clipped on to the welding wire and the system is

capable of measuring speeds up to 30 metres per minute.
Arc Time (SECONDS)
Arc time is expressed in seconds and can be divided into the length of the
run to reproduce a travel speed (mm or inches per second). Travel speed
affects weld quality and production rates. Arc time is printed in the weld
summary. The range is 0.3 to 9999 secs  0.1%.
Real Time Heat Input (J/mm) – (Optional)
The heat input (J/mm) is derived by dividing the total arc energy consumed
by the length of the weld bead as measured by the traverse optical encoder
or inputted by the operator using the data entry switches.

1.6 ALXII Secondary Parameters
ALX II Secondary parameters – Temperature, Gas Flow and Traverse

Speed. These are selected by pressing “ALT DISPLAY” button.
Temperature
Measurements of pre-heat and interpass are important in welding processes

to ensure correct heat input has been achieved. Readings are taken
remotely, via a type „K‟ thermocouple. The thermocouple is capable of taking
readings between 0 - +1000C  1% of reading.
Shielding Gas Flow Rate
Shielding gas flow rate is measured to ensure the correct flow rate is
maintained. Low flow rate will cause contamination of the weld due to a high
level of oxygen and a high flow rate will cause turbulence around the weld
pool.
The NFM / NFM II / GTFM unit is designed to measure inert shielding gases
at the welding torch only. When using on welding processes that include wire
feed units (for example GMAW, SAW etc), the wire feed drive must be
switched off when measuring the nozzle gas flow.
When measuring the gas flow of welding processes that include HF (for
example GTAW) the HF function on the welding power source must be
switched off.
Severe damage will occur to the NFM / NFM II / GTFM if this instruction is not
followed.
Once gas flow measurement is complete the NFM / NFM II / GTFM is to be
switched off and disconnected from the ALXII"
Traverse Speed (Boom or Bogey)
Changes in traverse speed during a weld process can critically affect weld
heat input per unit length of weld.
To measure this an optical incremental encoder is fitted to either the boom or

bogey of the welding head. The output of the encoder is pulsed at the rate of
rotation. The system is capable of measuring 0 – 200cm/min 1% FSD.

1.7 ALXII Averaged and Totalled Parameters
The calculation of the averages and totals of the welding parameters are
logged and printed in the weld summary at the end of the weld, these
comprise of:-
Overall Averages
Welding Current, Arc Voltage, Wire Feed Speed and Traverse Speed.
During welding, these 4 parameters are averaged every 2 seconds. At the

end of the weld the summary printed will show maximum, minimum and
average readings of wire speed, voltage current and traverse speed.
Total Values of the Cumulative Parameters
The cumulative parameters are:-
Arc Energy
Arc energy is expressed in kilojoules (kJ). It is calculated from the average

values of the current, voltage and the arc time. The total for arc energy is
then printed in the weld summary. The range is 1 – 9999KJ  2% FSD.
Wire Payoff
Wire payoff, the total quantity of wire consumed in MIG/MAG or submerged

arc weld, is expressed in either metres or inches. The quantity of wire
consumed relates directly to the volume of weld metal deposited. The total is
printed in the weld summary. The range is 0 – 999m  2.5% FSD.
Arc Time
Arc time is expressed in seconds and can be divided into the length of the
run to reproduce a travel speed (mm or inches per second). Travel speed
affects weld quality and production rates. Arc time is printed in the weld
summary. The range is 0.3 to 9999 secs  0.1%.
Heat Input per Unit Length
The heat input (J/mm) is derived by dividing the total arc energy consumed
by the length of the weld bead as measured by the traverse optical encoder
or inputted by the operator using the data entry switches.
Gas Consumed
Gas consumed, the total quantity of gas consumed during the welding
process expressed in litres.

1.8 ALXII Unit Layout & Functions
This section should be read and used in conjunction with the pictures in the next
section (section 1.9)
Fig 1 – ALX II Front Panel:-
1 – Right Fan Grill

2 – Internal Hard Copy Printer Unit
3 – Power On/Off Switch
4 – Power Indicator
5 – Mouse Track Ball
6 – Left Fan Grill
7 – Interconnection Panel Cover
8 – Industrial IP Rated Keyboard
Fig 1a – ALX II Front Panel (with Interconnection Panel Cover Opened)
9 - Interconnection Panel Cover Opened
Fig 1b - II Front Panel (with Interconnection Panel Cover Opened) Close Up
10 – Master Reset Switch

11 – Main Unit Fuse
12 – Ethernet Connector
13 – USB Connector
14 – USB Connector
Fig 2 – ALX II Screen Panel
15 – Left Hand Push Button Controls

16 – Main TFT Screen
17 – Right Hand Push Button Controls
18 – TFT Interwiring Connections
Fig 3 – ALX II Transducer Connections
19 – Traverse Speed Tachometer Input

20 – Gas Flow Transducer Input
21 – Aux 1 – Auxillary Input for Special Options
22 – Aux 2 – Auxillary input for Special Options
23 – Temperature Probe Input
24 – Wire Feed Speed Tachometer Input
25 – Current Transducer Input
26 – Voltage Lead Input
Fig 3a – ALX II Transducer Cover

27 – Left Hand Transducer Connector Cover (Closed)

28 – Left Hand Cooling Fan Air Inlet Grill/Filter
29 – Main Transducer Input Connectors
30 – Right Hand Transducer Connector Cover (Opened)
Fig 4 – ALX II Unit Front View
31 – Battery Pack Compartment
Fig 5 – ALX II Unit Rear View
32 – Mains PSU Input
Fig 6 – ALX II Unit Left Hand View
33 – Transducer Input Connectors (Covers Closed)

34 – Left Hand Cooling Fan Air Inlet Grill/Filter
Fig 7 – ALX II Unit Right Hand View
35 – Right Hand Cooling Fan Air Inlet Grill/Filter
Fig 8 – ALX II Battery Pack
36 – Battery Pack Warning Sticker

37 - -Ve Connectors
38 - +Ve Connectors
Fig 8a
37 - -Ve Connectors
38 - +Ve Connectors
Fig 8b
39 – Battery Pack Retaining D‟Ring Turn Buckles
Fig 8c
40 – Battery Pack Charger Input

1.9 ALXII Unit Layout Pictures
Fig 1.
6 1
2
7
3
4
8
Fig 1a

Fig 1b
10
13
11
12 14
Fig 2
15 17
18
16

Fig 3
19 23
20 24
21 25
22 26
Fig 3a
29
27
28
30

Fig 4 Fig5
32
31
Fig 6 Fig 7
33
34 35
36
Fig 8
37 38

Fig 8a Fig 8b
37
38 39 39
Fig 8c
40

2 ALX II Operating Instructions
2.1 Introduction
The ALXII is a complete self-contained package running under a standard windows

XP operating system. The ALXII is capable of running several user selectable TVC
software packages which are selected from an initial user interface. (The
specifications are dependant on what has been ordered with the base ALX II unit.)
The package is housed in a strong robust case with a high quality and robust
integrated tracker ball (mouse) and keyboard.
Two rows of four Soft buttons to the left and right of the display may be used when a
corresponding text button is displayed next to them. The tracker ball can also be
separately used on the same buttons if easier.
Note: that when the ALXII unit is powered up, the ALX II Software is automatically
started displaying the initial user interface.
2.2 ALXII Basic Logging Software
2.2.1 Basic Logging Mode
When the ALXII is used in basic logging mode it behaves like a standard TVC
ALX. Pre-formatted headings can be programmed by the user and this data
together with the welding data which is time and date stamped is saved
directly to the unit‟s internal hard drive.
This data can be retrieved at any time and using the onboard reporting
software can be transferred into MS-Excel spreadsheets.
2.3 ALX II Pipeline Procedure Software

The Pipeline Procedure software has a number of useful functions designed
specifically for the development and recording of Pipe based welding
Procedures:
2.3.1 Project and procedure set up/editor:

A full welding procedure specific to pipeline welding can be created or edited
by using the unique TVC editing software suite.
2.3.2 Project and procedure selector

Any existing projects and procedures may be selected form a drop down menu
box and loaded into the ALXII logger ready for a live logging session
2.3.3 Weld data reporting

The ALXII reporting software can be used to create MS-Excel weld data
reports. The user can select either the standard MS-Excel templates supplied
with the ALX II or custom MS-Excel templates can be designed and used by
the user.

2.4 ALX II Standard Procedure Software

As with the Pipeline Procedure software the ALX II Standard Procedure
software has a number of useful functions designed specifically for the
development and recording of non-pipe Welding Procedures:
2.4.1 Project and procedure set up/editor:

A full welding procedure specific to general welding/fabrication can be
created or edited by using the unique TVC editing software suite.
2.4.2 Project and procedure selector

Any existing projects and procedures may be selected form a drop down menu
box and loaded into the ALXII logger ready for a live logging session
2.4.3 Weld data reporting

The ALXII reporting software can be used to create MS-Excel weld data
reports. The user can select either the standard MS-Excel templates supplied
with the ALX II or custom MS-Excel templates can be designed and used by
the user.
2.5 ALX II Pulse Measurement Software
The ALX II Pulse Measurement software has been designed to measure,

record and calculate the welding parameters for all types of pulsed Arc
Welding processes. These are generally, but not limited to Pulsed GMAW and
Pulsed GTAW process. There is also a setting more specific to double pulsed
or reactive arc processes such as STT.
2.5.1 Pulse Measurement

The ALX II pulse measurement software has been designed so as it can be
used with any of the other software options. When used with the ALX II Basic
Logging Software the user selects either Normal or Pulsed mode, when used
with Pipeline/Standard Procedure software the operator pre-programmes the
process type (ie; Pulsed or Non-pulsed) within the procedure set up software.
The pulse parameters for the current and voltage channels are displayed in
real time on the ALX II during the weld and an average is calculated after the
weld has been completed.
2.5.2 Pulse Scope

During the weld the ALX II records data points at the pre-set sample frequency
on to the unit‟s internal hard drive. This data can then be recalled using the
Pulse Scope software to plot and analyse the welding waveforms.
2.6 ALX II Robotic Software
The ALX II Robotic monitoring software is currently under development and is

due for release in the 2nd quarter of 2008.

2.7 ALX II Operating Instructions – Equipment Pre-checks & Installation
2.7.1 Pre-checks:
Un-pack the ALX II unit and its transducers from its plastic transportation and
storage case. It is recommended that the ALX II unit is stored in the Black
Plastic, Roll Along Transportation Case when not in use and also when it is
returned for servicing/calibration.
First check that all of the required transducers and battery pack/PSU are with
the ALX II. It would also be wise to check the condition of the unit and
transducers at this time to ensure it has not been damaged by weld spatter or
grinding dust. Always ensure that the battery pack(s) are in good condition,
have been charged and have not suffered any physical damage.
Check that the printer unit has enough paper loaded for your logging
requirements and that you have spare paper rolls and ink ribbons.
2.7.2 Equipment Set Up

Careful attention is recommended when connecting the ALX II to the welding
power source/generator, particularly to the positioning of the ALX II unit and
the transducer cabling.
Always place the ALX II unit on a flat, preferably non-metallic/conductive

surface away from the welding bench/work-piece. Do not place the ALX II unit
on top of the Welding Power Source/Generator or Welding Bench.
Ensure that all transducer cables are un-coiled and laid out as straight as
possible between the ALX II the appropriate connection on the Welding
Equipment. Do not let the cables get tangled up with the welding cables and
always ensure that the transducer cables are not left in such a manner that
they could cause a trip hazard to the operator or welder.
Once a suitable position for the ALX II unit has been selected the transducers
should be connected to the ALX II and the welding equipment before switching
the ALX II unit on. The connections will be dependant on the welding process,
the following gives a brief synopsis of the transducer connections. A set of
diagrams showing the specific connections by process follows this section.
i) Current Probe
The current probe should be clamped around the earth return cable, as far
away as possible from the welding power source whilst observing the correct
current flow as indicated by the arrow on the current probe.
ii) Voltage Lead

The voltage lead with integral HF suppression is fitted with large, colour coded
and insulated crocodile clips. Although the ALX II has internal rectification it is
recommended that whenever possible the correct polarity of the voltage
connections should always be observed.
On negative earth processes the Black Negative clip should be connected to

the work-piece earth and the Red Positive clip should be connected as close
as possible to the electrode to avoid any voltage drop the welding cables. On
Positive earth processes these connections should be reversed.

On GMAW processes where it is not always possible to gain access directly to
the contact tip it is often easier to connect the Positive clip onto the Positive
welding connection inside the wire feed unit.
iii) Wire Feed Speed Tachometer (Optional)
The optional tachometer will measure the wire speed allowing the ALXII unit to
display and print the welding wire speed. It will also enable the ALXII unit to
calculate and print the wire consumed in the summary print.
Operation.
Prior to powering up the ALXII unit clip the wire feed tachometer on to the welding
wire in a suitable place where the wire will run freely through the tachometer rollers,
on most welding sets, this will be in the wire feed mechanism.
1) Press the sliding shroud down 2) Align the groove in the idler 3) Ensure that the wire runs freely
with your thumb and slide the wheel with the wire and release through the tacho in-line with the
tacho over the wire. the tacho sliding shroud. groove in the idler wheel.
Connect cable between wire feed tachometer and input socket. Normal operation of
ALXII unit can now take place.
Note: Ensure that the correct size grooved idler wheel is fitted to the Tachometer
prior to attachment to the wire feeder. There are 4 diameter ranges available
which are:-
Groove Depth (mm) Wire Diameter Range (mm)

0.5 0.6 to 1.6
1.0 1.0 to 2.8
1.6 1.6 to 4.5
2.1 2.0 to 6.0
For guidance on changing the idler wheels please refer to section 8.5 in this manual.
The optional encoder based wire speed tachometer is designed to be easily clipped
on to the welding between the wire drum and drive wheels/mechanism. It can be
used with all types of wire (solid/flux-cored) and is designed for use with wire
diameters ranging from 0.8mm to 4.0mm.

iv) Traverse Speed Tachometer (Optional)
The optional encoder based traverse speed tachometer is designed for use
with automatic welding processes. When used with Sub-arc processes it can
be attached to the welding head to record the weld head travel speed (note: a
suitable bracket may need to be fabricated to mount the tachometer).
When used with pipe welding the tachometer can be attached so as the wheel
runs either directly on the pipe or on the rotator itself.
The ALX II software can be set up to correct for any size difference between
the pipe/work-piece and the rotator/turntable.
v) Temperature (Optional)
The optional temperature transducer is a type K direct contact thermocouple. It
can be used to measure either pre-heat or interpass temperatures by placing
and holding the contact tip of the thermocouple directly on to the work-piece.
Please note temperature measurements should only be taken when welding is

not in progress. It is recommended that the thermocouple is removed from the
ALX II after each temperature measurement has taken place.
vi) Gas Flow (Optional)

The standard gas flow option is designed to be used before welding takes
place by using the NFM² to measure the gas flow at the torch shroud.
Alternative transducers are available to measure the gas flow whilst welding is
in progress, please contact TVC to find all of the available options.
vii) ALX II Mains Power Supply

Although the ALX II is battery powered a mains power supply can be used to
power the ALX II whilst welding. However it is recommended that the mains
power supply should always be connected to a mains supply which is on a
different phase or ring main to the one on which the welding set is powered.
It is also recommended that you do not use the ALX II mains power supply
when monitoring any welding processes with HF Arc starting.

2.8 ALX II Operating Instructions – Connection Drawing
2.8.1 ALXII to Welding Set Connections MIG and Positive Earth MMA/Tig

2.8.2 ALXII to Welding Set Connections Negative Earth MMA/Tig

2.9 ALX II Operating Instructions – Switch On/Switch Off
2.9.1 Ensure that the ALX II has been checked and set up as per section 2.6 and
2.7 in this manual.
2.9.2 Installation of the ALX II battery
The ALX II is a Portable Unit which can be powered either by the battery pack supplied with
the unit or via a mains powered DC Adaptor which is also supplied with the unit.
To install the battery pack first of all align the battery pack guide rails at the top of the battery
pack with the support guide rails on the base of the ALX II unit.
Once the battery pack is aligned with the guide rails slide the pack fully into the ALX II.
For the battery pack to locate correctly the „D‟ rings on the front of the battery pack should be
vertical. Once located the „D‟ rings should be turned through 90 degrees so as they lock the
battery pack in place.
To remove the battery pack the „D‟ rings should be turned through 90 degrees so as they are
in the vertical position. The battery pack can then be extracted from the ALX II unit using the
„D‟ rings.

2.9.3 ALX II Mains Powered DC Adaptor
The ALX II unit can also be powered directly using the supplied DC PSU. The input for the
DC Adaptor is located at the rear of the ALX II unit.
The DC PSU and Battery Pack have designed to be „Hot Swappable‟. This means that if the
battery is powering the ALX II unit the DC PSU can be plugged in to the unit and the ALX II
will immediately swap over to being powered by the DC PSU.
Warning:
It is recommended that the Battery Pack only is used when monitoring any HF welding
processes.
2.9.4 Switch On
Once the transducers and also suitable power (either Mains or Battery) have been connected
to the ALX II unit it can be powered up by switching the On/Off switch located in the centre of
the front panel to the On position – Note: If suitable power is connected to the ALX II unit the
Green LED located next On/OFF switch will illuminate immediately. If the LED does not
illuminate then either the battery pack is low or the mains PSU has not been connected, you
should switch the unit Off immediately and re-check all connections.
2.9.5 Power Status and Automatic Shut Off:
Once powered up the ALX II displays the supply voltage on the logging screen, in Normal
Mode this is between 16 and 12 volts on Battery and 18.3volts when connected to the mains
PSU. In Pulse Mode this will change to OK if the battery level is sufficient to power the unit or
if the mains PSU is connected.
When the battery level drops to a low level a warning message will appear on the screen
when 15 minutes running time is left. If this is ignored the ALX II unit will automatically save
any information and shut down fully.
The 15 minute battery warning and automatic cut off will operate continuously whilst the ALX
II Unit is powered by its battery pack irrespective of whether the ALX II Weld Monitoring
Software is running or not.

2.9.6 Switch Off – Powering Down
When switching off the ALX II Unit it is recommended that you only use the On/Off Switch
located in the Centre of the ALX II front panel. The standard system software has been set
up to automatically save, error check and power down the ALX II unit in a pre-set order.
It is recommended that you do not use the normal windows „Shut Down‟ facility within the
windows operating system to shut down the ALX II.

2.10 ALX II Operating Instructions – Basic Logging Software
2.10.1 Overview
The ALXII is controlled either by mouse or by soft buttons. The “Menu Button” is two deep .
This means when pressed once the Button captions change to another set. When pressed
again the caption reverts back . The display itself has two “modes” not to be confused with
PIPLELINE and STANDARD Procedure modes. The display modes are
 Normal displaying four digital LCD style meters for the weld parameters
 Pulse displaying a number of LCD style meters for the Current and Voltage Pulse
parameters
2.10.2 Power Up
Once switched on (see section 2.8.4) the ALX II unit will power up, as with any PC based
equipment this will take approximately 1 minute to fully boot up directly into the ALX II
Software. Once the ALX II software has initialised the main navigation screen should appear.
To start weld monitoring immediately with the ALX II using the Basic Logging Software unit
press the „LOG‟ button either with the mouse or by pressing the round button directly next to
screen.
When the ALXII basic logging software is started the following screen is displayed.
Headings &
Printer
Setup
menu. Slope In/Slope
Out settings. Menu buttons, 2 sets of 4 buttons on
each side of the screen.
Main parameter
Menu LCD style
buttons, 2 displays.
sets of 4 (note Heat IP is
buttons Optional)
on each
side of
the
screen.
Weld Length Input Box Battery Status

2.10.3 Setting the Logging Data
You can set the Print Out and logging information by either using the mouse to select the
„Headings Menu‟ at the top left hand side of the screen or by pressing the „Menu‟ button
which will call up the alternate set of operational on-screen buttons and then press the
„Headers‟ Button.
ALX II alternate screen (use the „Menu‟ button to toggle between screens)
Using the „Headings‟ data input screens you can set the following information:-
Note:Click on the tabs at the top of the window to navigate between each of the screens.
2.10.3.1 Print Rate:
The ALX II has two pre-programmable Print Rates, these rates determine how often the
ALXII prints/logs the welding data. The settings for each of the Print Rates can be selected
by the user in seconds starting at 0.2 seconds. To set or adjust the rates simply click on the
input box next to either Rate 1 or Rate 2 and type in the required time period.
Using the 2 tick boxes next to the Print Rate you can select whether the ALXII prints or logs
the welding data. Once you have made your selections click on the „Apply‟ button at the
bottom right hand side of the window for your settings to take effect.
Selection of the Print Rate 1 and Print Rate 2 is made by pressing the Yellow Print Rate
button on the bottom right hand side of the ALX II logging menu screen 1.

2.10.3.2 Gas Type:
When monitoring welding processes that use shielding gases you may have a requirement to
document the type of gas that has been used. A selection of gas mixes/types has been pre-
programmed on the ALX II, you can select these by clicking on the drop down box labelled
Gas Type. Click on the required gas type which will then appear in the Gas Type box.
Using the 2 tick boxes underneath the Gas Type you can select whether the selection is
printed or logged. Once you have made your selections click on the „Apply‟ button at the
You can input custom gas types/names by typing the required gas type/name directly into the
„Add Gas‟ text box. When you press the „Add To List‟ button the new gas type/name will then
appear in the Gas Type drop down box. Any gas types/names that you wish to remove from
the list simply select the gas type as above and once highlighted press the „Delete From List‟
button
2.10.3.3 High/Low Limits:
You can set upper and lower alarm limits on each of the welding parameters by typing an
upper (Hi) limit value in the left hand Hi text box and a lower (Lo) limit value in the right hand
Lo text box. Once values have been set you will need to click on the On tick box for the
required parameter to start limit checking. In standard form the ALX II will only place an
asterisk on the printout directly next to any parameter value that exceeds the Hi/Lo limit.
Additional external alarms are available for the ALX II, please contact TVC for further
information.
If you want the Hi/Lo limit values to be printed on the header then you must click on the
„Display Limits On Header‟ tick box.

If you wish to save the Hi/Lo limit values so as they can be re-called in the future you must
first give your settings a filename by typing directly into the „Filename‟ text box at the top of
the screen and then clicking on the „Save‟ button on the right hand side of the window. Once
saved you can view your saved selections by either using the Next/Previous scroll buttons at
the top right hand side of the window or by clicking on the „Browse Files‟ button and selecting
the required file. Once you have made your selections click on the „Apply‟ button at the
2.10.3.4 Headings:
Within the ALX II Basic Logging Software you can input weld data heading information, this
information is printed/logged at the start of each weld. There are 7 programmable data fields
comprising of Project, Job No., Proc No., Welder, Welder No., Weld No. and Rod/Wire. You
can type text directly into the text boxes for each field. Any field that is left blank will not be
printed/logged.
If you wish to save the heading so as it can be re-called in the future you must first give your
settings a filename by typing directly into the „Filename‟ text box at the top of the screen and
then clicking on the „Save‟ button on the right hand side of the window. Once saved you can
view your saved selections by either using the Next/Previous scroll buttons at the top right
hand side of the window or by clicking on the „Browse Files‟ button and selecting the required
file. Once you have made your selections click on the „Apply‟ button at the bottom right hand
side of the window for your settings to take effect.
2.10.3.5 Run Number:
The Run Number settings are for use specifically with the „Auto Run‟ function button which is
located on the ALX II logging menu screen 1. When the Auto Run function has been selected
by the user the ALX II will assign a run number starting at 1 to each data set, when a new
data set is printed/logged the Auto Run function automatically increments the run number by
1. Sometimes during the welding process you may need to re-start the run due to arc striking
problems etc. In order for the ALX II to re-start at the correct Run Number you will need to set

the required Run Number to start from by typing the number into the left hand (New) Reset
Run Number Value text box.
Occasionally you may have requirements for the run numbers to increment in steps larger
than 1 (ie: Your ALX II unit may only be logging every other run and therefore will need to
increment in steps of 2) should this occur then you can set the incremental value by selecting
the required number from the drop down box labelled „Set Run Number Increment‟ .
Once you have made your selections you must press the „Apply‟ button at the bottom right
hand side of the window for your settings to take effect.
2.10.3.6 Options:
The last tab labelled „Options‟ allows the user to set up the ALX II internal hard copy printer
and the required logging channels.
By ticking the top tick box labelled Enable Printer the ALX II internal printer unit will be
enabled and the logged welding data will printed during the welding process. If the printer is
disabled by de-ticking the tick box then all of the welding data will be logged directly to the
ALX II unit‟s hard drive only.
If you have purchased either the Wire Feed Speed and/or Traverse Speed options you can
turn the logging facility for either of these options on or off by ticking/de-ticking the tick boxes
as required.
The last user selectable option is the Real Time Heat Input Calculation, you may only enable
this option when the Traverse Speed channel has first been enabled. When enabled an
additional LCD style display will appear on the ALX II logging screen which will use the
welding current, arc voltage and travel speed to calculate the heat input whilst welding is
taking place.
Once you have made your selections you must press the „Apply‟ button at the bottom right
hand side of the window for your settings to take effect.
To exit the Headings and Options set up pages click on the „Exit‟ button at the bottom right
hand side of the window.

2.10.4 Printing Options:
The ALX II unit has an onboard miniature impact printer and also an on-screen VDU printer.
You can select either or both of these print options whilst welding.
To select the on screen VDU printer simply press the VDU Printer button on the main ALX II
logging screen, when selected a scrolling window will appear between the 2 standard ALX II
windows.
To select or de-select the onboard hard copy printer either use the mouse to select the
„Printer‟ menu at the top left of the ALX II main logging screen and tick/un-tick „Enable‟ or use
the „Headers‟ button go to the „Options‟ tab and tick/un-tick the „Enable Printer‟ option.
All welding data is saved directly to the hard drive whilst welding. Each set of welding data is
saved with a filename comprising of the date & time, these files can be loaded back into the
onscreen VDU Printer at any time after welding is complete and then a hard copy of the print
out can printed using the menu buttons at the top of the VDU Printer Window.
2.10.5 Soft Button Operation
Left Hand Button Set ALX II Logging Screen 1
2.10.5.1 RESET
Used at the end of the logging session when the summary has been printed to return
the ALXII to an IDLE state waiting for the next log START operation. The Green
Reset button will flash indicating that it should be pressed at the end of each logging
session. Note:During IDLE the LCD meters will display information.
2.10.5.2 VDU PRINTER
This button is used to toggle the on-screen, scrolling print-out for the welding data.
When illuminated the Print-out Window will be displayed on-screen.
2.10.5.3 START
The START button has a number of states indicated by the CAPTION on displayed on the
button. The CAPTIONS depending on the operational status of the ALX II can be:
 START: Blue Button Flashing: When pressed a new weld logging session is started. A
header is printed the caption changes to “ARC”

 ARC: Blue Button Illuminated: The unit is waiting for a valid ARC to be detected after
which the caption changes to SUMMARY. A valid ARC is when the Welding Current rises
above 15amps, when this occurs the ALX II will automatically start printing/logging the
weld parameters.
 SUMMARY: Blue Button Flashing: If pressed in this state the current logging session
finishes and a summary is printed/logged.
2.10.5.4 MENU
The light blue MENU Button is used to toggle the operation of the buttons between
two levels.
Right Hand Button Set ALX II Logging Screen 1
2.10.5.5 INHIBIT
The Grey INHIBIT Button is used to „Pause‟ the printing/logging of a weld.
2.10.5.6 AUTO RUN
The Orange AUTO RUN Button Toggles the “AUTORUN function” ON and OFF. This
function when selected will Automatically Increment the Run Number each time a new
Header is printed/logged. Depending on the operational mode of the ALX II the operation will
change as listed below.
Basic Logging Mode:

 When AUTO RUN is OFF then no action is taken.
 When AUTO RUN is ON a RUN number appears on the print out. The number
will increment with every new weld.
Pipeline Procedure Mode:

 When AUTO RUN is OFF then no action is taken. The operator has to select the
next pass type (Root Fill Cap) on the drop down menu before the weld starts.
 When AUTO RUN is ON then the Pipeline procedure is stepped through
automatically.
Standard Procedure Mode:

 When AUTO RUN is OFF then no action is taken. The operator has to select the
next Run Number from the drop down menu before the weld starts.
 When AUTO RUN is ON then the Standard procedure is stepped through
automatically.
2.10.5.7 ALT DISPLAY
The Violet ALT DISPLAY Button is used to toggle the large LCD Style Digital displays. When
off the main primary parameters are displayed and when on (Illuminated) the optional
secondary parameters are displayed.
Used to select the period between print outs during a weld logging session. Two user
programmed print rates periods are available. These are set in the “HEADERS Button”
section of the manual.

2.10.5.8 PRINT RATE
The Yellow PRINT RATE Button is used to toggle between the 2 user programmed
print/logging rate settings (See section 2.9.3.1 for additional details on Print Rate Settings).
When Off the ALX II will print/log at the user selected time period for Print Rate 1, when on
(Illuminated) the ALX II will print/log at the user selected time period for Print Rate 2.
Left Hand Button Set ALX II Logging Screen 2 (selected by pressing the MENU Button)
2.10.5.9 POWER OFF
The Red POWER OFF Button is used to terminate the ALX II Logging application.
2.10.5.10 HEADERS
When the Grey HEADER Button is pressed the header editing form is displayed. Please see
section 2.9.3.1 to 2.9.3.6 for additional information on setting the ALX II Headings and
Options.
2.10.5.11 PULSE MODE
When selected the Grey PULSE MODE Button toggles the unit between Normal Welding
Process MODE (Average) and Pulsed Welding Process MODE (Calculates the
Peak/Average/Background Parameters).
 NORMAL mode the sample rate is fixed and the averaged Welding Parameters
are displayed.
 PULSE MODE the sample rate can be selected by the user from the “Pulse
Sample Rate” drop down menu. An expanded set of displays calculate and show
the Welding Current and Arc Voltage Peak/Average/Background data and also
the Pulse Frequency/Width data.
2.10.5.12 MENU
The light blue MENU Button is used to toggle the operation of the buttons between
two levels.
Right Hand Button Set ALX II Logging Screen 2 (selected by pressing the MENU Button)
2.10.5.13 TEMP
The Grey TEMPERATURE Button (optional) will print/log the Displayed temperature value
when pressed. To view the Temperature display use the „ALT DISPLAY‟ button as detailed in
section 2.9.5.7 above.
2.10.5.14 GAS
The Grey GAS Button (optional) will print/log the Displayed Gas Flow value when pressed.
To view the Gas Flow display use the „ALT DISPLAY‟ button as detailed in section 2.9.5.7
above.

2.10.5.15 SENSOR SETUP
The Grey SENSOR SETUP button has two functions:
 When pressed a window is opened for the user to select the type of probe/transducers
connected to the ALXII. This information is saved for subsequent power ups.
 When Sensor Setup window is open the Current Display will show Current Sensor Offset
allowing the operator to Zero the Current Probe.
Note: Please read the Section in this manual on Zeroing the Current Sensor for additional
operational information.
2.10.5.16 PULSE SCOPE BUTTON
The ALXII is put into dormant mode and the TVC PULSE SCOPE becomes active. Please
see the PULSE SCOPE Section in this manual for additional operational information.
2.10.6 Additional Operational Information
2.10.6.1 VDU Printer (Additional Operational Information)
If you have selected the Onscreen VDU Printer by pressing the VDU PRINTER Button (see
section 2.9.5.2 above) the Onscreen Printer Window will be displayed onscreen between the
left and right ALX II Menu button windows. What ever is written to any connected printer is
always displayed within this window.
2.10.6.2 VDU Printer LOAD Button
Loads any previously saved ALX II weld log text files for re-viewing or re-printing.
2.10.6.3 CLR Button
Simply clears all the displayed data from the virtual printer. It does not delete any log
from the equipment.
2.10.6.4 Print Button
Sends the data displayed to the printer ALX II internal hard copy printer unit.

2.10.6.5 Exit
The Exit button closes the onscreen VDU Printer window.
2.10.6.6 Multiple Files Tick-box
When selected by clicking on the Tick-box allows the operator to load several ALX II
weld log text files from a single folder in to the VDU Printer window at once. If the
Print button is then pressed all of the selected and displayed files will be printed on
the AL XII internal hard copy printer in the order that they appear in the VDU Printer
window.
2.10.6.7 Cancel
The Cancel button can be used at any time when re-printing a weld log text file to
stop the printing.
2.10.6.8 Printer Menu tab
The Printer menu tab located at the top of the ALX II Logging screen allows the
operator to quickly Enable or Disable the internal hard copy printer unit.
2.10.6.9 Basic Scope Menu tab
The ALX II has a very simple Oscilloscope facility which can be used for setting up and
viewing wave forms. This I selected by clicking on the „BasicScope‟ menu tab located at the
top of the ALX II Logging Screen. The operator can select a single parameter to view, there
are no Save or Load functions within this application. (For full waveform analysis you should
use the ALX II Pulse Scope application.)
2.10.7 Weld Monitoring Operational Sequence:
2.10.6.1 Connect ALX II unit to welding set and switch unit on.
2.10.6.2 Select Log from ALX II Main Menu
2.10.6.3 Set up Printer and Print out information.
2.10.6.4 Press Flashing Blue „Start‟ Button – Headings date will immediately be
printed and the Start Button will now read „Arc‟ with a constant Blue Light.
2.10.6.5 Once a welding current of over 15amps is detected by the ALX II unit the on
screen digital displays will start reading and an average for each of the
welding parameters will be printed at the pre-selected Print Rate.
2.10.6.6 Once the weld is complete the operator can input the measured weld length
using the mouse and keyboard via the Weld Length input box at the bottom
of the ALX II logging screen. (Note: If the Traverse Transducer has been
used to measure the Welding Travel Speed then by leaving the Weld Length
input box at Zero (0) the weld length will automatically be calculated using
the travel speed and arc time. If a manual weld length is inputted by the
operator this will override the calculated weld length).
2.10.6.7 The Blue Start Button will now once again be flashing and will have changed
to „Summary‟. By pressing this button a summary will be calculated and
printed. This will provide the Min/Max/Ave values for each monitored
parameter, it will also calculate the Arc Energy, Heat Input and total Arc
Time.
2.10.6.8 Once the weld has been summarised the Green „Reset‟ button will flash.
When pressed the ALX II unit is once again ready to start monitoring, the
operation should be repeated from step 2.10.5.4

3 Operating Instructions – ALX II Pipeline Procedure Software
3.1 Pipeline Procedure Software – Set Up
The ALX II Software as previously described within this manual, can be used in 3 different
modes these comprise of Procedure Data input Specific to Pipeline Welding Procedures,
Standard Non-Pipeline Procedures and Basic Weld Monitoring.
This section describes how to use and operate the Pipeline Software.
3.1.1 From the main ALX II Menu Navigation Page select „Setup Pipeline‟ using either the
mouse or by press the button.
3.1.2 Once selected you have the choice of either creating a new project or using an
existing project. If you have not already created and saved any projects you will have
to select „Create New Project‟ using either the mouse or by pressing the button.

3.1.3 You will be prompted to input a Project name. Enter the required project name into
the box and press/select „Next‟.
3.1.4 A project file will now be created on the ALX II unit‟s hard drive. You will now need to
fill in the Procedure Number and Data. Note: You can save several Procedures
under the same project name.

3.1.5 You must fill in a Procedure Number and then using the Drop Down box select either
a „Full‟ or „Repair‟ procedure type.
If you select a „Full‟ Procedure then the „Repair Type‟ and „Repair Pass Number‟ will
automatically be greyed out.
If the number of Fill Passes are known then they can be filled on this page, if the number
of Fill Passes is not known then the „Number Of Fills‟ can be set at 1 and additional
Passes added once the welding process has started.
You will also need to fill in the „Number Of Caps‟ and the „Pipe Diameter‟ and „Wall
Thickness‟, metric or imperial measurement can be set for these independently.
If you are setting up a Repair Procedure then all of the other fields will be greyed out
apart from „Repair Type‟ and „Repair Pass Number‟ where you can set the Repair Pass
information.
3.1.6 Within the next pages you can set up information on each of the passes, this
information will be printed on the header of each weld.

3.1.7 To set the Welders Name and ID Number first tick the „Enable Welder‟ box and then
fill in the welders name and ID boxes.
Note: Any boxes/fields that are left empty will not be printed on the header or saved in to the
weld log.
3.1.8 The welding position information can be set by first ticking the „Enable Position‟ box
and then select the required information from the drop down boxes.

3.1.9 There are several options available for Travel Speed measurement and calculation to
enable the selection first tick the „Enable Travel Speed‟ box.
If you have purchased the Traverse Option and wish to measure the actual travel speed in
real time then select the „Tacho‟ option. When using this option you may also select the „Heat
IP Real Time Calculation‟ option. (This option will add an additional real time digital display
on the ALX II Logging screen which will calculate and display the Heat Input whilst welding is
in progress).
If the travel speed is known then this can be pre-programmed by selecting the „Pre-
Programmed‟ option and then inputting the travel speed in cms/min into the box. (Note: This
must be a single value, you cannot enter a range).
Alternatively if you do not know the travel speed and do not have the traverse option then the
ALX II can calculate the Average Travel Speed at the end of the weld by using the weld
length and arc time. This can be selected using the „Calculated‟ option.
Note: If your pipe has been set up either on a rotator or in a chuck with a different diameter to
the pipe and you are measuring the chuck/rotator speed you can set up the software to
correct the speed measurement. First tick the „Rotational Correction‟ box. Input the diameter
of the Chuck/Rotator in the box marked „Chuck‟ then input the pipe diameter in the box
marked „Pipe‟. This correction data will be printed on the weld summary at the of the weld
together with the corrected Travel Speed and Weld Length.

3.1.10 There are also several options for the Weld Length input/calculation.
First tick the „Enable Weld Length‟ box and then select the required option.
The normal/standard method of input is to measure the weld length after the pass has been
completed and input the measured length into the Weld Length box on the ALX II Logging
screen. Select „Input on the ALX2 at End of Weld‟ for this option.
Alternatively if you already know the Weld Length before starting the weld then you can Pre-
Programme the length in mm.
If you have selected either a Pre-Programmed or Measured Travel Speed option then you
can set the ALX II software up to calculate the Weld Length using the Travel Speed and Arc
Time.

3.1.11 To select the Welding Process and Consumable information first tick the „Process‟
box and then select the Process from the Drop Down Menu.
The consumable fields will change depending on which Process you select. Any fields
that are left blank will not be printed on the header.
3.1.12 The last section of the Process information selection allows you to select how the
Welding process is deployed from a drop down menu.

A drop down menu allows you to select the Welding Polarity (Positive electrode/Negative
electrode/AC).
There are also selections for the Automatic Welding where a bug is used that can be set up
with a fixed Weave/Oscillation Frequency and Width.
3.1.13 The Thermal Efficiency Process „K‟ Factor can also be selected, the value is
automatically set when you select the process type. You can choose whether to
correct the Heat Input Calculation with the Thermal Efficiency Process „K‟ Factor by
ticking or un-ticking the „Use K Factor‟ selection box.
3.1.14 Once you have inputted the required data you will then need to fill in the data for all
of the other passes, they are tabbed along the top of the data input fields and can be
selected by clicking on the required tab.
If the data is to remain the same or very similar for all of the other passes then you can use
the „Copy To All‟ button on the RHS of the screen. This will copy the data on the pass that
you are presently displaying to all other passes.
If you want to copy each pass one at a time then use the „Copy Previous‟ button, this will
allow you to copy all of the data one pass to the next. (For Example: If you type all of the data
in to the Root Pass and then want to copy the same data to the Hotpass only then simply
select the Hotpass tab so as you are displaying the Hotpass without any data in the fields
and then press the „Copy Previous‟ button. If you make any mistakes you can press the
„Copy Undo‟ Button).

3.1.15 Once you have filled in all the required information for each of the passes you must
save the data by pressing the „Save All To Disk‟ button.
The Save As window will appear, simply press the Save button. Do not attempt to re-
name the file.
You are now ready to start monitoring your weld procedure.
3.2 Pipeline Procedure Software - Weld Data-Logging
3.2.1 Press the „Log‟ button and the ALX II logging screen will be loaded.

You now have the option of either manually selecting each pass by clicking on the pass
name located in the „Pipeline‟ drop down box located in the centre of the ALX II logging
screen.
Alternatively you can set the software to automatically increment the Pass each time a
new Header is printed by pressing the „Auto Run‟ button on the RHS of the screen.
You can edit any of the Procedure Information whilst in the ALX II Logging screen by
pressing the „Proc‟ button located under the Pass name in the centre of the ALX II
Logging screen. Once pressed the full procedure data set will appear and can be edited
and additional passes can be added if required. You must re-save the data set before
closing the Procedure screen for any changes to take affect.
3.2.2 If a „Stripper‟ Pass is required select the required Pass from the drop box and then
press the „Stripper Pass‟ button. When the next header is printed the pass will be
called „Strip Pass‟ and then the Pass name (ie: Strip Pass Fill 1).

3.2.3 Once in „logging‟ mode the operational sequence for logging your procedure is as
follows:-
a) Select automatic Run as required by pressing the „Auto Run‟ button. If selected the
first pass will start at Root and then automatically increment on to Hotpass and Fills
etc. If de-select you will have manually select the Pass (see item xvi above).
b) Press the Blue Flashing „Start‟ button, the ALX II will print/log the Header and the
Blue Flashing Start button will change to a Blue Continuously Illuminated „Arc‟ button
indicating that the ALX II unit is waiting for an Arc to strike.
c) Once the Welding Current exceeds 15amps then the ALX II will start Printing/Logging
at the pre-set print rate.
d) When the weld is complete depending on how you have set up the software you will
need to input the measured weld length, please see item x) above which will explain
the available options.
e) The Blue Flashing Start Button will now change to a „Summary‟, you may now press
this button and a summary of the weld will be printed/logged.
f) Once the Summary has been printed/logged the Green „Reset‟ button will flash you
should now press this button.
g) The procedure will now re-start from b) above. (Note: If you have set the ALX II to
Auto Run then the Header will have already automatically incremented to the next
pass. If you have not set the ALX II to Auto Run then you will need to set the Pass
manually.
3.3 Pipeline Procedure Software - Weld Data
3.3.1 The welding data is logged directly to a file on the Hard Drive of the ALX II unit, the
File name is the same as the Procedure name. The saved welding data can be re-
printed on the ALX II unit‟s internal printer after welding is complete.
3.3.2 To re-call or re-print the logged pass data open the on-screen VDU printer (if not
already open) by pressing the „VDU Printer‟ button. Using the mouse press the „Load‟
button at the top left hand side of the on-screen VDU Printer window.
3.3.3 Select and open the required Project file and Procedure file from the TVC Pipeline
main file on the ALX II Hard Drive.

3.3.4 Select and open the required data file, this will now load into the VDU Printer.
3.3.5 You can now press the „Print‟ button at the top centre of the VDU Printer. Ensure that
the Internal ALX II Printer unit is „Enabled‟ and the complete print-out as it appears
on the screen will be re-printed.
5.6.31 If you need to print/re-print all of the Passes then tick the box marked „Multiple Files‟
underneath the „Load‟ button at the top left hand side of the VDU Printer window.

3.3.7 Again press the „Load‟ button and select the Pipeline Project and Procedure file. All
of the weld data files in the Procedure file will be displayed in the left hand box, click
and highlight the required files and press „OK‟
3.3.8 The selected files will now be loaded into the VDU Printer and can be printed by
pressing the Print button at the top of the VDU Print window. If you need to Stop the
printing partway through press the „Cancel‟ at any time.
3.3.9 The logged data files can be exported into an MS-Excel spreadsheet by using the
ALX II Reporting software. See Section 7 for further information on using the ALX II
reporting software.

4 Operating Instructions – ALX II Standard Procedure Software
4.1 Standard Procedure Software – Set Up
The ALX II Software can be used in 3 different modes these comprise of Procedure Data
input Specific to Pipeline Welding Procedures, Standard Non-Pipeline (Standard) Procedures
and Basic Weld Monitoring.
This section describes how to use and operate the Standard Software.
4.1.1 From the main ALX II Menu Navigation Page select „Setup Standard‟ using either the
mouse or by press the button.
4.1.2 Once selected you have the choice of either creating a new project or using an
existing project. If you have not already created and saved any projects you will have
to select „Create New Project‟ using either the mouse or by pressing the button.

4.1.3 You will be prompted to input a Project name. Enter the required project name into
the box and press/select „Next‟.
4.1.4 A project file will now be created on the ALX II unit‟s hard drive. You will now need to
fill in the Procedure Number. Note: You can save several Procedures under the
same project name.

4.1.5 You must fill in a Procedure Number and then using the Drop Down box select the
procedure type.
If the number of Runs are known then they can be filled on this page, if the number of
Runs are not known then the „Number Of Fills‟ can be set at 1 and additional Runs added
once the welding process has started.
You can also to fill in the information on the Type of Material and wall thickness used if
required.

4.1.6 Within the next pages you can set up information on each of the passes, this
information will be printed on the header of each weld.
4.1.7 To set the Welders Name and ID Number first tick the „Enable Welder‟ box and then
fill in the welders name and ID boxes.
Note: Any boxes/fields that are left empty will not be printed on the header or saved
in to the weld log.

4.1.8 The welding position information can be set by first ticking the „Enable Position‟ box
and then select the required information from the drop down boxes.
4.1.9 There are several options available for Travel Speed measurement and calculation to
enable the selection first tick the „Enable Travel Speed‟ box.
If you have purchased the Traverse Option and wish to measure the actual travel speed in
real time then select the „Tacho‟ option. When using this option you may also select the „Heat
IP Real Time Calculation‟ option. (This option will add an additional real time digital display
on the ALX II Logging screen which will calculate and display the Heat Input whilst welding is
in progress).
If the travel speed is known then this can be pre-programmed by selecting the „Pre-
Programmed‟ option and then inputting the travel speed in cms/min into the box. (Note: This
must be a single value, you cannot enter a range).
Alternatively if you do not know the travel speed and do not have the traverse option then the
ALX II can calculate the Average Travel Speed at the end of the weld by using the weld
length and arc time. This can be selected using the „Calculated‟ option.

Note: If your pipe has been set up either on a rotator or in a chuck with a different diameter to
the pipe and you are measuring the chuck/rotator speed you can set up the software to
correct the speed measurement. First tick the „Rotational Correction‟ box. Input the diameter
of the Chuck/Rotator in the box marked „Chuck‟ then input the pipe diameter in the box
marked „Pipe‟. This correction data will be printed on the weld summary at the of the weld
together with the corrected Travel Speed and Weld Length.
4.1.10 There are also several options for the Weld Length input/calculation.
First tick the „Enable Weld Length‟ box and then select the required option.
The normal/standard method of input is to measure the weld length after the pass has been
completed and input the measured length into the Weld Length box on the ALX II Logging
screen. Select „Input on the ALX2 at End of Weld‟ for this option.
Alternatively if you already know the Weld Length before starting the weld then you can Pre-
Programme the length in mm.
If you have selected either a Pre-Programmed or Measured Travel Speed option then you
can set the ALX II software up to calculate the Weld Length using the Travel Speed and Arc
Time.

4.1.11 To select the Welding Process and Consumable information first tick the „Process‟
box and then select the Process from the Drop Down Menu.
The consumable fields will change depending on which Process you select. Any fields
that are left blank will not be printed on the header.
4.1.12 The last section of the Process information selection allows you to select how the
Welding process is deployed from a drop down menu.

A drop down menu allows you to select the Welding Polarity (Positive electrode/Negative
electrode/AC).
There are also selections for the Automatic Welding where a bug is used that can be set up
with a fixed Weave/Oscillation Frequency and Width.
4.1.13 The Thermal Efficiency Process „K‟ Factor can also be selected, the value is
automatically set when you select the process type. You can choose whether to
correct the Heat Input Calculation with the Thermal Efficiency Process „K‟ Factor by
ticking or un-ticking the „Use K Factor‟ selection box.

4.1.14 Once you have inputted the required data you will then need to fill in the data for all
of the other Runs, they are tabbed along the top of the data input fields and can be
selected by clicking on the required tab.
If the data is to remain the same or very similar for all of the other runs then you can use the
„Copy To All‟ button on the RHS of the screen. This will copy the data on the run that you are
presently displaying to all other runs.
If you want to copy each pass one at a time then use the „Copy Previous‟ button, this will
allow you to copy all of the data one pass to the next. (For Example: If you type all of the data
in to the Run 1 and then want to copy the same data to Run 2 only then simply select the
Run 2 tab so as you are displaying Run 2 without any data in the fields and then press the
„Copy Previous‟ button. If you make any mistakes you can press the „Copy Undo‟ Button).
4.1.15 Once you have filled in all the required information for each of the Runs you must
save the data by pressing the „Save All To Disk‟ button.
The Save As window will appear, simply press the Save button. Do not attempt to re-
name the file.
You are now ready to start monitoring your weld procedure.
4.2 Standard Procedure Software - Weld Data-Logging
4.2.1 Press the „Log‟ button and the ALX II logging screen will be loaded.

4.2.2 You now have the option of either manually selecting each run by clicking on the run
number located in the „Standard‟ drop down box located in the centre of the ALX II
logging screen.
Alternatively you can set the software to automatically increment the run number each
time a new Header is printed by pressing the „Auto Run‟ button on the RHS of the screen.
You can edit any of the Procedure Information whilst in the ALX II Logging screen by
pressing the „Proc‟ button located under the Run Number in the centre of the ALX II
Logging screen. Once pressed the full procedure data set will appear and can be edited
and additional passes can be added if required. You must re-save the data set before
closing the Procedure screen for any changes to take affect.
4.2.3 If a „Stripper‟ Run is required select the required Run Number from the drop box and
then press the „Stripper Pass‟ button. When the next header is printed the run will be
called „Strip Pass‟ and then the Run Number (ie: Strip Pass Run 2).

4.2.4 Once in „logging‟ mode the operational sequence for logging your procedure is as
follows:-
a) Select automatic Run as required by pressing the „Auto Run‟ button. If selected the
first pass will start at Run 1 and then automatically increment on to Run 2 and Run 3
etc. If de-select you will have manually select the Run Number (see item xvi above).
b) Press the Blue Flashing „Start‟ button, the ALX II will print/log the Header and the
Blue Flashing Start button will change to a Blue Continuously Illuminated „Arc‟ button
indicating that the ALX II unit is waiting for an Arc to strike.
c) Once the Welding Current exceeds 15amps then the ALX II will start Printing/Logging
at the pre-set print rate.
d) When the weld is complete depending on how you have set up the software you will
need to input the measured weld length, please see item x) above which will explain
the available options.
e) The Blue Flashing Start Button will now change to a „Summary‟, you may now press
this button and a summary of the weld will be printed/logged.
f) Once the Summary has been printed/logged the Green „Reset‟ button will flash you
should now press this button.
g) The procedure will now re-start from b) above. (Note: If you have set the ALX II to
Auto Run then the Header will have already automatically incremented to the next
run. If you have not set the ALX II to Auto Run then you will need to set the run
number manually.
4.3 Standard Procedure Software - Weld Data
4.3.1 The welding data is logged directly to a file on the Hard Drive of the ALX II unit, the
File name is the same as the Procedure name. The saved welding data can be re-
printed on the ALX II unit‟s internal printer after welding is complete.
4.3.2 To re-call or re-print the logged pass data open the on-screen VDU printer (if not
already open) by pressing the „VDU Printer‟ button. Using the mouse press the „Load‟
button at the top left hand side of the on-screen VDU Printer window.
4.3.3 Select and open the required Project file and Procedure file from the TVC Standard
main file on the ALX II Hard Drive.

4.3.4 Select and open the required data file, this will now load into the VDU Printer.
4.3.5 You can now press the „Print‟ button at the top centre of the VDU Printer. Ensure that
the Internal ALX II Printer unit is „Enabled‟ and the complete print-out as it appears
on the screen will be re-printed.
4.3.6 If you need to print/re-print all of the Passes then tick the box marked „Multiple Files‟
underneath the „Load‟ button at the top left hand side of the VDU Printer window.

4.3.7 Again press the „Load‟ button and select the Standard Project and Procedure file. All
of the weld data files in the Procedure file will be displayed in the left hand box, click
and highlight the required files and press „OK‟
4.3.8 The selected files will now be loaded into the VDU Printer and can be printed by
pressing the Print button at the top of the VDU Print window. If you need to Stop the
printing partway through press the „Cancel‟ at any time.
4.3.9 The logged data files can be exported into an MS-Excel spreadsheet by using the
ALX II Reporting software. See Section 7 for further information on using the ALX II
reporting software.

5 Operating Instructions – ALX II Pulse Measurement Software
5.1 Introduction
The ALX II can be supplied with a software option specifically designed for the monitoring
and analysis of pulsed welding processes. Whilst welding is in progress the ALX II can
analyse each of the parameters, calculate and display information on the pulse
characteristics.
The software is also capable of recording thousands of data-points for each of the main
welding parameters and storing the data on the unit‟s hard drive. This information recorded
during the welding process can be used to reproduce graphical representations of the
welding waveforms which can then be fully analysed.
The software has been designed to be intuitive and user-friendly and offers an easy bi-
directional windows interface for the ALX II, and includes the following features:
 Real time calculation and display of pulse parameters

 Waveform capture of Welding Current and Arc Voltage
 Storage, recall, compare of archived waveforms
 Zoom and cursor controls
 Sophisticated filtering algorithms to remove inverter noise
 Export of data into excel worksheets spreadsheets.
 Statistical analysis package
IMPORTANT NOTE:
To ease the learning curve and avoid unnecessary waste of time TVC recommends you read
this manual carefully and completely before starting the application. There is a questions and
answer section that should be referred to first before ringing TVC.
5.2 Running The Pulse Software
When the ALX II is power up and connected to a welding power source the Pulse
Measurement Mode of operation can be entered quickly and easily using the Menu buttons.
Access the Pulse Measurement software by pressing the Menu button to access the second
level of ALX II menu buttons.
ALX II Menu
Selection
Button

With the second level of ALX II menu buttons on display the „PULSE MODE‟ button will be
accessible.
Once the Pulse Mode has been pressed then the LCD Style Displays in the centre of the
ALX II logging screen will immediately change.
ALX II
Pulse
Mode
Button
The pulse data for the welding current and arc voltage will now be displayed.
The operator can now set up the Sampling frequency for the ALX II if required. The ALX II
sample frequency is usually set at 16000hz, however the operator may wish to reduce the
sampling frequency to increase the length of time that the ALX II can record the welding data
for. Alternatively the sampling rate can be increased to capture glitches and fast acting
events within the welding waveforms.
To change the sampling frequency click on the drop down box in the centre of the ALX II
logging screen labelled „Pulse Sample Rate‟ and select the required frequency from the list.

The typical maximum single file recording times for each of the sample frequencies are:-
1000 = 256 minutes

2000 = 128 minutes
4000 = 64 minutes
8000 = 32 minutes
16000 = 16 minutes
32000 = 8 minutes
Most pulsed GMAW processes will require a sample frequency of 8000 or 16000. However
pulsed GTAW processes which usually have a much lower pulse frequency than GMAW
processes will only need a sample frequency of 1000 or 2000. This is a guide only and the
operator may choose any sample frequencies that suit there application.
When monitoring either double pulsed or adaptive/reactive pulsed processes such as STT
the operator should tick the STT tick box which is directly below the Pulse Sample Rate
selection menu.
Ticking the STT box will ensure that the ALX II calculates the correct pulse parameter data
when monitoring STT, double pulsed or adaptive/reactive pulsed processes.
The ALX II when in Pulse Mode should be operated in the same manor as when it is in
Normal Mode. The Pulse Mode can be used in conjunction with any of the other ALX II
software packages including the Pipeline and Standard Procedure logging software.
Once welding is in progress and the ALX II is printing/logging the weld data the LCD Style
Displays will update the Pulse Parameter data every second.

Please note that the ALX II VDU Printer and internal hard copy printer will only print/log the
average value for the parameters whilst welding is taking place.
At the end of the weld once the Summary button has been pressed the ALX II will calculate
and print/log the average pulse parameters.
Once welding is complete further analysis of the welding waveform can be performed by the
operator by selecting the ALX II Pulse Scope.
5.3 ALX II Pulse Scope Software
The ALX II Pulse Scope is selected from the ALX II logging screen by pressing the „PULSE
SCOPE‟ button.
Menu
Toolbar
Once opened the Pulse Scope will fill most of the top half of the ALX II screen. To select and
open the required data file use the mouse to click on „File‟ in the menu toolbar at the top of
the Pulse Scope window.

Select „Open‟ and the windows open file will appear, it should automatically look in C:/Arclog.
In the Arclog folder there are 3 TVC Folders these are TVC_ALXII_LOGS, TVCPipeline and
TVCStandard. The depending on how you have chosen to log the welding data the required
ALX II files will have been saved to one of these.
If you have used the basic ALX II logging software then the file will have been saved directly
into the TVC_ALXII_LOGS folder. If you have used the Pipeline Procedure software then the
files will have been saved into the TVCPipeline folder under the Project and Procedure name.
If the Standard Procedure software has been used then the files will have been saved into
the TVCStandard folder under the Project and Procedure name.
Select and open the required folder/file.
The data files are saved with a filename that consists of the date and time in reverse. The
Pipeline and Standard Procedure files also include the Pass/Run Number.
Select the required file and click on „Open‟.

The weld data will now load into the Pulse Scope. To zoom in on the weld data use the
mouse to position the cursor on the graph area. Click and hold the left hand mouse button
whilst moving the mouse to the left or right. The area that you select will be expanded as
soon as you release the left mouse button.
Depending on how you have set the Graph time base this may take 2 or 3 attempts to get the
graph expanded to the required level.
If at any time you have expanded the graph too far you can use the „Unzoom‟ button.
The graph scaling can be customised to suit your requirements. Click on the „SETUP‟ button
underneath the Graph to open the setup window.

First click on the „Time Secs‟ drop down box and click on the required time in seconds to
select the timebase width that the graph will always initialise and open with. Note: The
shorter the timebase the quicker the weld data will load into the graph.
Click on each of the other parameter settings and select the required maximum parameter
scaling. You can also click on the parameter scaling text box and type the required maximum
parameter scaling if it does not appear on the listing in the drop down box.
You can also turn the parameter traces on or off by ticking/un-ticking the boxes next to the
parameter name in the centre of the setup window.
The additional fields/selections are for use when you operate the Pulse Scope in manual
mode. Details of this operation can be found further on in this section.
Once you have made your selections you must then press the „Apply‟ button at the bottom of
the setup window for the selections to take affect.
Use the „Close‟ button to exit the setup window.
You can now start analysing the waveforms. By pressing the „Stats‟ button a second set of
menu buttons will be called up onto the screen. If you press the „Window Stats‟ then the
software will analyse the Expanded welding data that is displayed on the graph and a set of
statistics will be produced underneath the Pulse Scope.

Pressing the „Overall Stats‟ will call up a set of statistics for the full weld underneath the Pulse
Scope. These statistics will be identical to the statistics previously saved in the weld
summary.
To accurately measure the value of any of the traces on the waveforms you can simply use
the mouse to align the Cursor on the graph and then press the left mouse button. When the
left mouse button is pressed all of the trace values and the time will appear at the bottom left
hand side of the Pulse Scope.
To accurately measure the time of the pulses/glitches/events on the waveform traces you can
use the Time Base Cursor facility. To activate first tick the „Cursor‟ box located on the Pulse
Scope underneath the „Set Up‟ button.
Once pressed 3 text boxes will appear, the first box will be grey. Set your measurement
starting point by using the mouse to align the cursor at the required point on the graph. Once
aligned press the left mouse button and a vertical line will be drawn on the graph. Now set
the measurement finishing point by using the mouse to align the cursor at the required point
on the graph, press the left mouse button and a second vertical line will be drawn on the
graph. The time between the 2 measurement points will now be displayed in the first
(grey/highlighted) cursor text box.
Time base measurement Cursor tick box
Ensure that the mouse pointer/cursor is over the graph area and press the right mouse
button. The grey highlight will now move on to the next text box. Repeat above to record a
second measurement.

Repeat all of the above to make a third measurement. You can use the „Clear All‟ to remove
the cursor measurement lines.
Measurement Measurement finishing

starting point point
Time base measurement
To exit the Time Base Cursor Measurement mode de-tick the „Cursor‟ box.
5.4 Reporting
The Pulse Data together with a screenshot of the Pulsescope software can be saved directly
into a Spreadsheet report by first clicking on „File‟ in the top menu, then select „Create
Report‟ from the drop down menu.
When „Create Report‟ has been selected the ALX II reporting software will open at the file
data input page. You will now need to select an MS-Excel Spreadsheet template to load the
weld data in to. To do this first select the „Excel Templates‟ tab at the top right.

Using the mouse press the „Select Excel File‟ button, a „Load File‟ window will open
displaying the available MS-Excel Spreadsheets saved in the ALX II „Arclog‟ folder on the
hard drive.
Select the required Spreadsheet and click on „Open‟. The name of the selected spreadsheet
will now appear in the box at the top of the „Excel Templates‟ window. You will now need to
click on the „File Data‟ central tab to once again display the grid with the file data to be
exported into the Excel Spreadsheet.
Click on the „Export Weld Data to Excel‟ button at the bottom right hand side of the window.
MS-Excel will now open and the weld data will automatically load into the spreadsheet
together with a screenshot of the Pulsescope. You can now save/cut/copy/modify this
spreadsheet as per a normal Excel spreadsheet.
Note: There are a selection of standard spreadsheets loaded onto the ALX II hard drive, the
spreadsheets designed specifically for use with the Pulse software will have „Pulse‟ as part of
the filename.
If you wish to simply load the welding data into a spreadsheet without using a template then
leave the box at the top of the „Excel Template‟ window blank. When you press the „Export
Weld Data to Excel‟ button all of your selected welding data will load in a spreadsheet in
exactly the same format as it appears in the Grid.
Alternatively you can use the ALX II Spreadsheet Layout software within the ALX II reporting
to create your own Spreadsheet Templates, please the separate section on Designing
Templates.
5.5 Pulse Scope Controls
Menu Bar
Along the top of the software window is the menu bar.
File:
Open : loads an archived file

Save AS: Saves the current file
CreateReport: This will export a save & loaded pulse weld into the
export page on the ALX II Reporting Software program. The data
can then be loaded into Excel with a screenshot of the weld graph.
Control:
Clear Display: simply clears the display!

View:
These “options” toggle on/off
“Display ALX header”: turns ON/OFF the procedure/date/time status on the

graph.
Instantaneous energy: AFTER a test or downloaded archive file this will display a
graph of AMPS * VOLTS over time .
Test Compare: Select another archived file to compare against the one already
displayed.
Graph Grid: Displays grid lines.
Options:
SETUP: See section on set up button below.
Analgue Scaling. DO NOT CHANGE THIS UNLESS INSTRUCTED TO!
Arc Detection AMPS:
This is usually enabled. A test WILL NOT START until the amps rise to above 15 AMPS
threshold for more than 200 ms. Turning arc detection OFF by de-checking will allow logging
with NO ARC
Arc detection VOLTS:
Not implemented on this version
Enable High Speed:
This is automatically enabled when using SETUP: frequency = HIGH sampling in the SETUP
screen. It enables correct operation of the time axis. It made be turned off to see a real time
display if required. BUT this may cause the sampling time x axis to “slow”
Inverter Noise filter.
Many Welding sets have an inverter frequency, which is superimposed on the set up pulse
frequency selected by the operator. For example two pulses per second may be selected but
on test the inverter frequency can be seen and invalidates the required statistics.. The filter
setup is shown below with the default values. Only trial and error can be used when applying
the filter for the correct result.

The default values are shown above..

Severity of filter; a number 0.001 thru 0.5
Sharpness of filter: a number 2 – 64
Apply Inverter filter when sampling:
When checked the filter is applied to the finish of a test BEFORE the statistical analysis is
applied
Apply Now: applies the filter immediately to the displayed graph

Restore: restores the graph to its previous state. This means the filters can be configured
and tested on a displayed graph.
HIDE: Simply hides the window.
The following graph using the View_test compare function shows the before and after effect
of the filter.

Controls Pushbuttons
The lower part of the user interface has control pushbuttons. These are described as follows:
SETUP
Brings up the SETUP window:
TIME SEC‟s
A drop down menu gives a X range of 0.5 thru to 1 seconds. Note this is NOT the length of
the test .It is a window showing the progress of the test .
HINT: keeping this window time as small as possible enables a faster graph update of the
test.

AMPS MAX
A drop down menu enables the operator to select the required range for the test.
VOLTS MAX
WF MAX
I
The Y axis can be deselected. No plot will be recorded. HOWEVER if disable is made
AFTER a test then the plot axis is simply made invisible but is still stored.
V
WF
FREQUENCY:
The frequency selection selects the sampling speed of the data. There are three settings
SLOW:
300 samples per sec for each channel.
NORMAL(default)
800 samples per second for each channel
HIGH:
3000 samples per second for each channel
HINT: TIG SETUP:

The pulse frequency should be set to low.
Other settings as required
(The inverter noise filter may also be required. see relevant section)
HINT: MIG SETUP:

The pulse frequency should be set to low
Other settings as required
DELAY:
Not applicable in this version of software
SLOPE IN
The statistical package ignores start date for this amount of time
SLOPE OUT
The statistical package ignores last part of the data of this amount of time
APPLY
The settings will be immediately applied when this button is pressed.
START
Pressing this button STARTS the test.
HINT: This is a “slave” of the START button on the ALX II so it will not START the ALX II.
Normal operation is to use the START button on the ALX II which will then start the pulse
package.

STOP
Stops the test immediately. The data is stored and may be viewed. NOTE: This is a “slave” of
nd
the START/SUMMARY (2 push) button on the ALX II so it will not force a summary on the
ALX. Normal operation is to use the blue START button on the ALX II which will then stop the
pulse package.
HINT: The START ALX II button on the ALX II has two functions:
 START a test and starts the pulse data acquisition
 On second press, finishes the current test, starts the summary print out and stops the
pulse software acquisition
ALX II STATE
This shows the connection state between the PULSE program and the ALX II.During the test
it can display OFF LINE,ARC WAIT,ARC START,ARC STOP.
5.6 STATS
AFTER a test or when loading an archived file this button will display the statistics page.
Archived tests or the currently finished test may be viewed, zoomed and the overall statistics
of the complete test or just that zoomed on the graph may be performed.
README:
There are two ways of zooming and applying cursor markers.
The graph may be viewed in NORMAL mode where the _ and + buttons (see later) may be
used but cursor markers are disabled.
OR
If the mouse is dragged across a portion of the screen with the LH mouse button depressed,
on release that part of the screen will be EXPANDED. This is called expanded mode. A
cursor check box only appears in EXPANDED mode and when selected 3 cursor markers
(see later) can be manipulated.

OVERALL STATS
Shows the statistics of the complete test:
WINDOW STATS
Shows the statistics of that portion of the test displayed in the TFT monitor
BACK TO TEST MODE
Simply return to test mode.
UNZOOM
After many zooms and stretches this conveniently returns the graph to its initial display.
“-“
incrementally unzoom
“+”
Incrementally ZOOM.
SCROLL BAR
When displayed the scroll bar scrolls through the complete test.
HINT: If the test is less than the time axis then no horizontal scroll bar is displayed.

CURSOR
Cursors are used ONLY IN EXPANDED MODE and when the Cursor Enable box is checked.
Three cursors windows are available the required one being selected by Right hand click of
the mouse. Each window works with a pair of cursors. The distance between the cursor pair
being displayed in their cursor window.
EG:
Click the RH mouse until the first window is selected (shaded). Position the cursor over the
graph , depress the LH mouse , a vertical cursor will appear and may be dragged to the
required part of the graph. Release the LH mouse and the cursor stays put. Again depress
the LH mouse. Again another cursor will appear and may be similarly dragged. On release of
the LH mouse the difference between the cursors is shown in their window.
5.6 QUESTIONS & ANSWERS:
Time base seems slower than real time !

Some set-ups can create a fantastic amount of data using up the computers resources very quickly. To
counteract this simply ensure the
“Options-enable High Speed” is checked.
Loading and Saving data takes a long time !

Some set-ups can create a fantastic amount of data and do take time to load. If this is a problem review
if you can use use a different “SETUP-FREQUENCY” value. The lower this option is the less data is
stored. Similarly if the frequency is that required then simply take a shorter weld time if all you need to
do is look at the wave form.

How to Save a test
After a good test when the RESET button is pressed on the ALX the Pulse application will prompt the
user to save the latest test.
The Current or Volt‟ plot has noise effecting the summary results!
This is noise generator from sources such as the welding set. See the inverter noise filter section to
reduce this noise.
Can I edit the data:

The .TVC files are stored in text format. Make a copy of the required file.
Edit the copied file:
In the Header: DO NOT change any of the spelling in the first column.
Other columns may be changed.

6 Operating Instructions – ALX II Robotic Software
The ALX II Robotic Software Option is due for release in Spring 2008. Please
contact TVC/Your Local Distributor for further information.

7 Operating Instructions – ALX II Reporting Software
7.1 Tile screen and report selection
The report software has two functions, one for reporting normal ALX welds and the
second for ALX pipeline reports
To select either report function, click on the appropriate button.
7.2 Selecting weld files to view
7.2.1 Standard Reports
First click on the “browse for folder” button. A folder browser will appear, allowing the
user to select the appropriate folder containing ALXII weld file(s). Once a folder has
been selected, the program will list all the welds found. (Welds without a heading or
summary will not be listed as they are incomplete welds)
With the imported list of weld files, the user can select the desired welds to view. Once a
file has been selected it appears in the selection box.
Select welds by:
 Select single weld by double clicking with the left mouse button on a
weld.
 Selecting multiple welds by holding the left mouse button down, dragging
the mouse icon over multiple welds. Selected welds are then highlighted
blue. Click on the right arrow to add selected files to the selection box.
 Click once with the left mouse button on a single weld selecting it, then
going to the last desired weld and while holding the “shift” key, click on
the last desired weld. This will select all the welds between the fist and
last selected welds. Click on the right arrow to add files to the selection
box.
Note: The selection box will only contain one instance of a weld and not
multiples of the same weld.
Remove welds from selection box by:
 Double clicking on a weld.

 Highlighting multiple welds and clicking on the left arrow to remove them.
Once all the desired weld files have been selected click the “add files to grid” button.
Once clicked all the selected welds will have their weld data displayed on the weld grid.
More weld files can be added to the grid after its first population of weld(s)

Page
tabs
Select folder
Weld files in folder Selected welds Import weld data to

weld grid
7.2.2 Pipeline Reports
First click on the “browse for folder” button. A folder browser will appear, allowing the
user to select the appropriate folder containing weld file(s). Once a folder has been
selected, the program will list all the welds found.
There are two methods to select files to be imported to the weld grid.
One is to click the “add all files to grid” button which will import all weld files to the weld
grid. The second method is to double click on each desired weld file to create a weld
procedure. When a file is double clicked the program will place the appropriate file in the
correct procedure box.
A procedure can have; one root pass, one hot pass, multiple roots and multiple caps.
Once a procedure is complete click the “add procedure to grid” button.
Multiple weld procedures can be added to the weld grid after the first one is entered
Folder select
Clear file from box
Weld files in Import all weld Weld procedure Import weld

folder data to weld grid procedure to weld
grid

7.3 Viewed Files - editing welds in grid
The weld grid is used to display all the weld data stored in the selected weld files. The
data displayed includes all the data found on the ticker tape printed from the ALX.
WELD GRID
Weld
information
Export weld
Clear the grid grid to Excel
Note: If the weld grid is cleared then all the weld data will be removed and will not be
included if any new weld files are added to the grid.
To edit data click on the weld grid with the right mouse button. A selection box will
appear with the options to edit a cell, or delete rows.
7.4 Deleting rows
Right click with the mouse anywhere on the weld grid and select the option “delete rows”
from the activated list. The delete box will now appear.
To delete rows, enter the start row and end row to be deleted, then click the “delete”
button.
All weld files between and include the start and end row entered will be deleted.
You can delete a single row by entering the same row number in the start and end row
boxes.
Start & end row Start deletion
7.5 Editing a cell
If a cell in the weld grid contains the wrong information, the user has the option to
edit the data using the editing function.
Click on the cell to be edited with the right mouse button and select the “edit” option.
The edit box will now appear.
The cell row and column will be displayed (to indicate what cell you are in) as well as
the cells current data.
Edit the information in the edit box then click the “ok” button to change the cell
information.
Cell to edit
Edit box

7.6 Selecting an Excel template for reports
To export the weld grid using a template click on the “Excel Templates” tab. From this
page you can select an Excel template to be used to export the weld grid information too.
To select a template, click the “select Excel file” button. Use the file-browser to find the
correct Excel template and select it. Once the template is selected, the template name
will be entered into the selected template box.
Templates selected should have an alxlayout page, which the program uses to identify
where to place weld information. If the template selected has no layout information, then
a warning message will appear and data exported to the template may not appear
correctly
Select an Excel
template
Selected
Template
TVC supplies a set of existing templates.

Standard templates:
TVC_ML1.xlt
TVC_ML2.xlt
WELDGRAPH_ML
WPARXX_ML
Pipeline templates:
TVC_ML_Pipeline1.xlt
WELDGRAPH_ML_Pipeline1.xlt
WPARXX_ML_Pipeline1.xlt
7.7 Exporting weld data to Excel reports
To export the weld grid information to Excel or an Excel template (if ones selected) goto
the “file data” tab and click the “export weld data to excel” button. If a template has not
been selected then the program will export the whole weld grid to Excel, row for row,
column to column.
7.8 Creating a new Excel report
To create a new template goto the “Excel templates” tab.

The template creator will allow you to print a column of weldgrid controlling its;
 direction of print
 amount to print
 Excel sheet to print too
 whether to print the data in columns or rows
Note: Each column of data can only be printed once and not in multiple places.
Column data will always print in series.
Both the pipeline and standard reporting pages uses the same method for creating Excel
templates, the difference being the fields of data are slightly different.

7.9 Creating the template
1. Open Excel and create a basic template for the weld data.
2. Note the cell where each item of weld data should start, the amount of the item to
print and which Excel sheet to print too, if the template contains multiple worksheets.
For example, if weld item “date” is printed in cell C4 and only printed once, it means
that the first instance of “date” in the weldgrid will be printed to cell C4 in Excel.
3. Select the newly created template using the “Select Excel File” button. The program
will indicate that no layout data is present, which is correct at this stage.
4. Setup each item in the weld list to match your template.
No# = the weld field number.

Item = the weld field name
On/Off = weaver the welds items should be printed
Sheet = the Excel worksheet to print too.
Cell = the Excel cell which the weld field should start printing
Direction = to print the weld data going left or downwards
Amount = How much of the weld field to print (not all the fields data needs printing)
If you right click on the “Sheet” box(s) a list will appear showing the available
worksheets in the selected Excel template.
If you right click on the “Direction” box(s) a list of available directions to print will be
listed (either left or down)
To print all data in a field, enter “all” in the amount columns.
The field “Raw Data” is not displayed on the weldgrid as it contains all the printed raw
data values also found on the ALX ticker tape (set via print rate). If this field is turned
on then you must select what raw data is to be printed. I.e. amps, volts, wire feed,
arc time and any auxiliary channel present, using the appropriate tick-boxes.
The raw data prints all together i.e. row one of the weld grids raw data, prints first
and is followed by the second rows raw data
Weld 1 Weld 2
Amps Volts ArcTime Amps Volts ArcTime
5. Once all the weld fields are setup, click the “Save layout to Excel” button. This will
save the Excel layout just created to the Excel template.
In future the layout information will be loaded automatically from the template by the
software, when the template is used.

7.10 Example Setup
Excel Template
In this diagram the field “Welder” is set to print, starting cell D12, direction down and to print
all welder entries in the weldgrid.

8 ALX II Servicing
8.1 PRINTER PAPER CHANGE
8.1.1 Ensure that the ALXII is either switched „Off‟ or that the „On/Off‟ switch has
been set to the „Off‟ position and you have „Loaded 300 Seconds‟ (5 Minutes)
on the ALX Shut Off Window.
8.1.2 Unscrew by turning anti-clockwise the two knurled bolts on the top panel of
the printer (1) fig 1.
8.1.3 Withdraw the printer by pulling on the two bolts and slowly easing the printer
upwards away from the ALXII unit.
8.1.4 The front panel is in two halves. Slide the half panel with the paper aperture
away from the half with the knurled bolts.
8.1.5 Under this panel is the ink ribbon cartridge, unclip from printer mechanism
and remove by pressing the end of the cartridge marked „Push‟.

8.1.6 Remove the empty printer roll from the holder by pulling out of the sprung
slotted axle holder. When removed DO NOT discard the plastic axle.
8.1.7 Take a new roll of paper and ensure that the end of the paper is cut straight
a cross. Lie the printer down so that the slots for the paper roll axle are
pointing upwards (and the connector is at the bottom).
8.1.8 With the paper roll lying next to the connector and the paper take off from the
bottom of the roll, feed the paper end underneath the black fixed roller to the
front of the mechanism, pulling through about 10cm.
8.1.9 Insert plastic axle into the new roll and press into slots.
8.1.10 Insert paper end into the metal aperture underneath the rubber roller situated
at the front of the mechanism.

8.1.11 Holding the paper in the centre of the aperture rotate rubber roller toward the
paper with the forefinger.
8.1.12 Rotate until about 20mm of paper has been drawn through.
8.1.13 Feed the paper through the ink ribbon ensuring that the ribbon is one side of
the paper and the Ink Cartridge plastic case is on the other side of the paper.
Push the ink ribbon cartridge (ensuring that the ribbon is located correctly)
fully home.
8.1.14 Using your forefinger turn the knurled knob at the end of the ink cartridge in
the direction of the arrow stamped on the cartridge. Turn until the ink ribbon
becomes tight.
8.1.15 Feed the end of paper through aperture of front panel and slide back into
position.
8.1.16 Pull a little paper through to ensure central and running freely.

8.1.17 Refit printer into the ALXII unit.
8.1.18 Gently push the printer down until it locates correctly.
8.1.19 Turn the knurled knobs in the clockwise direction to tighten. Ensure these are
Finger tight, do not use tools to tighten.
8.1.20 Tear off any excess paper.
8.1.21 Test printer by switching on the ALXII unit and then press the blue flashing
„Start‟ button. Ensure that the paper feeds freely and the text prints clearly.

8.2 INK RIBBON CHANGE
8.2.1 To remove the ink cartridge follow steps 8.1.1 to 8.1.5 as detailed under the
paper roll changing section.
Note: you do not need to remove the paper roll, the paper can be left in place
and the new ink cartridge slid over the top of the paper.
8.2.2 Follow steps 3.1.14 to 3.1.22 as detailed under the paper roll changing
section to refit the ink cartridge and printer unit.
8.3 PRINTER LIFE
8.3.1 The manufacturer of the printer states that the mechanism has a life
expectancy of approximately 300 hours of running time.
8.3.2 The calibration engineer will recommend when the printer mechanism should
be changed.
8.4 CURRENT PROBE ZERO
8.4.1 After long periods of use the current clamp may retain some residual
gaussing causing the ammeter to read a current value greater than 15 amps.
When this occurs the clamp should be zeroed.
8.4.2 Connect the current clamp to the ALXII input socket . DO NOT CONNECT
THE CLAMP TO THE WELDING SET.
8.4.3 Power up ALXII unit using Power „On/Off‟ button
8.4.4 Once the ALX II Software has booted up select „Log‟. When the ALX II Logging
screen is displayed use the „Menu‟ button to display the second level of menu
buttons.
8.4.5 Select „Sensor SetUp‟ once pressed a window will appear listing the ALX II
transducers. It should already have the „Current Channel‟ selected, if it does not then
use the mouse to select the Current Channel.
8.4.6 Ensure that the sensor set up has the Current Clamp selected, (not In-Line Box). If
necessary select Clamp.
8.4.7 Once the Sensor Set Up window is opened the LCD Style Display on the ALX II
Logging screen will display the Current (Amps) with a resolution down to 0 (normally
it starts at 15 amps).
8.4.8 On the current clamp handle adjust the knurled knob marked „zero‟ until the current
(Amps) LCD Style Display on the ALX II Logging screen reads 0.
Note: Sometimes when zeroing the current clamp it may not be possible to
achieve „0‟. If this occurs adjust to the lowest possible value. If you
cannot adjust the offset value to less than 15 amps please contact your
nearest ALXII service centre.
12.5.9 Close the Sensor Set Up window and the ALX II is now ready for use.

8.5 WIRE FEED SPEED TACHOMETER IDLER WHEELS
8.5.1 The wire feed speed tachometer is supplied with a kit of 4 grooved idler wheels and
an hex head allen key. Always ensure that the correct size idler wheel is used with
the wire diameter being measured. The following tables shows the size of the wheel
and the ranges of wire diameters they can be used on.
Groove Depth (mm) Wire Diameter Range (mm)

0.5 0.6 to 1.6
1.0 1.0 to 2.8
1.6 1.6 to 4.5
2.1 2.0 to 6.0
8.5.2
1) The Tacho is supplied with 2) Insert the Hex Head Allen 3) Remove the Hex Socket
4 grooved idler wheels and a Key into the Hex Socket Screw Screw and the idler wheel.
suitable Hex Head Allen Key. And unscrew.
8.5.3
4) Select and insert the correct 5) Insert the Hex Socket Screw. 6) Slide the tacho body away
size grooved idler wheel. To align the central hole in the from the idler wheel to release
idler wheel you can slowly let the tension on the wheel and
the tacho body close against then tighten the screw finger
the Idler wheel. tight. DO NOT OVER TIGHTEN
8.5.4
7) Ensure that the shroud 8) Finally clip the tacho onto the
moves freely up and down. Wire and ensure the idler wheel
runs freely.

8.6 BATTERY PACK INSTALLATION/REMOVAL
The ALX II is a Portable Unit which can be powered either by the battery pack supplied with
the unit or via a mains powered DC Adaptor which is also supplied with the unit.
8.6.1 To install the battery pack first of all align the battery pack guide rails at the top of the
battery pack with the support guide rails on the base of the ALX II unit.
8.6.2 Once the battery pack is aligned with the guide rails slide the pack fully into the ALX
II.
8.6.3 For the battery pack to locate correctly the „D‟ rings on the front of the battery pack
should be vertical. Once located the „D‟ rings should be turned through 90 degrees
so as they lock the battery pack in place.
8.6.4 To remove the battery pack the „D‟ rings should be turned through 90 degrees so as
they are in the vertical position. The battery pack can then be extracted from the ALX
II unit using the „D‟ rings.

8.7 BATTERY STATUS
8.7.1 The battery voltage is displayed on the ALX II Logging Screen
8.7.2 The battery is a 15 volt NiMH rechargeable battery pack. The nominal
voltage when fully charged is approximately 15 volts.
Note: If the ALX II is running on mains power the battery voltage on the
screen will always be 18.3 volts.
8.7.3 When the battery voltage drops below 13 volts the unit has approximately 15
minutes of use left, a warning message will appear on the ALX II Screen to
warn the operator.
8.7.4 When the battery voltage drops below 13 volts the ALXII unit will
automatically switch off to preserve the battery.
Note: The battery should be recharged before it drops below 13 volts.
8.8 BATTERY CHARGING
8.8.1 The re-chargeable 15v NiMH battery pack must be removed from the ALXII
for recharging and only the battery charger supplied with the ALX II can be
used.
Warning: Do not attempt to use any other charger except the unit supplied
with the ALX II. Using the incorrect charging unit could cause serious damage.
8.8.2 Ensure the ALXII charger is switched „Off‟. Connect the 3 step ALX II
charger to the 4 pin input socket on the right hand side of the ALX II Battery
pack.
8.8.3 Connect the charger to a suitable mains supply. The Following details the
Charge Cycle and LED Indications for the ALX II battery charger.
LED Mode
Yellow Battery not connected
Yellow Battery initialisation and analysis
Orange Fast charge
Green with intermittent yellow flash Top off charge
Green Trickle charge
Alternating orange-green Error
8.8.4 When fully charged disconnect the charger from the mains supply prior to
disconnecting the charger from the ALXII unit.

8.9 BATTERY PACK – ADDITIONAL NOTES
1) Always use the correct battery charger to re-charger the ALX II

battery pack.
2) Never store or charge the ALX II battery pack in direct sunlight.
3) If the ALXII unit fails to re-charge it is possible that the thermal trip
has activated in the battery pack, disconnect the battery pack from the
charger and allow at least 90 minutes for the battery to cool off before
re-connecting.
4) Never attempt to re-charge the ALX II battery pack after it has already
completed a charge cycle. You must allow the battery pack to dis-
charge either fully or partially before attempting to re-connect the
battery pack to the charger.
5) The ALX II battery pack is a multi-cell NiMH unit and should be
disposed of accordingly or by returning to TVC for disposal.

9 FAULT FINDING & DIAGNOSIS
This section is an operator guide to the most common faults that may be
encountered whilst using an ALX II, it is by no means an exhaustive list of all faults
that may occur.
9.1.1 FAULT: ALXII will not power up.
(a) Check the fuse on the front panel – if blown replace and retry.
(b) Place the battery on charge for about an hour (this will given enough
charge to be able to power up the unit assuming the battery is flat). If
the unit will now power up the problem was a flat battery, place
battery on charge for a full charge before using.
9.1.2 FAULT: ALXII unit will not power down („On/Off‟ switch inoperative).
Remove the unit fuse with the „On/Off‟ switch in the Off position, this will
normally cause the unit to power down correctly.
The fault is a sticking switch. If the problem becomes a regular occurrence

return the unit for repair and servicing.
9.1.3 FAULT: ALXII unit powers and appears to function Ok however once the
headers have been printed the unit continually prints 15/16 amps even
though the weld has not started. This is because the current clamp needs to
be zeroed. Refer to section 8.4 of the Servicing Section for this procedure.
9.1.4 FAULT: No voltage reading.
Check that the connections have been made to the correct points, and that
the connection points are clean and not corroded/dirty.
9.1.5 FAULT: Wirefeed reading unstable or non-existent.
Check the tachogenerator and connections for signs of damage and check
that the connections have been correctly made.
If there is no obvious damage and all connections are secure do the

following:-
(a) Check that the correct size grooved idler wheel is fitted to the tacho.
See section 8.5 for further information on wheel sizes and fitting.
(b) Remove the shroud from the tacho, by removing the idler wheel and
then by sliding the tacho body out of the shroud.
(c) Check that the drive roller has not become loose on the shaft of the
tachogenerator.
(d) Check that the rollers are not heavily worn – if so replace the drive
and idler rollers.
If none of the above applies, return the unit for investigation/repair.

9.1.6 FAULT: Printout line spacing erratic/uneven.
(a) Check that the paper has been fed through the printer mechanism
correctly – refer to section (8.1) of the operating instructions.
(b) Check that the ribbon cartridge had not jammed or become
excessively stiff in operation – replace the ribbon if necessary.
(c) Ensure that the correct type/grade of paper is being used – heavy-
weight/thicker grades of paper will tend to stress the mechanism.
9.2 RECOMMENDED SPARES
Item Quantity Description

1 1 Battery Pack
2 20 Printer Paper Rolls
3 5 Printer Ink Ribbons
4 5 Main Unit Fuses
5 1 WFS Tacho Wheel Set

10 ADDITIONAL USER INFORMATION
10.1 Calibration
It is recommended that the ALX II is serviced and re-calibrated on a 6

monthly basis by an approved calibration/repair workshop. For a full listing of
TVC approved calibration/repair workshops please contact TVC or your
equipment supplier.
10.2 Equipment Disposal
To meet our obligations under the WEEE directive we have financed a

collection point for the recycling of this product once it has reached the end of
its normal working life. In these circumstances, please contact us for further
instructions.

11 ALX II RS
11.1 General Description
The ALXII RS unit differs from the ALXII Portable in hardware only. The
setup, operation and software are identical and the relevant sections for the
ALXII Portable can be referred to.
The ALXII RS is a stand-alone battery powered unit which conditions
incoming signals from the probes to be fed to a computer via a standard USB
connection. Under normal circumstances we recommend the use of a laptop
computer with the following minimum specification.
Recommended spec for a PC to use with the ALXII RS.

4 GB Ram,
60 GB hard drive with 5 GB free,
1.5Ghz processor speed,
Dedicated USB connection,
Win XP with service pack 3,
Microsoft office (for reporting).

If preferred a semi-permanent setup using a desk top computer can be

utilised provided the specification is as stated above.
All probes are connected in the same way as for the ALXII Portable.
Connections to the ALXII RS unit are made on the back panel of the unit. All
connections are gendered and configured to prevent incorrect connections.
The battery fitted to the ALXII RS is a 12 volt sealed, gel filled lead acid type
which requires no maintenance other than regular charging. The ALXII RS
unit is fitted with a battery status meter which indicates the state of charge to
the operator.
In addition a “5v” indicator confirms the supply to the ALXII RS unit‟s

electronics is present. In the event of a fuse blowing this indicator will turn off.

The fuse is a 5 amp, 20mm type and is located on the unit back panel.
The ALXII RS units battery charger is a three stage unit with the following
indications.
RED – Indicates a flat battery on charge
AMBER – Indicates the battery has reached 60% charge
GREEN – Indicates a fully charged battery
In addition to the ALXII RS battery, close attention should be paid to the state
of charge of the laptop battery.
As with all TVC welding data logging systems the units are protected against
damage from HF processes. In order to maintain this protection TVC
recommend that both the laptop and ALXII RS unit are disconnected from
their chargers when using HF processes such as GTAW. When using non HF
processes the units can be run with the battery chargers connected.

11.2 Connection to a PC
Connecting the ALXII RS to the PC is via a standard USB port. TVC

recommend that the port used is dedicated to the ALXII RS unit. We do not
recommend the unit is connected via a USB hub, which is sharing the port
with other equipment. The following paragraphs detail the connection process
to a laptop computer. These instructions apply the same to a suitable desk
top or computer tower.
If the laptop PC was supplied by TVC then the initial connection process will
be completed prior to delivery. The dedicated USB port will be clearly
marked. The ALXII RS unit MUST be connected to this USB port when in
use. Connection to another USB port will result in the following error code.
If the above appears please reconnect to the correct port.

If the connection to the correct port is made and the above error appears,
please restart the system. If the problem persists, please contact TVC or your
local agent for assistance.
Connection to the laptop is made via the USB connection on the rear of the
ALXII RS and the dedicated USB connection on the laptop. A suitable
connection lead is supplied with the ALXII RS.
The USB connection must be made prior to switching on the laptop
computer. The power to the ALXII RS unit is controlled via the laptop USB.
Switching on the laptop will activate the power supply from the battery inside
the ALXII RS
If the laptop has been sourced from an alternative supplier, then the software
for the ALXII RS will need to be loaded and the initial connection process
completed. See annexe A1 and A2.

Annexe
Annexe A1
ALXII-RS Computer Setup For Windows XP

Note: 1. ALXII-RS software must be installed BEFORE the unit is connected to a computer
via USB.
2. Due to Windows issues, Windows XP can only run ONE RS unit at a time
1. Installing the ALXII-RS Software

The ALXII-RS installation will install the required files to your computer, parts of the
installation will require the computer to have ‘administrator rights’ to copy files on to the
computer. If you are unsure this affects your computer, please contact your I.T. department
for assistance.
Run the ALXII-RS installation
program called:
ALXIIRS Installation (version).exe
and you will be prompted with the
initial installation screen
Click Next to continue the

installation or Cancel to stop the
installation.
For the selected installation

destination, it is best to use the
default location which initially
appears.
C:\Program File\TVC
Click Next to continue.
If you wish to rename the shortcut

seen on the Windows start menu,
change the default title.

If you require a desktop icon to

launch the ALXII-RS program, tick the
appropriate box.
Once the installation is complete a

new icon will appear on your
computer desktop, allowing you to
quickly launch the ALXII-RS software.
Make sure the Restart Computer box

is also ticked.
Review the installation options and

click the Install button to continue.
If not correct use the Back button to

return to the screen to be changed.
The installation will now start

copying the required files to your
computer’s hard disk.
Once the installation is complete,

Computer registry will be updated.
Click the OK button when this process
is complete.

Dongle drivers will now be installed. Click

the OK button when prompted to
continue.
The installation will now run another

installation program which is used to
install device software for the external
printer.
Click the Next button to start the

installation.
Wait for the installation to finish and click

the Finish button to close this form when
prompted.
The installation is now finished. Select

the option Yes, restart the computer now
and click the Finish button.


Connecting the ALXII-RS to the computer
Before the ALXII-RS can be used, the computer needs to be setup with the ALXII-RS
equipment. This is achieved by allowing the computer to recognise the hardware contained
in the ALXII-RS unit and installing the hardware device drivers.
Connect the ALXII-RS unit into the computer

using the USB cable. Windows will automatically
detect the new hardware and will attempt to
install its drivers.
This process will occur several times and you will

have to wait for Windows to load the driver
setup screen.
If Windows prompts you to Connect to Windows

Update, select No, not this time.
Click Next to continue
You will now be asked to how to install the new

Hardware. Try installing using the
recommended option, but if this fails to install,
click the Back button until you see the adjacent
screen and select Install from a list or specific
location.
You may need to instruct Windows where the

required driver files are to install the new
hardware.
Tick the box Include this location in the search
Click the Browse button and select the folder
location where the driver files are kept (or type
the location manually). Locations can be:
 C:\Windows\Inf (For USB 2.0

HUB)
(For USB Key)
(For USB Device)

 C:\Program Files\DAQ\ (Windows version)
(This is where installation files are likely to be

kept)
Click the Next button to install the Hardware
Once all items are installed, Windows will report

the following message.
Restart the computer and run the ALXII software for

the first time.
The ALXII software can be run from the Windows

Desktop Icon.
Each RS unit will be shown as a drive in “My Computer” and will be labelled with the RS
unit number and its data-card serial number.

2. Trouble Shooting
1. The installation does not complete or error messages are show

Make sure your virus checker has not interrupted the installation.
The computer may not have the correct ‘administrator rights’ required to install the
program. Please contact your I.T. department for support, on providing access
rights to your computer.
Try re-installing the software again. If the program persists, contact T.V.C.
2. The Hardware device’s will not install, or the drivers are not found
Make sure you have tried using all the specified locations when searching for device
drivers.
Locations
 C:\Windows\Inf
 C:\Windows\System
 C:\Windows\System32
 C:\Program Files\DaqX
3. The ALXII-RS asks to be reinstalled when another USB port is used.

None of the USB ports on a computer are linked, so when a device is plugged into a
different USB socket, the computer treats the device as a new item. This means you
will have to go through the steps again of setting up the ALXII hardware.
Once the ALXII is setup on a USB port, the computer will remember the device and
will not need to be setup again.
4. The ALXII-RS does not print to the external printer.

The ALXII-RS printer connects to the computer using a port and the software needs
to be setup to use the correct port number. Make sure the ALXII-RS software is
setup to use the correct port by:
1. From the software’s file menu select Printer - Select ComPort
2. Make a note of the selected port number
3. Open the Windows Device Manager and select the device:
Ports (COM & LPT) – Proligic USB-to-Serial...
4. View the selected device’s properties
5. Form device properties, click on the Port Settings tab then click on the
Advanced button
6. Select the COM port used by the ALXII-RS software (if available) and
click the OK button
Make sure the printer is enabled in the ALXII-RS software. From the software’s file
menu select Printer – Enable.
5. Printout is coming out of the wrong RS unit when used with more than one RS
unit.
This can be corrected by changing the selected Com port in the logging software or,
with the software closed, swapping the computer USB ports the RS units are
connected to
Note. If you need support from TVC or your local service centre, please provide exact
details on; the problem, error messages that occurred and the computer details.

Annexe A2
ALXII-RS Computer Setup For Windows Vista / 7

Note: ALXII-RS software must be installed BEFORE the unit is connected to a computer via
USB
3. Installing the ALXII-RS Software

The ALXII-RS installation will install required files to your computer, parts of the installation
will require the computer to have ‘administrator rights’ to copy files on to the computer. If
you are unsure this affects your computer, please contact your I.T. department for
assistance.
Run the ALXII-RS installation program

called:
ALXIIRS Installation (version).exe and
you will be prompted with the initial
installation screen
Click Next to continue the installation or

Cancel to stop the installation.
For the selected installation destination,

it is best to use the default location
which initially appears.
C:\Program File\TVC
If you wish to rename the shortcut seen

on the Windows start menu, change the
default title.

If you require a desktop icon to launch

the ALXII-RS program, tick the
appropriate box.
Make sure the Restart Computer box is

also ticked.
Once the installation is complete a new

icon will appear on your computer
desktop, allowing you to quickly launch
the ALXII-RS software.
Review the installation options and click

the Install button to continue.
If not correct use the Back button to

return to the screen to be changed.
The installation will now start copying

the required files to your computer’s
hard disk.
Once the installation progress bar has

finished, the program will display the
message “Registry setup complete”.
Click the OK button to continue

The installation will now install device software
produced by Microcsm Ltd.
Tick the box labelled Always trust software from

“Microcosm Ltd”.
Click Install to continue.
Wait until the setup reports the Dinkey Dongle

drivers have been successfully installed and click
the OK button to continue.
Note. These drivers may take upto a minute to

install and the completion message may be
hidden, so check the task bar for the message
symbol.
The installation will now run another installation

program which is used to install device software
for the external printer.
Click the Next button to start the installation.

Wait for the install to finish.
Click the Finish button to close this form.
Once the installation is complete, select the

option to restart the computer and click the
Finish button.

4. Connecting the ALXII-RS to the computer
Before the ALXII-RS can be used, the computer needs to be setup with the ALXII-RS
equipment. This is achieved by allowing the computer to recognise the hardware contained
in the ALXII-RS unit and installing the hardware device drivers.
Connect the ALXII-RS unit into the computer

using the USB cable.
Windows will automatically detect the new

hardware and will attempt to install its drivers.
To show this, Windows will produce an
installation dialog box which can be clicked on
to view the hardware being installed
Once Windows has finished installing the

hardware devices, you will see either a tick or a
cross, next to the hardware item(s) being
installed.
A tick means the hardware was installed

correctly.
A cross means Windows could not install the

hardware automatically.
Click the Close button to continue
If there were hardware items that could not be

installed using the automatic Windows system,
they will now need to be installed manually by
using the Windows Device manager.
To open the Device Manager click on the

Windows Icon and select Control Panel.

Click on the item System and Security.
In the System area select the option Device

Manager.
Hardware devices that have not been installed

are labelled with a ’!’ (as shown next to the
USB2 Device).
Right mouse click on the device labelled USB2

Device and select the option Properties. Once
the Properties page has opened select the Driver
tab and click on the Update Driver button.
Try selecting the option to automatically search

for the drivers. If Windows still can’t install the
device, select the option Browse my computer
for driver software.
You may need to instruct Windows where the

required driver files are, to install the new
hardware.
Tick the box Include subfolders.
Click the Browse button and select the folder

location where the driver files are kept.
Locations can be:
• C:\Windows\system32
• C:\Windows\system
(For USB2 Device)

• C:\Program Files\DAQ\ (Windows
version)
(This is where installation files are likely to be

kept)
Click the Next button to install the Hardware.

Wait until the installation finishes and

Windows will report if the installation
was a success or not.
Restart the computer and try running

the ALXII software for the first time.
The ALXII software can be run from

the Windows Desktop Icon.
Each RS unit will be shown as a drive in “My Computer” and will be labelled with the RS
unit number and its data-card serial number.
5. ALXII-RS Software Information

The ALXII-RS software operates as a rack system which can log data from up to four RS
units simultaneously.
When the software loads it will list all of the detected

RS units. Before logging starts you will be prompted
for how many RS units you want to use to log data
During logging each RS unit is assigned its own

logging panel called a “WorkStation” which is
assigned a unique workstation number (W1 to W4)
making it easier to identify which RS unit is assigned
to each station
The WorkStation number can be swapped between RS

units by clicking on the current station number
It is recommended to keep using the same

computer USB ports per RS unit once the RS unit has been setup. This stops any
confusion of setting up the RS units on another USB port.

Trouble Shooting
6. The installation does not complete or error messages are show

Make sure your virus checker has not interrupted the installation.
The computer may not have the correct ‘administrator rights’ required to install the
program. Please contact your I.T. department for support, on providing access
rights to your computer.
Try re-installing the software again. If the program persists, contact T.V.C.
7. The Hardware device’s will not install, or the drivers are not found
Make sure you have tried using all the specified locations when searching for device
drivers.
Locations
 C:\Windows\Inf
 C:\Windows\System
 C:\Windows\System32
 C:\Program Files\DaqX
8. The ALXII-RS asks to be reinstalled when another USB port is used.

None of the USB ports on a computer are linked, so when a device is plugged into a
different USB socket, the computer treats the device as a new item. This means you
will have to go through the steps again of setting up the ALXII hardware.
Once the ALXII is setup on a USB port, the computer will remember the device and
will not need to be setup again.
9. The boarders overlap each program window.

This is a Windows setup issue, which can be resolved by:
1. Open the Control panel and select the option Appearance and Personalization
2. Select the option Personalization and then select Windows color
3. Select the option Advanced appearance settings
4. From the Item box, select Boarder Padding and set the Size section to 1
5. Click the Apply button
10. The ALXII-RS does not print to the external printer.

The ALXII-RS printer connects to the computer using a port and the software needs
to be setup to use the correct port number. Make sure the ALXII-RS software is
setup to use the correct port by:
7. From the software’s file menu select Printer - Select ComPort
8. Make a note of the selected port number
9. Open the Windows Device Manager and select the device:
Ports (COM & LPT) – Proligic USB-to-Serial...
10. View the selected device’s properties
11. Form device properties, click on the Port Settings tab then click on the
Advanced button
12. Select the COM port used by the ALXII-RS software (if available) and
click the OK button
Make sure the printer is enabled in the ALXII-RS software. From the software’s file
menu select Printer – Enable.

11. Printout is coming out of the wrong RS unit when used with more than one RS
unit.
This can be corrected by changing the selected Com port in the logging software or,
with the software closed, swapping the computer USB ports the RS units are
connected to
Note. If you need support from TVC or your local agent, please provide exact details on;
the problem, error messages that occurred and your computer details.

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ALX II Portable Operators Manual

ALXII MANUAL Page 1 of 119

SECTION 1 ....................................................................................... / Introduction

1.1 ........................................................................................ / Revision

SECTION 2 ................................................ / Operating Instructions – Basic ALX II

2.1 ................................................................................... / Introduction

SECTION 3 ............................................................. / Pipeline Procedure Software

3.1 ........................................................................................... / Set Up

SECTION 4 ........................................................... / Standard Procedure Software

4.1 ........................................................................................... / Set Up

SECTION 5 ........................................................... / Pulse Measurement Software

5.1 ................................................................................... / Introduction

ALXII MANUAL Page 2 of 119

SECTION 6 ............................................................................... / Robotic Software

SECTION 7 ........................................................................... / Reporting Software

7.1 .................................................. / Tile Screen and Report Selection

SECTION 8 ........................................................................................... / Servicing

8.1 ................................................................... / Printer Paper Change

SECTION 9 ..................................................................... / Fault Finding/Diagnosis

9.1 ......................................................................... / Fault Descriptions

SECTION 10 ............................................................. / Additional User Information

10.1 ................................................................................... / Calibration

SECTION 11………………………………………………………/ ALXII RS

11.1……………………………………………………/ General Description

Revision No: Details: Author: Date:

ALXII MANUAL Page 4 of 119

ALXII MANUAL Page 5 of 119

The ALXII may best be described as a versatile, instrumentation package dedicated

1.4 WARNINGS/PRECAUTIONS – The following must be read before

1. The monitor must not be connected to or disconnected from a welding

3. The unit must not be powered up or reset whilst weld monitoring is in

4. Do no allow the unit to become heavily contaminated with weld dust.

5. All fuses must be replaced with correct type and rating.

6. Do not use damaged probes (especially applicable to TIG Voltage

8. No user serviceable parts are in the main ALXII unit.

ALXII MANUAL Page 6 of 119

1.5 ALXII Primary Parameters

Welding Current (AMPS)

The current is measured by using a „hall effect‟ current probe clamped

Arc Voltage (VOLTS)

Arc voltage, the electrical representation of arc length, is particularly

Wire Feed Speed (WIRE) – (Optional).

The tachogenerator is clipped on to the welding wire and the system is

Arc Time (SECONDS)

Real Time Heat Input (J/mm) – (Optional)

ALXII MANUAL Page 7 of 119

1.6 ALXII Secondary Parameters

ALX II Secondary parameters – Temperature, Gas Flow and Traverse

Measurements of pre-heat and interpass are important in welding processes

Shielding Gas Flow Rate

Traverse Speed (Boom or Bogey)

To measure this an optical incremental encoder is fitted to either the boom or

ALXII MANUAL Page 8 of 119

1.7 ALXII Averaged and Totalled Parameters

During welding, these 4 parameters are averaged every 2 seconds. At the

Total Values of the Cumulative Parameters

The cumulative parameters are:-

Arc energy is expressed in kilojoules (kJ). It is calculated from the average

Wire payoff, the total quantity of wire consumed in MIG/MAG or submerged

Heat Input per Unit Length

ALXII MANUAL Page 9 of 119

1.8 ALXII Unit Layout & Functions

Fig 1 – ALX II Front Panel:-