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Incorrect operation and incorrectly performed work can cause serious injury and property

damage. Installation, repair, and maintenance work may only be carried out by trained per

sonnel. The following documents must be read in full and understood:

These Operating Instructions

All system component Operating Instructions, especially the safety rules

Dispose of old devices in accordance with safety rules and not in normal domestic waste.

Software and

product updates

Because of software updates, certain functions may be available for your device but not

described in these Operating Instructions or vice versa. In addition, individual figures may

also differ slightly from the operating controls of your device. However, these operating

controls function in exactly the same way.

Содержание Virtual Welding 2.0

Страница 1: ...ntal chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0089 EA 011 29062020 Virtual Welding 2 0 Operating Instructions Virtua...

Страница 2: ...2...

Страница 3: ...h screen and sensor 23 Touch screen and sensor 23 Operating controls and connections 24 Connections on the StandUp Terminal 24 MobileCase operating controls and connections 25 Position of the ventilat...

Страница 4: ...sers 68 Activating course mode 68 Preparing the system for the users 68 Ghost 69 Explanation and configuration options 71 Explanation 71 Creating a variable Ghost 71 Available modes on the Virtual Wel...

Страница 5: ...e for administrators 118 Performing sensor registration only available for administrators 119 Technical settings menu item 122 Setting the date and time only available for administrators 122 Displayin...

Страница 6: ...6...

Страница 7: ...parties Damage to the device and other material assets belonging to the operating company Inefficient operation of the device All persons involved in the commissioning operation maintenance and servic...

Страница 8: ...are trained in handling the device Have read and understood these Operating Instructions and have confirmed this with their signature Are trained according to the requirements for the work and traini...

Страница 9: ...lug from being connected and switched on again by applying a clearly legible and understandable warning sign After opening the device Discharge all electrically charged components Ensure that all comp...

Страница 10: ...ther devices in the vicinity Place the device far away from the affected receiver Turn the device away from the affected receiver Adjust the antenna of the affected receiver Connect the device to anot...

Страница 11: ...t be repaired before the device is switched on Never bypass or disable safety devices Before switching on the device ensure that no one can be put in danger The device must be examined at least once a...

Страница 12: ...part of the purchaser If you have any suggestions for im provement or can point out any mistakes that you have found in the Operating Instruc tions we will be most grateful for your comments Disposal...

Страница 13: ...General information...

Страница 14: ......

Страница 15: ...s of welding heat welding fu mes welding spatter noise etc The learning progress of the trainees is documented and can be compared The learning content can be adapted to suit individual needs With the...

Страница 16: ...stallation in closed and dry rooms Never Convert the device yourself Handle the device incorrectly Operate the device with programs other than the manufacturer s software Operate service or repair the...

Страница 17: ...em component Operating Instructions especially the safety rules Dispose of old devices in accordance with safety rules and not in normal domestic waste Software and product updates Because of software...

Страница 18: ...ion to StandUp Terminal or the MobileCase the following system components are included in the scope of supply Work table Workpiece holder Single V butt weld workpiece layer 1 square butt weld Single V...

Страница 19: ...for connecting to a socket Cable for 3D glasses Network cable In addition to the supplied MobileCase but not shown 3D glasses 2 keys This document Mains cable for connecting to a socket Cable for 3D g...

Страница 20: ...20 Robotics function package MMA function package...

Страница 21: ...Operating controls connections and mechanical components...

Страница 22: ......

Страница 23: ...conjunction with the supplied NFC keys performs the following func tions Touch the sensor with NFC key once Access terminal management to create curricula for example also see section First step of co...

Страница 24: ...iller material For connecting the sensor cable from the Robotics Clip For connecting the sensor cable from the filler material TIG 3 Connection 1 for welding torch For connecting the sensor cable from...

Страница 25: ...witch 10 Fuse 2 x 3 15 A slow blow 11 Mains connection MobileCase oper ating controls and connections The operating controls and connections shown below are located on the right hand panel of the Mobi...

Страница 26: ...he sensor cable from the welding torch For connecting the sensor cable from the electrode holder 8 Connection for Robotics Clip or filler material For connecting the sensor cable from the Robotics Cli...

Страница 27: ...tilation open ings on the StandUp Terminal 1 Ventilation openings at the front of the device 2 Ventilation openings at the rear of the device Ventilation open ings on the Mobi leCase 1 Ventilation ope...

Страница 28: ...28 2 Ventilation openings at the rear of the device 2 2 2...

Страница 29: ...Installation...

Страница 30: ......

Страница 31: ...ot included in the scope of supply of the device The installer is responsible for selecting the correct screws For more information on installing the StandUp Terminal see section Installing the Standu...

Страница 32: ...vironmental con ditions on page 8 Special regulations apply in areas at risk of fire or explosion follow the appropriate na tional and international regulations NOTE Risk of frequency interference Thi...

Страница 33: ...on This can result in severe personal injury and damage to property Observe the information in section Setup regulations from page 31 Screw the mount ing bracket to the StandUp Termi nal Top of StandU...

Страница 34: ...34 Top of StandUp Terminal side view 2 mounting bracket 3 screws with washers 2 3 3 3 3 2...

Страница 35: ...ed in the scope of supply The installer is responsible for selec ting the proper mounting materi als Tighten the 4 M8x16 mm screws 3 on the mounting brackets Screw the StandUp Terminal through the hol...

Страница 36: ...For better visibility the mounting brackets for wall mounting have been removed in the following images However the StandUp Terminal must always be screwed to the mounting brackets on the wall For in...

Страница 37: ...hown below Top of StandUp Terminal with tool table mounted 10 bracket 11 bracket 12 tool table CAUTION Danger from falling tool table Personal injury and damage to property may result Always make sure...

Страница 38: ...lished CAUTION Risk of poor acclimatization of components by connecting the device to the mains too early This can result in damage to the device Do not connect the device to the mains and switch it...

Страница 39: ...ecure the device to prevent it from being switched back on again WARNING Danger from incorrect installation This can result in severe personal injury and damage to property Observe the information in...

Страница 40: ...rly This can result in damage to the device Do not connect the device to the mains and switch it on until 4 hours after the setup has been completed Waiting time until the power con nection is estab l...

Страница 41: ...corresponds to the standard moun ting position The workpiece holder 1 can be mounted in other positions on the tool table These are shown at the end of the section Place the workpiece holder 1 on the...

Страница 42: ...elding torch electrode holder to the Virtual Welding system For more information on the connections on the StandUp Terminal see section Connections on the StandUp Terminal from page 24 on the MobileCa...

Страница 43: ...positions of workpiece holder 2 Insert the projection 5 into the recess 4 on the tool table CAUTION Risk of falling workpiece holder Personal injury and damage to property may result The two alternat...

Страница 44: ...er the setup has been completed Plug the mains cable into the connec tion 1 Plug the mains cable into a socket Switch the power switch 2 to the I position Initial steps Confirm the license agreement d...

Страница 45: ...Commissioning...

Страница 46: ......

Страница 47: ...ual Welding systems for example Course A is assigned to the systems used for basic training Course B is assigned to the systems used for advanced training Commissioning procedure 1 Create a curriculum...

Страница 48: ...sioning To do so see section Creating a course from page 63 If you purchased Fronius licenses with the system you can still create your own curriculum However this is not necessary Configuring the USB...

Страница 49: ...nd plug it into a PC Open the USB thumb drive on the PC Open the QuizEditor exe file Select button 1 Fill in the text fields 2 6 for the first question of the knowledge check Select button 7 to add an...

Страница 50: ...e created To do so see section Quiz from page 99 Saving content to the USB thumb drive NOTE It is recommended that the learning content and WPS are given a practical and unique file name as this file...

Страница 51: ...the knowledgecheck folder The quiz folder already contains a Quiz if it has been created Importing content Connect the USB thumb drive to the USB port of the Virtual Welding system With the NFC key to...

Страница 52: ...t the desired file for example 4 Select button 5 To import theory content Make sure the correct welding process is selected 6 Select checkbox 7 to accept the original file name Select button 8 to impo...

Страница 53: ...53 EN US To import the knowledge check Select button 9 Select tab 10 Select button 11 To import the knowledge check Select the desired file for example 12 Select button 13 9 10 11 11 12 13 13 12 14 15...

Страница 54: ...sure that the correct welding process is selected 14 Select checkbox 15 to accept the original file name Select button 16 to import the file To import WPS Select button 17 Select tab 18 Select button...

Страница 55: ...the system For example the USB thumb drive can be used to store curricula on it backup copy Merging content into a curriculum In the following section the previously imported content is merged into a...

Страница 56: ...onding additional con tents etc Individual courses for users can be created from the curriculum To do so see section Creating a course from page 63 Select button 1 Select button 2 To create the first...

Страница 57: ...ual content types or all content types Select button 5 In the next steps the individual contents are inserted in the chapter To insert training into the first chapter Only possible if this content typ...

Страница 58: ...t see section Ghost from page 69 The acceptable deviation can be set within a range of 60 90 60 execution of the task may differ by a maximum of 30 from the Ghost to be evaluated positively 90 task mu...

Страница 59: ...his content type was selected when the chapter was created Make sure the correct welding process is selected If necessary select the button 6 to change the welding process Select button 7 to insert th...

Страница 60: ...wledge check Select what percentage of knowledge check questions need to be answered correctly in order to positively complete the knowledge check 8 A value of 80 or more is recommended The settings c...

Страница 61: ...on 18 To complete the curriculum creation Select button 19 to complete the curriculum creation A new chapter can be added to the curriculum at this point optional In this case select the button 20 and...

Страница 62: ...62 Give the curriculum a name Select button 21 The new curriculum is displayed in the overview 22 21 25 26 22...

Страница 63: ...mple Course A is assigned to the systems used for basic training Course B is assigned to the systems used for advanced training Creating a course With the NFC key touch the sensor on the Virtual Weldi...

Страница 64: ...e 9 Fronius curricula are displayed under the tab 7 Self created curricula are shown under the tab 8 Select the content you want to add to the course 10 You can use the settings button 11 to Disable t...

Страница 65: ...lect button 13 The new course appears in the course overview After creating all the desired courses it is recommended that you back up your data For more information see section Creating a backup expo...

Страница 66: ...ection Touch screen and sensor on page 23 Select button 1 Available terminals are displayed 2 If there is only one terminal in the network the serial number is displayed as the terminal name Select bu...

Страница 67: ...tiple ter minals If multiple Virtual Welding systems are in use it is possible to combine them into groups Cluster networking See section Creating cluster networking from page 108 for the description...

Страница 68: ...ate course mode Select button 4 to save the entries The system is now ready Refer to the following section for the necessary settings to allow users to begin the exercises Preparing the system for the...

Страница 69: ...Ghost...

Страница 70: ......

Страница 71: ...tandard standard Ghost The Ghost button 1 allows you to create a variable Ghost A variable Ghost can be created in addition to the standard Ghost and adapted to your own requirements A variable Ghost...

Страница 72: ...72 Use the arrow keys to make the desired settings Select button 4 Select button 5 4 4 5 5 6...

Страница 73: ...the additional instructions on the touch screen NOTE In Virtual Welding Robotics the ghost creation distinguishes between Polygon and Cycles Polygon Allows for recording of a completely free path move...

Страница 74: ...74...

Страница 75: ...Available modes on the Virtual Weld ing system...

Страница 76: ......

Страница 77: ...n creating users see section Profile from page 78 In course mode the following functions are available Training practical welding tasks Theory learning content Knowledge check review of knowledge lear...

Страница 78: ...ile for each user A profile allows you to perform the following actions Saving of data for each individual user trainees Follow up of the last welding results of each individual user An overview of th...

Страница 79: ...79 EN US Select button 3 Enter required data Read and understand the text next to the checkbox 4 and select the checkbox 4 Select button 5 Confirm the displayed message 3 4 5 5 4 6 7 8...

Страница 80: ...e listed in the ranking list a profile must be created for each user and the user must be logged in to complete the tasks See Profile from page 78 Ranking lists can be exported with the respective cou...

Страница 81: ...Make sure the correct welding process is selected If necessary select the button 3 to change the welding process Select button 4 next to the desired course Select button 5 Course data are stored on th...

Страница 82: ...owing functions are available Free training practical welding tasks Quiz for more information see section Quiz from page 99 Activating open mode With the NFC key touch the sensor on the Virtual Weldin...

Страница 83: ...ls In showroom mode only open training can be selected Activating show room mode With the NFC key touch the sensor on the Virtual Welding system to open terminal management For the position of the sen...

Страница 84: ...84...

Страница 85: ...Calibration...

Страница 86: ......

Страница 87: ...re compared with each other System calibration must always be carried out when starting for the first time and when the Virtual Welding system is changed to a different location Performing sys tem cal...

Страница 88: ...88 Select the welding process for which system components are to be calibrated Follow the instructions on the touch screen 5 6...

Страница 89: ...forming room calibration NOTE Risk from optical sources of interference These can affect the quality of the calibration During calibration shield the unit as much as possible from sunlight headlights...

Страница 90: ...90 Select tab 3 Select button 4 Follow the instructions on the touch screen glasses 4 5 6...

Страница 91: ...nent calibration is started automatically before each training session Performing com ponent calibra tion With the NFC key touch the sensor on the Virtual Welding system to open terminal management Fo...

Страница 92: ...92 Follow the instructions on the touch screen 6...

Страница 93: ...sed to move the displayed image closer or farther away Changing the camera settings With the NFC key touch the sensor on the Virtual Welding system to open terminal management For the position of the...

Страница 94: ...94 Follow the on screen instructions 6...

Страница 95: ...Other settings...

Страница 96: ......

Страница 97: ...ding system to open terminal management For the position of the sensor see section Touch screen and sensor on page 23 Select button 1 Select tab 2 Select button 3 License information is displayed Inst...

Страница 98: ...e arm of the robot manufacturer during robotic welding With the NFC key touch the sensor on the Virtual Welding system to open terminal management For the position of the sensor see section Touch scre...

Страница 99: ...open terminal management For the position of the sensor see section Touch screen and sensor on page 23 Select button 1 Select tab 2 Select button 3 5 Select button 3 to activate deactivate the quiz f...

Страница 100: ...n 6 to export individual own segments Creating a Quiz Connect a USB thumb drive configured for Virtual Welding to a PC See section Configuring the USB thumb drive from page 48 for the description of c...

Страница 101: ...steps as many times as desired NOTE It is recommended that the Quiz be given a practical and unique file name when sav ing since this file name can be transferred to the Virtual Welding system during...

Страница 102: ...e filled in Importing a quiz Connect the USB thumb drive with the quiz data to the USB port of the Virtual Welding system With the NFC key touch the sensor on the Virtual Welding system to open termin...

Страница 103: ...103 EN US Select button 3 Select tab 4 Select button 5 Select and import the desired file 5 5 4 6 7 8...

Страница 104: ...104...

Страница 105: ...Setup Menu...

Страница 106: ......

Страница 107: ...ens The limited settings available for users are listed separately below For detailed information on registering and removing NFC keys see section Performing sensor registration only available for adm...

Страница 108: ...ding systems This allows you to control the entire course management of Virtual Weld ing systems from a master device Creating cluster networking Connect all Virtual Welding systems to a commercially...

Страница 109: ...ned as the master To define all other systems as Slave the settings must be made individually on each additional system Select checkbox 8 Select checkbox 9 Select button 10 and assign a name Select bu...

Страница 110: ...10 Define all other systems as Slave in the same way NOTE If the master is restarted during active cluster networking all slaves must also be restarted in order to be able to reconnect to the master 1...

Страница 111: ...list contains the licenses currently available on the Virtual Welding system in cluding additional information such as license name description etc Enter the Setup menu see Accessing the Setup menu o...

Страница 112: ...data on a USB thumb drive for example to back up data It is recommended to back up the Virtual Welding system data once a week To export data Connect a USB thumb drive to the USB port of the Virtual W...

Страница 113: ...tton can only be selected if a variable Ghost has been created Select button 4 to start data export Disconnect the USB thumb drive from the Virtual Welding system Management code This section describe...

Страница 114: ...n 2 Language set tings The Virtual Welding system is available in up to 8 languages Of these 8 languages a maximum of 6 languages can be activated The language settings determine which languages are a...

Страница 115: ...on page 107 Select button 1 To change the language settings In area 2 select the languages to be activated Select button 4 to save To define the default language In area 3 define the desired language...

Страница 116: ...can be imported from a USB thumb drive Risk of data loss Importing will overwrite the settings stored on the system To import data Connect a USB thumb drive to the USB port of the Virtual Welding syst...

Страница 117: ...the corresponding data are available Select the content to import for example 4 and 5 Select button 6 to start the data import Displaying changing coun try profiles only available for ad ministrators...

Страница 118: ...example 2 Select button 3 to save Restoring factory settings only available for ad ministrators NOTE Risk of data loss Restoring the factory defaults resets all settings in the Setup menu to factory d...

Страница 119: ...r ter minal management or the Setup menu When starting for the first time it is possible to create an administrator or a user using an NFC key The administrator has access to the full range of functio...

Страница 120: ...strators Keep the NFC key in question ready In area 2 select the administrator button When prompted on the touch screen pass the NFC key over the sensor Confirm the message that now appears To registe...

Страница 121: ...ouch screen pass the NFC key over the sensor Confirm the message that now appears To remove the NFC key for users Keep the NFC key in question ready In area 3 select the user button When prompted on t...

Страница 122: ...etup menu on page 107 Select button 1 Change the desired data Displaying the NSB number The NSB number is the version number of the Virtual Welding software This number is required for support questio...

Страница 123: ...ows you to check the screen settings Enter the Setup menu see Accessing the Setup menu on page 107 Select button 1 Touch anywhere on the touch screen After each touch of the touch screen the next test...

Страница 124: ...rrect data Save the entries Activating the memory check only available for administrators Select the ScanDisk menu item to identify and correct errors on the hard disk As a rule the system will become...

Страница 125: ...As long as the memory check is activated it is performed each time the Virtual Weld ing system is restarted Performing the touch screen test only available for administrators The touch screen test is...

Страница 126: ...A square indicates where the touch was registered When the test is complete select button 2 Setting the vol ume only avail able for administrators Enter the Setup menu see Accessing the Setup menu on...

Страница 127: ...127 EN US Make the desired settings Select button 2 2 3 4...

Страница 128: ...128...

Страница 129: ...Troubleshooting maintenance and disposal...

Страница 130: ......

Страница 131: ...g work switch off all the devices and components involved and discon nect them from the mains Secure all devices and components involved so they cannot be switched back on After opening the device use...

Страница 132: ...medy Remove devices Cause Metallic objects are located in the immediate vicinity of the Virtual Welding system Remedy Remove objects The 3D visualization appears incorrectly on the touch screen The mo...

Страница 133: ...ect the 3D glasses Cause The 3D glasses were connected after switching on the Virtual Welding system Remedy Turn off the Virtual Welding system connect the 3D glasses turn on the Vir tual Welding syst...

Страница 134: ...nt This may result in serious injuries or death Before starting work switch off all the devices and components involved and discon nect them from the mains Secure all devices and components involved s...

Страница 135: ...Update...

Страница 136: ......

Страница 137: ...system To configure the USB thumb drive for the update Download the update folder to a PC The update folder can be found at www virtualwelding com Unzip the update folder Connect a boot capable USB th...

Страница 138: ...138 Use button 3 to select the iso file that is located in the update folder 3 VWUPDATE 10...

Страница 139: ...139 EN US Select GPT with button 4 4 VWUPDATE 11...

Страница 140: ...140 Select UEFI or BIOS with button 5 Depending on the system one of the two options is available 5 VWUPDATE 12...

Страница 141: ...141 EN US Enter VWUPDATE in field 6 6 VWUPDATE 13...

Страница 142: ...142 Select Large FAT32 Default with button 7 select 32 kilobites default with but ton 8 VWUPDATE 7 8 14...

Страница 143: ...143 EN US Select Checkbox 9 and 10 VWUPDATE 9 10 15...

Страница 144: ...144 Select button 11 VWUPDATE 11 16...

Страница 145: ...145 EN US By selecting button 12 all existing data on the USB thumb drive are deleted and all data required for the update are saved on the USB thumb drive Select button 12 12 17...

Страница 146: ...lding system to the O position Connect the USB thumb drive to the USB port of the Virtual Welding system Switch the power switch of the Virtual Welding system to the I position elo is displayed on the...

Страница 147: ...147 EN US BIOS menu Use the arrow keys on the keyboard to select the Save Exit menu item 1 1 5 2...

Страница 148: ...epare the USB thumb drive see section Preparation for the update from page 137 After selecting the USB thumb drive press Enter to start the update Once the touch screen displays Press any key to conti...

Страница 149: ...Technical data...

Страница 150: ......

Страница 151: ...rds in line with the applicable guidelines and compliance with these has been determined Mains voltage 10 110 V 230 V Grid frequency 50 60 Hz Mains fuse protection 2 x 3 15 A slow blow Current consump...

Страница 152: ...INTERNATIONAL GMBH Froniusstra e 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and lo...

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