Operating
Instructions
Virtual Welding 2.0
EN-US
Operating instructions
42,0426,0089,EA 015-24012023
Table of contents
Safety Instructions 6
Explanation of Safety Instructions 6
General 6
Environmental conditions 7
Obligations of the operating company 7
Obligations of personnel 7
Mains connection 7
Danger from mains current 8
EMC device classifications 8
Particular hazard areas 9
Safety measures at the setup location and during transport 10
Safety measures in normal operation 10
Maintenance and repair 10
Safety symbols 10
Data backup 11
Copyright 11
Disposal 11
General information 13
General 15
Device concept 15
Intended use 16
Warning notices on the device 16
Software and product updates 17
Scope of supply and optional function packages 18
Scope of supply 18
Function packages 19
EN-US
Operating controls, connections and mechanical components 21
Touch 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 ventilation openings 27
Ventilation openings on the StandUp Terminal 27
Ventilation openings on the MobileCase 27
Installation 29
Before installation and initial operation 31
Safety 31
Setup regulations 31
Installing the Standup Terminal 33
Safety 33
Screw the mounting bracket to the StandUp Terminal. 33
Assemble and screw in the StandUp Terminal 35
Waiting time until the power connection is established 38
Installing the MobileCase 39
Safety 39
Setting up the MobileCase, mounting the tool table 39
Waiting time until the power connection is established 40
Fitting/connecting the system components 41
Installing and connecting the tool table and other system components 41
Powering on, initial steps 44
Plug in the mains cable and turn on the device 44
Initial steps 44
Commissioning 45
3
Training concept and procedure for commissioning 47
Training concept 47
Commissioning procedure 47
First step of commissioning: Create a curriculum 48
General 48
Configuring the USB thumb drive 48
Creating a knowledge check 49
Saving content to the USB thumb drive 51
Importing content 52
Merging content into a curriculum 57
Second step of commissioning: create a course 64
Using a course 64
Creating a course 64
Third step of commissioning: assign courses 67
Assigning courses to the Virtual Welding system 67
Assigning courses to multiple terminals 68
Fourth step of commissioning: enable course mode, prepare the system for users 69
Activating course mode 69
Preparing the system for the users 69
Deleting content 69
Ghost 71
Explanation and configuration options 73
Explanation 73
Creating a variable Ghost 73
Available modes on the Virtual Welding system 77
Course mode 79
Explanation 79
Activating course mode 79
Profile 80
Ranking list description, exporting course data 82
Open mode 84
Explanation 84
Activating open mode 84
Showroom mode 85
Explanation 85
Activating showroom mode 85
Calibration 87
Room calibration 89
Function 89
Performing room calibration 89
System calibration 91
Function 91
Performing system calibration 91
Changing the camera setting 93
Function 93
Changing the camera settings 93
Component calibration 95
Function 95
Performing component calibration 95
Other settings 97
License management 99
Function 99
Opening license management 99
Installing a license 99
Changing the robot manufacturer 100
Description 100
4
Quiz 101
Function 101
Activating/deactivating a quiz, importing/exporting a quiz 101
Exporting a quiz 101
Creating a Quiz 102
Importing a quiz 104
Setup Menu 107
Permissions and accessing the Setup menu 109
Different permissions 109
Accessing the Setup menu 109
Network menu item 110
Description 110
Creating cluster networking 110
Other settings menu item 113
Displaying the license list 113
Creating a backup (exporting data) 114
Management code 116
Language settings 117
Importing data (only available to administrators) 119
Displaying / changing country profiles (only available for administrators) 121
Restoring factory settings (only available for administrators) 122
Performing sensor registration (only available for administrators) 123
Technical settings menu item 127
Setting the date and time (only available for administrators) 127
Displaying the NSB number 127
Test image (only available for administrators) 128
Defining the model 129
Activating the memory check (only available for administrators) 129
Performing the touch screen test (only available for administrators) 130
Setting the volume (only available for administrators) 131
EN-US
Troubleshooting, maintenance, and disposal 133
Troubleshooting 135
General 135
Safety 135
Troubleshooting 136
Maintenance and disposal 139
General 139
Safety 139
Maintenance at every start-up 139
Disposal 139
Update 141
Installing the Update 143
Preparation for the update 143
Performing the update 153
Technical data 157
Technical data 159
Special voltage 159
StandUp Terminal, MobileCase 159
Standards 159
5
Safety Instructions
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
▶
WARNING!
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are
▶
not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured in line with the state of the art and according
to recognized safety standards. If work is carried out improperly or the device is
used incorrectly or misused, however, it can cause:
Serious or fatal injury to the operator or third 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 servicing
of the device must
Be suitably qualified
-
Have fully read, understood, and precisely followed these Operating Instruc-
-
tions
The Operating Instructions must always be kept to hand wherever the device is
being used. In addition to the Operating Instructions, all applicable local rules
and regulations regarding accident prevention and environmental protection
must also be followed.
All safety and danger notices on the device:
Must be kept in a legible state
-
Must not be damaged/marked
-
Must not be removed
-
Must not be covered, pasted, or painted over
-
For the location of the safety and danger notices on the device, refer to the section headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
6
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.
Installation and operation may only take place within closed and dry rooms.
Temperature range of ambient air:
During operation: - 10 °C to + 35 °C (14 °F to 95 °F)
-
During transport and storage: - 25 °C to + 55 °C (- 13 °F to 131 °F)
-
Relative humidity:
up to 50% at 35 °C (95 °F)
-
up to 90% at 20 °C (68 °F)
-
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6500 ft.)
EN-US
Obligations of
the operating
company
Obligations of
personnel
The operating company undertakes to
Read and understand the Operating Instructions
-
Only hand over the device keys to personnel who are familiar with the
-
product
The operating company must only allow persons to work with the device if they
Are familiar with the basic occupational safety and accident prevention regu-
-
lations and 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 training results.
-
The safety-conscious work of the personnel must be checked regularly.
All persons who are instructed to work with the device must do the following before beginning work:
Follow the basic regulations for occupational safety and accident prevention
-
Have read and understood these Operating Instructions.
-
Before leaving the workplace, ensure that no personal injury or property damage
can occur in their absence.
Mains connection
The mains voltage and grid frequency must match the specifications on the rating plate.
The Virtual Welding system must only be connected to a properly installed, secured, and grounded mains socket.
If the device is supplied without a country-specific cable, use the mains plug and
cable in accordance with local standards.
An electric shock can be fatal. Only trained personnel may install and connect
the mains plug.
Route the mains cable so that there is no risk of injury (risk of tripping, etc.) and
damage to the mains cable.
7
Danger from
mains current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
Do not wrap cables or leads around your body or parts of the body.
Have the mains and device supply lead regularly inspected by an electrician to
ensure that the ground conductor is functioning properly.
Only operate the device on a grid with a ground conductor and a socket with a
ground conductor contact.
Operating the device on a grid without a ground conductor and on a socket
without a ground conductor contact is considered gross negligence. The manufacturer accepts no liability for any damage resulting from improper use.
Switch off unused devices.
EMC device classifications
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the mains plug.
Secure the device to prevent the mains plug 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 components are disconnected from the power supply
-
If work is needed on voltage-carrying parts, bring in a second person who will
switch off the main switch at the correct time.
Repair work (e.g., opening the device) must only be carried out by qualified personnel trained for this purpose. If a defect occurs, unplug the device immediately
and have the repair carried out by trained and qualified personnel.
Repairs must only be carried out in a de-energized state
-
Only use original spare parts
-
Only unplug the device when it is switched off
-
The Virtual Welding system is an emission class A device
Devices in emission class A
Are only designed for use in industrial areas
-
Can cause wiring-related or radiated interference in other areas.
-
In certain cases, even though a device complies with the standard limit values for
emissions, it may affect the application area for which it was designed (e.g., when
there is sensitive equipment at the same location, or if the site where the device
is installed is close to either radio or television receivers).
8
If this is the case, then the operating company is obliged to take appropriate action to rectify the situation.
Check and evaluate possible problems and the interference immunity of equipment in the vicinity according to national and international regulations. For example, from:
Safety devices
-
Mains power lines, signal lines, and data transfer lines
-
IT and telecommunications equipment
-
Devices for measuring and calibrating
-
Supporting measures to avoid EMC problems:
Mains power supply
a)
Use only the supplied power cables
-
If electromagnetic interference occurs despite a mains connection that
-
complies with regulations, take additional measures (e.g., use a suitable
mains filter).
No modifications to the device
b)
Modifications made to the device without prior agreement with the man-
-
ufacturer may result in loss of type approval
If the device is suspected of interfering with the reception of television or ra-
c)
dio signals or the operation of another device:
Confirm the device by switching it on and off as a source of interference
-
If this identifies the device as a source of interference, remedy the fault
-
using the anti-interference measures listed below
Anti-interference measures
d)
Shield other 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 another AC socket so that the device and the af-
-
fected receiver use different circuits.
Only connect the device to a grounded socket. Removing the grounding
-
may increase high-frequency emissions and cause an electric shock resulting in death. Do not use AC adapter plugs or extension cables
If the above measures do not provide a sustainable solution, contact the
-
manufacturer or a trained radio and television technician
EN-US
Particular hazard areas
Special regulations apply in areas at risk of fire or explosion
–follow the appropriate national and international regulations.
Always keep ventilation openings clear. For more information on the position of
the ventilation openings, see section Position of the ventilation openings from
page 27.
The ambient temperature must not exceed 35 °C (95 °F).
The device must not be transported using a crane.
Risk of personal injury due to toppling of the StandUp Terminal if set up incorrectly. Only set up the StandUp Terminal on a flat, stable surface and screw it to
the wall and floor using the supplied brackets with the help of trained personnel.
For more information on installing the StandUp Terminal, see section Installing
the Standup Terminal from page 33.
9
Safety measures
at the setup location and during
transport
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device. especially guidelines concerning hazards during transport and shipment.
Only carry out the transport in the original packaging. The original packaging is
available from the manufacturer.
Do not lift or transport any active devices. Switch off devices before transport or
lifting.
Carry out internal instructions and checks to ensure that the vicinity of the workplace is always clean and organized.
After transport and before installation and commissioning, it is essential to visually inspect the device for damage. Have a trained service technician repair any
damage before installation and commissioning.
Safety measures
in normal operation
Maintenance and
repair
Only operate the device when all safety devices are fully functional. If the safety
devices are not fully functional, there is a danger of:
Serious or fatal injury to the operator or third parties
-
Damage to the device and other material assets belonging to the operating
-
company
Inefficient operation of the device
-
Safety devices that are not fully functional must 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 week for externally detectable damage and functionality of the safety devices.
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
Use only original spare and wearing parts (also applies to standard parts).
-
Do not carry out any modifications, alterations, etc. to the device without the
-
manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
-
When ordering, please give the exact designation and part number as shown
-
in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.
Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directive (e.g., relevant product standards of
the EN 60974 series).
10
Fronius International GmbH declares that the device complies with Directive
2014/53/EU. The full text of the EU Declaration of Conformity is available on the
following website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant
standards for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves 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 purchaser. If you
have any suggestions for improvement, or can point out any mistakes that you
have found in the Operating Instructions, we will be most grateful for your comments.
EN-US
Disposal To comply with European directives and national law, waste electrical and elec-
tronic equipment must be collected separately and sent for environmentallyfriendly recycling. Used devices must be returned to a distributor or an approved
collection and recycling facility in your area. Proper disposal of used devices promotes the sustainable recycling of material resources. Ignoring this may have potentially adverse effects on the environment and your health.
Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the
volume of cardboard.
11
12
General information
13
14
General
EN-US
Device concept
Virtual Welding is used for the realistic
learning of welding skills. Virtual Welding offers the following benefits:
Very low cost of training. No con-
-
sumables are required (wire electrodes, welding gas, etc.)
The trainees are not exposed to
-
the dangers of welding (heat, welding fumes, welding spatter, noise,
etc.)
The learning progress of the train-
-
ees is documented and can be
compared
The learning content can be adap-
-
ted to suit individual needs
With the help of the various weld-
-
ing torches and workpieces, many
different tasks can be simulated
etc.
-
The Virtual Welding system is available
as a StandUp Terminal for stationary
use and as a MobileCase for mobile
use.
StandUp Terminal
MobileCase
15
Intended use The device is to be used exclusively for its intended purpose.
The device is intended for welding simulation only with the software and hardware supplied by the manufacturer.
Utilization for any other purpose, or in any other manner shall be deemed improper.
The manufacturer shall not be liable for any resulting damage.
Intended use also means:
Carefully reading and adhering to all instructions in these Operating Instruc-
-
tions
Carefully reading and understanding all warnings on the device
-
Carrying out all the specified inspection and maintenance work
-
Establishing the mains connection according to the specifications on the rat-
-
ing plate
Installation 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 device without observing the Operating In-
-
structions
Warning notices
on the device
The device is designed for operation in closed and dry rooms. The manufacturer
shall not be liable for any damage resulting from use in other environments.
The manufacturer shall also not be liable for faulty or incorrect training success.
Warning notices and safety symbols can be found on the StandUp Terminal and
MobileCase. These warning notices and safety symbols must not be removed or
painted over. They warn against incorrect operation, as this may result in serious
injury and property damage.
16
EN-US
Software and
product updates
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 personnel. 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.
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.
17
Scope of supply and optional function packages
Scope of supply In addition to StandUp Terminal or the MobileCase, the following system com-
ponents are included in the scope of supply:
Work table
Workpiece holder Single-V butt weld workpiece, layer 1 (square
Single-V butt weld workpiece, layer 2 and 3
(square butt weld)
butt weld)
Fillet weld workpiece
18
EN-US
Function packages
Pipe workpiece
2 NFC keys
In addition to the supplied StandUp Terminal, but not shown:
3D glasses
-
4 keys
-
4 M8 x 80 mm screws with washers, for screwing together the upper and
-
lower parts
Mounting bracket including 4 M8x16 mm screws and washers
-
This document
-
Mains cable (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 glasses
-
Network cable
-
The function packages are not included in the scope of supply of the Virtual
Welding system. At least one of the following function packages must be ordered
with the Virtual Welding system.
MIG/MAG function package TIG function package
Robotics function package
19
MMA function package
20
Operating controls, connections
and mechanical components
21
22
Touch screen and sensor
(2)
(1)
(2)
Touch screen
and sensor
EN-US
Touch screen and sensor on the StandUp Terminal
The touch screen (1) allows for intuitive touch operation.
The sensor (2), in conjunction with the supplied NFC keys, performs the following
functions:
Touch the sensor with NFC key once =
-
Access terminal management to create curricula, for example - also see section First step of commissioning: Create a curriculum from page 48
Touch the sensor with NFC key twice =
-
Access the Setup menu - for more information see section Permissions and
accessing the Setup menu from page 109
Sensor on MobileCase
23
Operating controls and connections
(1) (2) (3) (4)
Connections on
the StandUp Terminal
(1) Connection for the workpiece
holder
For connecting the sensor cable
from the workpiece holder
(2) Connection for Robotics-Clip
or filler 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 the welding torch;
For connecting the sensor cable
from the electrode holder
(4) Connection 2 for welding
torches
For connecting the control
cable from the welding torch;
For connecting the control
cable from the electrode holder
Front of StandUp Terminal
24
(5) (6) (7) (8) (9)
(10)
(11)
(12)
(5) LAN connection
(5) (6)(4)(3)(1)
(8) (7)(9)(10)
(2)
For connecting a LAN network
cable
(6) External display connection
For connecting an external
monitor or projector (after connecting the monitor/projector,
restart the Virtual Welding system)
(7) USB port
For connecting the 3D glasses
data cable
(8) 3D glasses supply
(9) 3D glasses connection (display
port)
(10) Power switch
(11) Fuse
2 x 3.15 A slow-blow
EN-US
MobileCase operating controls
and connections
(12) Mains connection
Back of StandUp Terminal
The operating controls and connections shown below are located on the righthand panel of the MobileCase.
(1) 3D glasses connection (display
port)
(2) 3D glasses supply
(3) Sensor
See section Touch screen and
sensor on page 23
(4) USB port
For connecting the 3D glasses
data cable
(5) External display connection
For connecting an external
monitor or projector (after connecting the monitor/projector,
restart the Virtual Welding system)
25
(6) LAN connection
(10)
(11)
(12)
For connecting a LAN network cable
(7) Connection 1 for welding torch
For connecting the control cable from the welding torch
For connecting the control cable from the electrode holder
(8) Connection 2 for welding torch
For connecting the sensor cable from the welding torch
For connecting the sensor cable from the electrode holder
(9) Connection for Robotics-Clip or filler material
For connecting the sensor cable from the Robotics-Clip
For connecting the sensor cable from the filler material (TIG)
(10) Connection for the workpiece holder
For connecting the sensor cable from the workpiece holder
(11) Power switch
(12) Fuse
2 x 3.15 A slow-blow
(13) Grid connection
Back of MobileCase
26
Position of the ventilation openings
(1)
(1)
(1)
(1)
(1)
(1)
(1)(1)
EN-US
Ventilation
openings on the
StandUp Terminal
(1) Ventilation openings at the
front of the device
(2) Ventilation openings at the rear
of the device
Ventilation
openings on the
MobileCase
(1) Ventilation openings at the
front of the device
27
(2)
(2)
(2)
(2) Ventilation openings at the rear
of the device
28
Installation
29
30
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