Fronius Virtual Welding Operating Instructions Manual Download Page 25

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Work table

Workpiece holder

Workpiece single-V butt weld layer 1

Workpiece single-V butt weld layer 2

Workpiece fillet weld

Workpiece pipe

Housing of system components in the StandUp terminal:

The StandUp terminal is supplied with two
keys in a plastic pouch. One key locks the
upper part containing the technology. The
other key locks the lower part where the
system components are located.

Summary of Contents for Virtual Welding

Page 1: ...nts on elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0089 EN 001 04112019 Virtual Welding Operating Instructions Training EN ...

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Page 3: ... essential prerequisites for excellent results Explanation of safety symbols DANGER Indicates immediate and real danger If it is not avoided death or serious injury will result WARNING Indicates a potentially dangerous situation Death or serious injury may result if appropriate precautions are not taken CAUTION Indicates a situation where damage or injury could occur If it is not avoided minor inj...

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Page 5: ... Touchscreen and sensor 29 General 29 Touchscreen and sensor 29 Control elements and connections 30 StandUp terminal controls and connection sockets 30 Controls and connection sockets on the MobileCase 31 Mains switch with mains connection 32 Installation and commissioning 33 Before installation and commissioning 35 Safety 35 Setup regulations 35 Installation 37 StandUp terminal Installation and f...

Page 6: ...nistration 75 Terminal management Additional settings 77 Additional settings Overview 79 Additional settings Overview 79 Settings 81 Settings activating modes 81 Settings activating VR glasses 81 Course mode 82 General 82 Training 82 Ranking list 86 Profile 88 Log in and registration 89 Select language 91 Showroom mode 93 General 93 Try out now 93 Training 94 Open mode 95 General 95 Open training ...

Page 7: ...e model 134 ScanDisk 135 Calibrating the touchscreen 136 Touchscreen test 137 Adjusting the volume 138 Troubleshooting and maintenance 141 Troubleshooting 143 General 143 Safety 143 Fault diagnosis 144 Care maintenance and disposal 147 General 147 Safety 147 Every start up 147 Every 6 months 147 Disposal 147 Update 148 Installing updating the software 148 Appendix 151 Technical data 153 Special vo...

Page 8: ...8 LAN 163 PIN 163 Point to Point Protocol 163 PPPoE 163 PPTP 163 Protocol 163 RAM 164 S0 bus for ISDN 164 Server 164 SIM card 164 Splitter 164 Subnet mask 164 TCP IP 164 UMTS 164 WCDMA 164 WEP 165 ...

Page 9: ...nstructions carefully The operating instructions must always be at hand wherever the device is be ing used In addition to the operating instructions attention must also be paid to any generally applicable and local regulations regarding accident preven tion and environmental protection All safety and danger notices on the device must be in a legible state must not be damaged must not be removed mu...

Page 10: ...ould never be modified without authorisation handled improperly operated with software other than that supplied by the manufacturer operated maintained or repaired without observing the operating instruc tions The device is designed for use in a dry and enclosed environment The man ufacturer is not liable for any damage caused by use in a different environ ment The manufacturer likewise accepts no...

Page 11: ...ons instructed to do so undertake to observe the basic instructions regarding safety at work and accident prevention to read and observe the Safety rules section and the warning notices in these operating instructions Before leaving the work area ensure that people or property cannot come to any harm in your absence The mains voltage and frequency must conform to the data on the rating plate The V...

Page 12: ...deemed gross negligence The manufacturer shall not be held liable for any damage arising from such usage Switch off unused devices Wear a safety harness if working at height Before working on the device switch it off and pull out the mains plug Attach a clearly legible and easy to understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again...

Page 13: ...ins connec tion additional measures are necessary e g use of a suitable line filter b No changes to the device Changes made to the device without the agreement of the manufac turer may lead to withdrawal of the operating licence c If the device appears to interfere with reception of radio or TV signals or the operation of other equipment Turn the device on and off to confirm that it is a source of...

Page 14: ...ice that topples over can easily kill someone Set up the device in a dry and enclosed environment on a firm supportive horizontal surface making sure it is stable Trained personnel must fasten the Virtual Welding terminal to the wall or anchor it firmly to the floor using the holders provided It is strictly forbidden to install the Virtual Welding terminal in a damp or wet environment or on a surf...

Page 15: ...d accident prevention regulations This applies especially to guidelines regarding the risks arising during transport Transport the device only in the original packaging The packaging has the fol lowing item numbers 42 0411 0090 MobileCase packaging 42 0411 0104 Terminal packaging After transporting the device the device must be visually inspected for dam age before commissioning Any damage must be...

Page 16: ...l and Electronic Equipment and its im plementation as national law electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling fa cility Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area Ignoring this European Directive may hav...

Page 17: ...at the time of printing We reserve the right to make changes The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the pur chaser If you have any suggestions for improvement or can point out any mistakes that you have found in the instructions we will be most grateful for your comments ...

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Page 19: ...General information ...

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Page 21: ...ore realistic Operation and standard display are via a 22 inch high resolution touchscreen A sto rage space is provided for necessary equip ment such as the helmet workpieces and welding torch For basic training help features appear on the display to allow the trainee to internalise the principal movements step by step so that they learn the required skills quickly and in a goal orientated way In ...

Page 22: ...dying and obeying all safety and danger notices carefully performing all stipulated inspection and maintenance work connection to the mains power supply according to the values shown on the rating plate setting up in a dry and enclosed environment steady mounting on a firm and horizontal surface using the holders provided The device should never be modified without authorisation handled improperly...

Page 23: ...ion or poorly executed work can cause serious injury or dam age The device may only be installed repaired and maintained by trained and qualified personnel The following doc uments must be completely read and understood These Operating Instructions All the Operating Instructions for the system components especial ly the safety rules Do not dispose of used devices with do mestic waste Dispose of th...

Page 24: ...ories The new version of the VR glasses is requi red for Virtual Welding systems starting with serial number 22216701 onwards To use the new VR glasses with Virtual Welding systems up to and including serial number 22216700 the connecting plate conversion kit 42 0411 0133 is required StandUp terminal connecting plate MobileCase connecting plate ...

Page 25: ...eld layer 2 Workpiece fillet weld Workpiece pipe Housing of system components in the StandUp terminal The StandUp terminal is supplied with two keys in a plastic pouch One key locks the upper part containing the technology The other key locks the lower part where the system components are located ...

Page 26: ...using of system components in the carrying case for the MobileCase The MobileCase is contained in a robust carrying case As well as the MobileCase this also includes a storage space for the system components ...

Page 27: ...Controls connections and mechani cal components ...

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Page 29: ...re context sensitive and can be opera ted by the simple touch of a finger With an authorisation card the sensor 2 acts as follows Touch once Terminal management Touch twice Setup menu Touch three times Calibrate touchscreen This necessitates holding a valid authorisa tion card close to the sensor 2 NOTE Press the red Setup key to open the Setup menu on older systems with no sensor Press once acces...

Page 30: ...ing helmet for connecting the sensor cable of the filler material TIG 3 Connection socket for the welding torch sensor for connecting the sensor cable of the welding torch for connecting the sensor cable of the electrode holder 4 Connection socket for the welding torch control cable for connecting the control cable of the welding torch for connecting the control cable of the electrode holder 5 USB...

Page 31: ...screen More detailed information about Terminal management the Setup menu and Calibrate touchscreen can be found in the corresponding chapters and sections of these Operating Instructions No Function 3 External VGA connection socket for connecting an external monitor or projector in conjunction with a DVI VGA dis tributor 43 0004 4492 4 USB port for connecting the supply cable of the VR glasses op...

Page 32: ...erial TIG 9 Connection socket for the workpiece sensor for connecting the sensor cable of the workpiece holder Mains switch with mains connection The mains switch with fuse and mains connection is located on the back of the StandUp terminal and of the MobileCase No Function 1 Mains switch 2 Fuse Terminal 2 x 3 15 A fast blow MobileCase 2 A fast blow 3 Mains connection 1 2 3 ...

Page 33: ...Installation and commissioning ...

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Page 35: ...etup regulations WARNING A device that topples over can easily kill someone Set up the device in a dry and enclosed environment on a firm supportive horizontal sur face making sure it is stable In the case of the StandUp terminal trained personnel must fasten the device to the wall or anchor it firmly to the floor using the holders provided WARNING Risk of accident due to electric shock or device ...

Page 36: ...radiators air conditioning units sun terraces strong sunlight in areas subject to heavy environmental stress such as smoke and dirt rain and moisture strong magnetism or radio waves heat ambient temperature above 35 C 95 F cold Special regulations apply in rooms at risk of fire or explosion Observe relevant national and international regulations ...

Page 37: ...arts The StandUp terminal comes with two keys One key locks the upper part containing the technology The second key is for the lower part From the plastic film supplied remove the 4 Allen screws and washers for fastening the lower part to the upper part Place the upper part on the lower part Secure the upper part to the lower part using the 4 Allen screws 1 M8 x 80 mm and washers supplied Mounting...

Page 38: ...Description 1 Workpiece holder Connect the sensor cable to the connection socket for the workpiece sensor 2 Headband for VR glasses Connect the sensor cable to the connection socket for the helmet sensor or filler material sensor 3 Welding torch electrode holder Connect the sensor cable to the connection socket for the welding torch sensor Connect the control cable to the connection socket for the...

Page 39: ...lic objects are in the vicinity There must be no metallic objects in the immediate vicinity of the device To allow the device to acclimatise do not plug in the mains cable until the device has been assembled and do not switch on the device for 4 hours after setting up The MobileCase consists of an aluminium carrying case containing all the compo nents Remove the carrying case from the transport pa...

Page 40: ...k table on the front of the MobileCase Take the welding torch the welding helmet and the workpiece holder out of the carrying case MobileCase In stalling system components Connect the system components 1 3 to the right side panel of the MobileCase as shown 3 4 5 1 ...

Page 41: ...ion socket for the welding torch sensor Connect the control cable to the connection socket for the welding torch control ca ble If necessary connect a LAN network cable to the connection socket 4 Connecting the VR glasses NOTE The VR glasses must be connected when starting up the Virtual Welding system If the VR glasses are connected during operation restart the Virtual Welding system in or der to...

Page 42: ...R glasses Detailed information about calibrating the touchscreen can be found in the section Cali brate touchscreen in the chapter Technical settings menu item Connect the mains cable and switch on the de vice WARNING An electric shock can be fatal Use only the mains cable supplied Only plug the mains cable into a correctly earthed sock et WARNING An overheated device poses a risk of fire and dang...

Page 43: ...ed socket Set the mains switch 2 to the I posi tion NOTE Hemisphere tracking must be carried out every time the system is started Detailed information about calibration can be found in the Terminal management section under Calibration hemisphere tracking in the Additional settings subsection 1 2 1 2 3 ...

Page 44: ...al display besides the VR glasses NOTE There is a restriction on the lengths of cables For a correct complete display the connected hardware e g monitor or projector must support 1680 x 1050 resolution When operating with the VR glasses or an additional monitor it takes a few seconds before an image is displayed on the main screen after it has been switched on Display types Connection dia gram Ter...

Page 45: ...e from the monitor 3 to the free VGA connection socket on the optional DVI VGA distributor 2 Route the VGA DVI adapter cable 4 into the cable channels as shown in the Display types connection diagram section Connect the VGA DVI adapter cable 4 to the free DVI connection socket on the op tional DVI VGA distributor 2 Connect the VGA DVI adapter cable 4 to the other end of the external connection soc...

Page 46: ...l to the USB flash drive supplied when you pur chased the Virtual Welding System Update the Virtual Welding system to the latest software version you will find detailed information on this in the Update section Plug the USB flash drive containing the previously copied file into the Virtual Welding system In the Licensemanager dialogue window touch the button next to the license re quired changing ...

Page 47: ...subsection When completing this step teach in at least one authorisation card for administrators Choose model camera position specify whether a StandUp terminal or a MobileCase is being used specify whether a welding helmet headband or a breast clip is being used see Technical settings menu item Choose model subsection When completing this step teach in at least one authorisation card for administ...

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Page 49: ...Terminal management ...

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Page 51: ...risation card using the sensor provided see the Touchscreen and Sensor section on page 29 or the Operating elements and MobileCase connections section on page 31 or b by pressing the Fronius logo Touch the Fronius logo in this sequence left right left right left right An input window with a virtual keypad appears 1 ...

Page 52: ... settings section on page 123 Terminal management allows complete course management for Virtual Welding systems available on the network Overview Virtual Welding terminal management is divided into the following sections Curriculum Courses Ghost Terminals Additional settings The additional settings are described in a separate chapter 2 ...

Page 53: ... Metal active gas welding Metal active gas welding Manual metal arc welding Manual metal arc welding etc IMPORTANT Always organise the curricula in such a way that group specific courses can be de rived from them This makes it easier to handle successive courses with identical training content To delete a curriculum Select the deactivated tab Touch Delete Enter the following code 12111977 Creating...

Page 54: ...mber of training courses After you touch Add training you are presented with an overview of the available training parame ters For each parameter you can touch the Details button to obtain more information about that button Set all parameters and touch the Next button The task overview appears The training tasks can be defined here Example MIG MAG tasks 1 2 3 ...

Page 55: ...etal active gas welding process The colour of this ball GHOST shows how accurately the welding torch is being guided Green very good Yellow within the tolerance Red outside the tolerance requires correction Speed The trainee practises guiding the welding torch at the correct speed and in the correct po sition Proceed as follows Bring the tip of the torch to the target point until it turns green in...

Page 56: ...cross indicates the optimum welding torch position Green optimum position Yellow within the tolerance Red outside the tolerance requires correction Simulation with fixed parameters The simulation provides a representation of real welding with visualisation of the arc and of the formation of the weld seam The welding parameters of wire speed amperage and voltage are pre set for this task The traine...

Page 57: ...eshold for the number of ignition attempts that must be completed successfully can be specified The ignition sequences carried out are displayed as coloured circles Green circle ignition sequence successful Red circle ignition sequence failed Ignition The trainee practises igniting the rod electrode at the correct tilt angle and following the specified ignition sequence The longer of the two rod e...

Page 58: ...s a representation of real welding with visualisation of the arc and of the formation of the weld seam The welding parameters of amperage and voltage are pre set for this task The trainee guides the rod electrode freely without receiving any guidance Torch position The trainee practises guiding the TIG welding torch Torch position and fill er rood The trainee practises guiding the TIG welding torc...

Page 59: ...o practises guiding the welding torch to the workpiece with the correct stick out Speed Stick out Po sition In addition to the welding speed and stick out the trainee also practises guiding the weld ing torch with the torch in the correct position Simulation with fixed parameters The simulation provides a representation of real welding with visualisation of the arc and of the formation of the weld...

Page 60: ...ining Repeat the process described above Once all training courses have been created touch Next An input window with a virtual keyboard appears again in which you name and save the curriculum with the individually defined training courses The name of the curriculum should contain a reference to organisations such as schools training institutes or compa nies 2 3 4 5 6 ...

Page 61: ...61 EN Enter the name of the curriculum in the input window Touch Next to save the curriculum The saved curriculum appears in the curriculum overview on the Own templates tab 7 8 ...

Page 62: ...s The courses can be classified by welding process for example All Metal active gas welding Metal active gas welding Manual metal arc welding Manual metal arc welding etc Touch Courses The overview of all available courses is displayed Use the activate or deactivate function to change the status of the courses Creating a new course Touch New course 1 2 1 ...

Page 63: ... next to the curriculum you want An overview appears showing all training courses in this curriculum The course which you are about to name should be given a name that relates to the target group and the course year Touch Next to give the course a name The newly configured course appears in the overview of all activated courses 2 3 ...

Page 64: ...sed in numerous ways A Variable Ghost can be created for all welding processes The Ghost can be classified by welding process for example All Metal active gas welding Metal active gas welding Manual metal arc welding Manual metal arc welding etc Creating a Ghost Touch Ghost If no Variable Ghost has been created yet the following message appears No Ghost available Please create a new one Touch New ...

Page 65: ...le Ghost is available Otherwise a list of the Ghosts already created appears Select New Ghost or use an existing Ghost as a template if there is already a list of existing Ghosts An input window with a virtual keyboard appears in which you can enter a name for the Variable Ghost Weld position e g PF Layer e g Layer 2 Filler material e g G3 Si1 with a diameter of 1 2 mm Power supply e g TPS 500i We...

Page 66: ... for the corresponding window to appear In the meantime you see the message pro cessing Use the arrow keys to set the required number of steps per workpiece The number of steps per workpiece specifies how many defined periodic welding torch movements the trainee must complete in order to execute the weld seam correctly The setting range is from one step to 125 steps Choose Next to save the number ...

Page 67: ...here to in the longitudinal direction The resulting welding time appears in the field underneath Choose Next to save the welding speed and go to the dialogue box for starting ref erence welding Ghost Executing reference welding NOTE A Ghost can be recorded using the VR glasses Position the welding torch at the start of the weld seam 3 4 1 ...

Page 68: ... start playback of the recording to stop playback You can use the slider to move to any point in the recording If it is no longer needed remove the Playback field by touching the cross symbol If the reference weld proves unsatisfactory touch Repeat to carry out a new refer ence weld Once the reference weld has been completed it can be optimised in many different ways The Variable Ghost becomes an ...

Page 69: ...m To obtain the required dwell times at the edges the optimum start and end point should be in the centre To define the end point of the optimal oscillation select Next the starting point ini tially shown in yellow turns green Use the slider or arrow keys to move to the end point of the optimal oscillation Select Next to save the end point and move on to adjustment of the number of move ment steps...

Page 70: ...to 125 A complete weld seam can be obtained by multiplying a short optimal oscillation Use the arrow keys to set the required number of steps per workpiece Choose Next to save the number of steps per workpiece and move on to adjusting the welding speed Use the arrow keys to set the desired welding speed The welding speed corresponds to the welding torch rate which the trainee must adhere to in the...

Page 71: ...eview but ton Use the slider or arrow key to move to the point from which you want to start the weld ing process Touch the cross symbol to go back to the setting last selected Ghost Setting the stick out and tilt angle Use the arrow keys to adjust the stick out of the wire electrode on the welding torch The adjustment range for the stick out is from 10 to 25 mm 1 2 3 1 ...

Page 72: ...ition value extends from 45 backwards to 45 forwards and permits a tilt angle of 45 to 45 NOTE Extreme welding torch tilt angles particularly in connection with certain constella tions of weld seam profile and stick out can result in the welding torch being shown within the workpiece Select Next to go to the summary of parameter settings for the Variable Ghost 2 3 4 ...

Page 73: ...can enter a description for the Variable Ghost Enter a brief description of the Variable Ghost in the input window Touch Next to save the description of the Variable Ghost The name of the Variable Ghost which you assigned at the beginning now appears in the list of created Ghosts and is available to the trainee from now on 1 2 3 ...

Page 74: ...he following code 12111977 In Virtual Welding robotics a distinction is made between Polygon and Cycles when creating a Ghost Polygon Enables a completely free path to be traced inscription etc Cycles Corresponds to the behaviour described in the previous sections 1 2 3 ...

Page 75: ...ms Terminals Train ing administra tion Touch the Terminals button You will then see a list of the networked terminals and if already defined the courses as signed to them If the same training course is to be assigned to all terminals through cluster networking Select Change next to All terminals If a particular training course is to be assigned to a particular terminal within the framework of clus...

Page 76: ...om which the training course is to be selected You will then see a list of the trainings of the selected course Use the Details button to obtain information about the training content if required Touch Use to select the training course to be assigned to the Virtual Welding system or to all Virtual Welding systems 3 4 5 6 ...

Page 77: ...Terminal management Additional settings ...

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Page 79: ... more customisation options for the Vir tual Welding system available in the following tab Settings Settings activate modes Settings activate VR glasses Coursemode General Training Ranking list Profile Log in and registration Select language Showroom mode General Try out now Training Open mode General Open training ...

Page 80: ...MIG MAG welding torch Note on calibrating a TIG welding torch Calibrate camera settings Calibrate hemisphere tracking Miscellaneous Licensemanager Quiz overview Activate deactivate available quiz Change active quiz Administrate quiz Change robot manufacturer ...

Page 81: ...system leaves terminal management the selected mode is activated Settings activat ing VR glasses If the VR glasses are connected to the Virtual Welding system they can be activated or deactivated using the VR glasses function Detailed information on how to connect the VR glasses can be found in the Installation and commissioning section on page 41 Select VR glasses Press the button next to it chan...

Page 82: ...g lists so that it is possible to address the precise needs of the trainee welder To enter course mode proceed as described in the Terminal management section under Additional settings On the touchscreen to the right of the Fronius logo you will see the name of the logged in welder of the course of the selected training Training The training functions allows the trainee to practise the selected or...

Page 83: ...overview can contain up to five exercises of the following type Speed Speed Stick out Speed Stick out Position Simulation with fixed parameters Simulation with variable parameters Since movements of the welding torch below the workpiece surface are not normally en visaged any movement of the welding torch below workpiece level appears in mirror im age If the welding torch moves downwards below the...

Page 84: ...quires correction Always choose the stick out of the welding torch relative to the workpiece so that the dis tance arrow stays green and the torch tip is always inside the target circle Speed Stick out Po sition In addition to the welding speed and stick out the trainee also practises guiding the weld ing torch with the torch in the correct position If the welding torch points upwards too much a r...

Page 85: ...elding process return to the exercise overview Touch Back to exit the welding environment You are then shown the best results in the form of scores and traffic light colours If the defined threshold has been reached and therefore the next exercise is enabled all the par tial results are shown in green Further procedure for all exercises The first time a training course is started only the first ex...

Page 86: ...lding result which then likewise appears in the ranking list Ranking list The ranking list allows the trainee to compare his own welding results with those of other participants By default the currently assigned course ranking list appears If required touch Select course to access any ranking list The total number of points for the course is made up of all the training results allotted to the cour...

Page 87: ...to select the course In the next dialogue window Course details touch Export to export the course to the USB flash drive 2 Exporting a ranking list To export a ranking list proceed as follows Plug into the system the USB flash drive onto which the course will be exported In terminal management touch Courses 1 2 3 4 ...

Page 88: ...rnatively you can start the log on process by touching the Logon button To enter or change data select the Logon button next to the entry to be changed This opens a virtual keyboard with which you can enter and save the change Note that there is a shift key allowing you to select upper or lower case or special characters To check your own welding results select the Welding results button The follo...

Page 89: ...t to the corresponding entry to open the relevant ranking list and obtain a comparison with other welders Log in and regis tration To be able to use all functions and advantages of the Virtual Welding system it is neces sary to register with the system After touching the Login button you can create your own profile which is password protected Select the Login button to start registration An input ...

Page 90: ...ser name and a memorable password Touch Next You are invited to create a personal profile Select Yes This opens an input window in which you can enter the following details First name Last name E mail address 2 3 4 ...

Page 91: ...surname appear on the touchscreen to the right of the Fronius logo The Login button changes to Logout Use this button to log out of the Virtual Welding system Select language Eight pre set languages are available on the Virtual Welding system six of which can be displayed in the foreground Select Language A selection window appears containing buttons for the different languages 5 6 1 ...

Page 92: ...ing system Detailed information about higher level language settings can be found in the section Other Settings menu item under Language settings Note Virtual Welding is available in many languages but only eight languages can be se lected for each country configuration dongle Of these languages six can be defined for the selection window 2 ...

Page 93: ...Try out now For an initial introduction when you select Try out now the Virtual Welding system takes itself through all the virtual practice tasks Touch the Try out now button This opens a window containing the parameter overview To obtain details of the defined welding parameters and learn more about welding Select the Details buttons Select Start to start the wizard The Virtual Welding system no...

Page 94: ...irst exercise Select Info to familiarise yourself with the first exercise Touch Start to begin the first exercise As soon as the welding environment appears press the torch trigger to start the first exercise After completing the exercise touch the Playback button to analyse the welding process you have just carried out view the achieved result repeat the welding process return to the exercise ove...

Page 95: ...any training plan In this mode it is not possible to save or archive the scores obtained To enter Open mode proceed as described in the Terminal management section under Additional settings Open mode includes the Open training and Quiz functions which are explained below Open training Touch Open Training This opens a window containing the parameter overview 1 ...

Page 96: ... the exercise overview The exercise overview shows all available exercises Before touching Start to begin the desired exercise Select Info to familiarise yourself with the desired exercise Select the Start button for the desired exercise to begin that exercise As soon as the welding environment appears press the torch trigger to start the first exercise 2 3 4 5 6 ...

Page 97: ... the welding process return to the exercise overview Touch the Back button to exit the welding environment When you exit the welding environment with the Back button you are shown the best re sults in the form of scores with traffic light colours An explanation of the menu subitems Ranking lists and Profile can be found in the Course mode section 7 8 ...

Page 98: ...torch the electrode holder etc rela tive to the overall system depending on the welding process On the Calibration tab touch the Start button next to location adjustment Select the appropriate calibration process depending on the welding processes avail able Welding torch calibration will be started 1 2 ...

Page 99: ... Next the coordinates of the position are saved Position the welding torch according to the images on the touchscreen if necessary correct the position using the arrow keys Select Save to end system calibration and exit terminal management Note on calibrat ing a TIG welding torch NOTE When using a filler metal for TIG as illustrated pay attention to the notch 1 2 3 4 ...

Page 100: ...e resulting perspec tive Touch the Start button next to Camera Settings A dialogue window where you can enter settings for the VR glasses Glasses by adjusting the zoom level Zoom the welding helmet Helmet by adjusting the zoom level Zoom and height of the viewing angle Height Touch the Glasses or Helmet button A dialogue window e g for the welding helmet appears with a slider to adjust the height ...

Page 101: ...ctrode holder welding helmet etc each contain a position sensor which orientates itself using the magnet in the workpiece surface When entering the settings for hemisphere tracking the welding torch electrode holder welding helmet etc are positioned at specific points above the workpiece surface This enables the system to learn which magnetic pole is assigned to the area above the workpiece surfac...

Page 102: ...lding helmet Hold the welding torch or electrode holder and the welding helmet above the work ta ble Touch Next In the next dialogue window touch Finish NOTE If the calibration of the hemispheres is lost during the welding task 3D application the calibration process can be started by pressing the Fronius ellipse 3 seconds 1 2 3 4 5 ...

Page 103: ...rdware dongle serial number e g 14078 Country country of origin AT for Austria Product product manufacturer Fronius The following are required before you can use device functions such as MIG MAG simula tion TIG simulation simulation of manual metal arc welding or robot simulation Robotics Serial number of hardware dongle can be found in the Licensemanager dialogue window described below Serial num...

Page 104: ...or custom quizzes which can be accessed or created using the following menu items Quiz available Change active quiz Administrate quiz Activate deacti vate available quiz Change the button next to the Available Quiz menu item to activated or deactivat ed Press the apply button Change active quiz Touch Show next to the Change active quiz menu item Select the desired quiz from the list that is now di...

Page 105: ...d in the relevant language only Once it has been exported the quiz is saved in a pre defined folder In order for you to be able to edit an existing quiz or create a new personalised quiz Quiz Editor is provided on the USB flash drive for use on a PC Exporting a quiz to a USB flash drive Insert the USB flash drive Touch Export next to the relevant quiz 1 2 Importing a quiz from a USB flash drive To...

Page 106: ...dd question button to add a new question If applicable use the Delete question button to delete the open form entry and thus the corresponding question Select the Save button and save the quiz in the quiz folder on the USB flash drive this will be the same folder that the QuizEditor was started from Starting the quiz editor The Quiz Editor is saved on the USB flash drive in the quiz folder 1 Openi...

Page 107: ... as for editing an existing quiz Select the Save button and save the quiz in the quiz folder on the USB flash drive this will be the same folder that the QuizEditor was started from 1 2 3 Temporarily deactivat ing an existing quiz In the Administrate quiz window shown below touch deactivate on the activated tab 1 Reactivating a tempo rarily deactivated quiz Touch activate next to the relevant quiz...

Page 108: ...robot manufacturer If you have a Robotics licence for robot simulation the Change robot manufacturer menu item is available In the Change robot manufacturer menu the robotic arm displayed during Robotics weld ing can be changed Permanently deleting a temporarily deacti vated quiz Touch the wastepaper basket icon next to the relevant quiz and delete it using the code 12111977 It is only possible to...

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Page 111: ...Setup settings ...

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Page 113: ...alibration hardware test etc Overview of but tons Below is an overview of the buttons frequently used in the setup menu Accessing the Setup menu To access the setup menu Hold a valid authorisation card close to the sensor 1 The first scan provides access to Terminal Management The second scan provides access to the Setup menu Edit Remove Confirm OK Save Cancel Add Up and down Back 1 1 1 ...

Page 114: ...enu for users The restricted range of settings that is available to users is described separately in the sec tion below Detailed information about adding and removing authorisation cards can be found in the section Other Settings menu item under Sensor registration An Administrator authorisation card will open the Setup window The following sections contain detailed explanations of the menu items ...

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Page 116: ...om one master device Connect all the Virtual Welding systems with a commercially available router make sure that TCP port 778 is not blocked and follow these instructions On the menu touch the Cluster but ton in the cluster menu you can configure the system either as a master or as one of the slaves In the following we first explain how to configure as the master and then how to configure as a sla...

Page 117: ...declare the selected system as the master place a tick against Master To open the keyboard for entering a name touch the Edit button to the right of the name input field Give the Virtual Welding system a name of your choosing This will make it easier to identify the system 1 2 3 ...

Page 118: ...me Touch the Save button to save the settings To activate the slave system place a tick against Active To declare the selected system as a slave place a tick against Slave To open the keyboard for entering a name touch the Edit button to the right of the name input field Give the Virtual Welding system a name of your choosing This will make it easier to identify the system 4 5 6 7 Slave Now that y...

Page 119: ... Edit button to the right of the password input field In the password input field enter the password previously defined in the master screen in the same way as described for the name Touch the Save button to save the settings Repeat steps 1 to 7 for all Virtual Welding systems which you want to include in a local cluster network NOTE To guarantee fault free communication between the master and the...

Page 120: ...udes language settings country profiles and much more Restricted settings for the User profile Licence list The licence list contains the licences currently available on the Virtual Welding system in cluding additional information such as licence name description etc ...

Page 121: ...The setup settings for the Virtual Welding system can be exported to a USB stick Follow these steps Plug a normal USB stick into the USB connection socket 1 of the Virtual Welding sys tem Touch the Export button 1 1 1 2 ...

Page 122: ...culum Profiles Ranking lists without playback function Settings for the Variable Ghost Ghost only the settings for the Variable Ghost are exported NOTE The export function can be used to carry out regular data backups Back up data at least once a week to avoid any loss of data 3 ...

Page 123: ...e 1234 to a 4 digit code of your own choosing NOTE Be careful not to lose the code Never forget the code you entered otherwise you will no longer be able to define important settings If you do lose the code contact your dealer Touch the Managementcode button An input field with a virtual keypad appears 4 1 2 ...

Page 124: ...f data loss When you import data the settings saved on the terminal are overwritten Selected settings for the Virtual Welding system can be imported from a USB stick Plug a normal USB stick into the USB connection socket 1 of the Virtual Welding sys tem Touch the Import button Touch All data the following settings and data are imported Courses Curriculum Profiles Ranking lists without playback fun...

Page 125: ...to confirm Language set tings A country version of the Virtual Welding software can be provided in up to 8 languages of which 6 languages can be activated The language settings specify which languages can be selected by the user 4 ...

Page 126: ...y profiles can be selected Such country profiles can affect the availability of functions of the Virtual Welding software Changing the lan guage settings In the Active list touch the box of the desired language to activate or deactivate that language Once you have finished entering the settings touch Save 1 2 Defining the standard language In the Standard list touch the box of the desired language...

Page 127: ...e button to save the changes Reset The Reset button allows you to return the Virtual Welding system to the factory settings NOTE Risk of data loss When you reset the system all settings in the setup menu are reset to their factory defaults Settings you have entered such as network settings curricula courses ranking lists and so on will be lost 1 2 3 ...

Page 128: ...ed users and also protects against acciden tal deletion of important data Additional authorisation cards can be added by administra tors or users at any time as described below The Sensor registration menu item is used to add and remove authorisation cards The position of the sensor on the StandUp terminal and the MobileCase can be found in the following section Controls and connection sockets und...

Page 129: ...er Have the relevant authorisation card to hand In the Add sensor area touch User When the relevant request appears on the touchscreen hold the authorisation card above the sensor Confirm the message that appears by touching the tick icon 1 2 3 4 To remove an authori sation card for an ad ministrator Have the relevant authorisation card to hand In the Remove sensor area touch Administrator When th...

Page 130: ...ouch User When the relevant request appears on the touchscreen hold the authorisation card above the sensor Confirm the message that appears by touching the tick icon 1 2 3 4 To remove all authori sation cards In the Remove sensor area touch Delete all Confirm the warning prompt that appears by touching the tick icon 1 2 ...

Page 131: ...w The Technical settings area covers technical settings information and tests Restricted settings for the User profile Setting the date and time Touch the Adjust date time button to open the input window for setting the date time and time zone 1 ...

Page 132: ...owing the NSB number Touch the Show NSB number button Setting the date Use the and buttons to set the day month and year Touch the Save button to save the settings 1 2 Setting the time Use the and buttons to set the hours and minutes Touch the Save button to save the settings 1 2 Setting the time zone In the Time zone box select the applicable time zone Touch the Save button to save the setting 1 ...

Page 133: ...check the screen settings Every touch of the touchscreen display causes the next test screen to appear Opening the test screen Touch the Test screen button Touch any area of the touchscreen display 1 2 Closing the test screen Touch the cross symbol 1 ...

Page 134: ...lasses and modify other display parameters such as contrast Choosing the model The Choose model TerminalKind entry is used to select whether the Virtual Welding system is in a terminal or a MobileCase and whether a Helmet Headband or Breast clip is being used Choosing the model Touch the Choose model TerminalKind button 1 ...

Page 135: ...k is a program for detecting and correcting logical and physical errors on the hard disk This will usually make the system run more efficiently Touch the ScanDisk button Touch the run ScanDisk button Touch Save ScanDisk will run the next time the Virtual Welding system is started As long as run ScanDisk is selected it will run the next time the Virtual Welding system is started 2 3 1 2 3 4 ...

Page 136: ...at normal ambient temperature and with the Virtual Welding system at normal operating temperature To calibrate the touchscreen Touch the Calibrate touchscreen button Follow the instructions and touch the successively appearing cross hairs as close as possible to the centre before the time runs out 1 2 ...

Page 137: ...hscreen calibration was successful Touch the tick symbol to confirm If the result of the touchscreen calibration is not satisfactory Touch the button next to the tick symbol to repeat the touchscreen calibration Touchscreen test The touchscreen test is used to check the touchscreen calibration 3 4 4 ...

Page 138: ...are shows where the finger touch was registered Touch the cross symbol to exit the touchscreen test Adjusting the vol ume The Set volume function is used to adjust the volume for the application itself Volume application advertisement Volume advertisement minimum volume of the application Minimum volume for terminal 1 2 3 ...

Page 139: ...e Set volume button Use the sliders to set the desired volume While doing so touch one of the sound buttons loudspeaker symbols or music buttons note symbols a test sound or test music will be heard Touch the Save button to save the settings 1 2 3 ...

Page 140: ...140 ...

Page 141: ...Troubleshooting and maintenance ...

Page 142: ......

Page 143: ...s fused If the fuse has blown parts in the housing interior may still be live In all cases whether the fuse has blown or not before opening the device Move the mains switch to the O position Unplug the device from the mains Put up an easy to understand warning sign to stop anybody inadvertently switching it back on again Using a suitable measuring instrument ensure that electrically charged parts ...

Page 144: ...m Press Setup key once Setup menu Press Setup key twice Calibrate touchscreen Movement of the welding torch or electrode holder is shown as a mirror image If the welding torch or electrode holder moves downwards below the workpiece surface the corresponding image on the touchscreen is an upward movement from the workpiece surface If the welding torch enters the area of transition to the mirror ima...

Page 145: ...ing torch or electrode holder is not connected Remedy Connect the welding torch or electrode holder Cause The welding helmet is not connected Remedy Connect the welding helmet Cause The workpiece holder is not connected Remedy Connect the workpiece holder Cause A sensor cable or sensor connector is faulty cable kinked missing or broken pin in the connector Remedy Change the sensor cable Cause The ...

Page 146: ... during start up e g USB flash drive Remedy Remove USB device If this does not work reinstall the software using the DVD Note All courses and profiles will be deleted Cause The cable connection to the LocalNet converter is disconnected Remedy Reconnect the cable to the LocalNet converter Error message on the screen No Dongle connected Cause USB dongle not plugged in or is plugged into the wrong US...

Page 147: ... carried out incorrectly can cause serious injury and damage The following activities must only be carried out by trained and qualified personnel All in structions in the section headed Safety rules must be observed Every start up Check the mains plug mains cable and system component cables for damage Check that the device has an all round clearance of 0 5 m 1 ft 7 69 in to ensure that cooling air...

Page 148: ...on Warning notices on the device in the chapter General F2561xxx xx xx Win XP F2562xxx xx xx Win 7 The software from http www www virtualwelding com is provided as an iso file Burn this onto a blank DVD Proceed as described below to install new software In rare cases it may be necessary to reinstall the software To do this follow these steps Move the mains switch to the O position If the VR glasse...

Page 149: ...R glasses are to be connected Connect the data cable from the VR glasses to the DVI connection socket Connect the supply cable from the VR glasses to the USB connection socket Move the mains switch to the I position 9 ...

Page 150: ...150 ...

Page 151: ...Appendix ...

Page 152: ......

Page 153: ... found to be compliant pursuant to the following standards in accordance with the relevant guidelines Mains voltage 10 110 V 230 V Grid frequency 50 60 Hz Mains fuse 3 15 A Current input max 1 2 A EMC emission class A Mark of conformity CE EN 55032 2015 In accordance with 2014 30 EU and 2014 35 EU EN 55024 2010 A1 2015 EN 61000 3 2 2014 EN 61000 3 3 2013 EN 62368 1 2014 A11 2017 IEC62368 1 2018 EN...

Page 154: ... 42 0411 0087 42 0411 0089 42 0411 0088 42 0411 0099 42 0411 0074 4 100 621 42 0411 0072 until SN 24203464 42 0411 0068 42 0411 0098 42 0411 0103 41 0007 0116 42 0411 0102 42 0411 9023 42 0201 7271 after SN 24203465 audio amplifier RFID reader Mobilecase after 01 06 2013 before 01 06 2013 ...

Page 155: ...155 42 0411 0067 42 0411 0113 42 0411 0109 42 0411 0115 42 0411 0111 42 0411 0110 42 0411 0112 StandUp Terminal ...

Page 156: ...0088 42 0411 0087 42 0411 0102 41 0007 0007 41 0007 0116 42 0411 0074 42 0411 9023 42 0201 7271 Prod Nr F2561 xxx xx xx before Prod Nr F2562 xxx xx xx after until SN 24203464 42 0411 0068 after SN 24203465 audio amplifier RFID reader 42 0411 0086 42 0411 0114 StandUp Terminal ...

Page 157: ...11 0091 42 0411 0069 42 0411 0132 42 0411 9021 42 0411 0075 42 0411 9029 42 0411 9022 42 0411 9037 42 0411 9038 Euro US GB DK ZA SK CHINA AUS Sens 1 Sens 2 Sens 3 Sens 4 Sens 5 Sens 6 Sens 7 Sens 8 before 01 12 2011 after 01 12 2011 before 01 04 2013 after 01 04 2013 after 01 12 2011 42 0411 0084 44 0350 3614 42 0411 0125 42 0510 0030 42 0510 0023 42 0411 0077 42 0510 0018 42 0510 0148 before 01 0...

Page 158: ... 0001 0001 32 0402 1008 43 0002 0386 32 0405 0358 42 0401 0936 42 0405 1196 4 070 900 42 0405 0790 42 0401 1061 42 0404 0381 42 0100 1231 42 0100 1230 43 0004 5256 42 0405 1029 40 0001 0302 xx Specify the length required Virtual Welding MIG Torch 2 3m xx xx U xx 4 035 909 ...

Page 159: ...00 2499 4 070 803 42 0100 1374 42 0100 1375 44 0350 3613 44 0350 3612 Electrode Holder Virtual Welding 2 3m xx gewünschte Länge angeben xx Specify the length required xx Indiquer la longueur désirée xx Indicar la longitud deseada xx Indicare la lunghezza desiderat xx indicar o comprimento desejado xx uved te požadovanou délku xx 4 035 977 ...

Page 160: ...803 42 0401 1061 42 0100 0601 Virtual Welding TIG torch hand 2 3m filler rod xx gewünschte Länge angeben xx Specify the length required xx Indiquer la longueur désirée xx Indicar la longitud deseada xx Indicare la lunghezza desiderat xx indicar o comprimento desejado xx uved te požadovanou délku xx Virtual Welding filler rod Virtual Welding TIG torch hand 2 3m 44 0350 4246 4 035 996 4 035 986 ...

Page 161: ... 42 0405 0559 42 0100 1452 42 0401 0314 42 0300 3102 42 0100 1453 42 0100 1451 42 0405 0790 43 0004 5256 42 0405 0790 43 0004 1161 Virtual Welding Roboter xx gewünschte Länge angeben xx Specify the length required xx Indiquer la longueur désirée xx Indicar la longitud deseada xx Indicare la lunghezza desiderat xx indicar o comprimento desejado xx uved te požadovanou délku 4 051 103 ...

Page 162: ...on Protocol With the help of a suitable server it allows automatic dynamic assignment of network addresses to a computer in a network e g Internet or LAN DSL DSL stands for Digital Subscriber Line and is a technology that provides digital high speed transmission of data over two core copper telephone lines Either the same bandwidth is available for transmission in both directions or particularly i...

Page 163: ...nsists of two data channels B channels and a control channel LAN LAN means Local Area Network and is a local communication network within a relatively small geographical area consisting of the following components one or more servers workstations network operating system standard protocol special cables for communication PIN PIN stands for Personal Identification number A PIN is a secret number us...

Page 164: ...he data traffic interface Subnet mask The subnet mask defines the size of a TCP IP subnet A subnet is created by dividing all IP addresses into sub networks DNS The Domain Name System is a naming scheme for computers connected to the Internet DNS naming is far more user friendly than an IP address as real names are easier to re member than abstract sequences of numbers Name servers automatically c...

Page 165: ... WEP stands for Wired Equivalent Privacy and is a standard for the encryption of signals on a wireless network A WEP encryption code is used to encrypt the data The higher the bit rate the greater the protection ...

Page 166: ...166 ...

Page 167: ...167 EN ...

Page 168: ...NTERNATIONAL GMBH Froniusstraße 1 A 4643 Pettenbach Austria E Mail sales fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and locations ...

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