Fronius Xplorer Operating Instruction [EN]

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Fronius Xplorer

Operating Instructions

Software

42,0426,0051,EN 002-12042012

Dear reader,

Introduction Thank you for the trust you have placed in our company and congratulations on buying this

high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer. This will allow you to make full use of its advantages.

Please also note the safety rules to ensure greater safety when using the product. Careful handling of the product will repay you with years of safe and reliable operation. These are essential prerequisites for excellent results.

Contents

General 5

General ...................................................................................................................................................... 7

Principle ................................................................................................................................................ 7

Fronius Xplorer function packs ............................................................................................................. 7

Application areas .................................................................................................................................. 7

System requirements ................................................................................................................................. 8

PC system requirements....................................................................................................................... 8

Welding system requirements............................................................................................................... 8

Firmware versions................................................................................................................................. 8

System configuration example.............................................................................................................. 9

Configuring network ................................................................................................................................... 10

General ................................................................................................................................................. 10

Assigning an IP address ....................................................................................................................... 10

Assigning a firewall IP address ............................................................................................................. 10

Fronius Xplorer overview 11

Fronius Xplorer overview ........................................................................................................................... 13

General ................................................................................................................................................. 13

Fronius Xplorer ..................................................................................................................................... 13

Browser level overview ......................................................................................................................... 13

Work level overview .............................................................................................................................. 14

Buttons at the browser level.................................................................................................................. 15

Symbols for power source location ....................................................................................................... 15

System component symbols ................................................................................................................. 16

System status symbols ......................................................................................................................... 17

Symbols in the Jobs and Docu worksheets overview ........................................................................... 17

Menu - Tools 19

Options....................................................................................................................................................... 21

General ................................................................................................................................................. 21

LocalNet serial ports ............................................................................................................................. 21

Licences................................................................................................................................................ 21

Login ..................................................................................................................................................... 21

Creating a login via OPC ...................................................................................................................... 22

Creating a login via the UsbKey............................................................................................................ 22

User settings .............................................................................................................................................. 24

General ................................................................................................................................................. 24

Creating a new user with a new user profile ......................................................................................... 24

Managing the user profiles.................................................................................................................... 24

User management ................................................................................................................................ 25

Logging on and off automatically .......................................................................................................... 25

Changing the user................................................................................................................................. 25

Splitting the window ................................................................................................................................... 26

Splitting the window .............................................................................................................................. 26

Browser level 27

Browser level ............................................................................................................................................. 29

General ................................................................................................................................................. 29

Navigation in browser ........................................................................................................................... 29

Switching from browser view to status view.......................................................................................... 29

Copying a welding system to the selection bar..................................................................................... 30

Removing a welding system from the selection bar.............................................................................. 30

Worksheets 33

Worksheet overview................................................................................................................................... 35

Worksheet overview.............................................................................................................................. 35

Buttons and symbols in the Worksheet overview ................................................................................. 35

Backing up and restoring data .............................................................................................................. 36

Setting up automatic backup................................................................................................................. 36

Defining and cancelling the master backup .......................................................................................... 36

Displaying connection status ................................................................................................................ 37

Saving the device configuration ............................................................................................................ 38

Configuring the system name and location........................................................................................... 38

Control panel worksheet ............................................................................................................................ 39

Control panel worksheet ....................................................................................................................... 39

Operating the control panel using the keyboard ................................................................................... 39

Accessing a power source set-up menu ............................................................................................... 40

Jobs worksheet .......................................................................................................................................... 41

Jobs worksheet ..................................................................................................................................... 41

Buttons and symbols in the Jobs worksheet......................................................................................... 42

Displaying job data................................................................................................................................ 43

Copying and pasting jobs...................................................................................................................... 43

Exporting/importing jobs ....................................................................................................................... 43

Pasting job data into an external document.......................................................................................... 44

Attaching a file to a job/opening an attached file .................................................................................. 44

Deleting a job ........................................................................................................................................ 45

Changing a job...................................................................................................................................... 45

Job history............................................................................................................................................. 45

Docu worksheet ......................................................................................................................................... 46

Docu worksheet .................................................................................................................................... 46

Buttons and symbols in the Docu worksheet ........................................................................................ 46

Applying the default settings for consumption figures...........................................................................47

Automatic Excel export ......................................................................................................................... 48

Switching welding data recording on and off ........................................................................................ 48

Time synchronisation ............................................................................................................................ 48

Displaying welds/consumption figures menu ........................................................................................ 49

Showing as a graph .............................................................................................................................. 49

Weld seam sections menu.................................................................................................................... 50

Parameter set values menu .................................................................................................................. 51

Actual welding parameter values menu ................................................................................................ 51

Errors menu .......................................................................................................................................... 52

Loading and displaying recorded welding data..................................................................................... 52

Saving welding data as an Excel file..................................................................................................... 53

Importing welding data.......................................................................................................................... 53

Documented welding data .................................................................................................................... 54

Log book worksheet................................................................................................................................... 57

Log book worksheet.............................................................................................................................. 57

Buttons and symbols in the Log book worksheet.................................................................................. 57

Loading and displaying log book data................................................................................................... 57

Saving log book data as an Excel file ................................................................................................... 58

Statistics worksheet ................................................................................................................................... 59

Statistics worksheet .............................................................................................................................. 59

Buttons and symbols in the Statistics worksheet .................................................................................. 59

Creating a new statistics bar................................................................................................................. 60

Graph worksheet........................................................................................................................................ 61

Graph worksheet................................................................................................................................... 61

Buttons and symbols in the Graph worksheet ......................................................................................61

Creating a new job graph...................................................................................................................... 62

Hiding/showing jobs .............................................................................................................................. 62

Zoom..................................................................................................................................................... 62

Importing data from systems not in the network ........................................................................................ 63

General ................................................................................................................................................ 63

Adding a welding system ...................................................................................................................... 63

General

Principle The Fronius Xplorer software is a virtual control station for networked welding systems in

automated production areas. The graphical user interface, with its self-explanatory symbols, facilitates the clear and simple management of any number of welding systems that form part of a networked production line. The location and status of each welding system can be seen at a glance. Tried and tested settings can be copied easily from one system to another. The software also has touchscreen capability for faster operation.

Fronius Xplorer function packs

Fronius Xplorer is available with different function packs and associated options:

(1) Power source + Fronius Xplorer (basic package)

(2) Power source + Fronius Xplorer + Docu

(3) Power source + Fronius Xplorer + JobExplorer + Docu (optional)

(4) Power source + Fronius Xplorer + RCU 5000i remote control

Function packs (1) (2) (3) (4)

All systems in the network can be seen X X X X

Monitoring the current operating status X X X X

Backup/restore functions X X X X

Remote control of the power source using PC X X X -

Documentation of set values - - X X

Documentation of changes to set values - - X X

Attaching documents or images as information - - X X

Copying jobs from one power source to another - - X X

Documentation of weld seam actual values (with part number as option)

Limit monitoring of current and voltage - - - X

Motor current monitoring - - - X

Log book/graph/statistics - - - X

-**X

* Welds, sections

Application areas The application area encompasses all digital devices from the Fronius product family in au-

tomated and manual applications

- MIG/MAG welding and brazing (CMT)

- TIG welding

- DeltaSpot - spot welding

- Plasma welding

System requirements

PC system requirements

Welding system requirements

The system requirements of the computer depend on the number of connected welding systems for which data documentation is to be carried out. The following information relates to a system with 16 welding systems whose data is to be documented on the computer:

-3 GHz CPU

-2 GB RAM

- WinXP, Win7 or WinServer2008 operating system + latest service packs

- Microsoft.NET Framework 2.0 (on "ToolsCD" CD-ROM or via internet)

- Screen resolution of at least 1024 x 768

- One free serial interface (for configuring the network)

- At least 100 Mbit network connection

- No hub in network

- Digital power source

- Free LocalNet connection with "Ethernet" option on the power source

If no LocalNet connection is free:

- LocalNet passive distributor

For retrospective evaluation of welding data:

- RCU 5000i remote control

- or enabling of data documentation (Docu)

Firmware versions

To use the log book, graph and statistics functions, an RCU 5000i remote control must be connected to the respective power source.

The device firmware must be kept up-to-date in order to be able to use all Fronius Xplorer functions without any restrictions.

Minimum requirements: TS 4000 / 5000, TPS 2700 / 3200 / 4000 (CMT) / 5000 (CMT) / 7200 / 9000

- Power source firmware: OFFICIAL UST V3.32.30 or higher OFFICIAL UBST V1.4.31 or higher

- Wire-feed unit firmware: OFFICIAL SR 4X A V2.1.27 or higher

- RCU 5000i firmware: OFFICIAL RCU V1.13.7 or higher

System configu-

Welding cell

Production hall

Welding cell

Production hall

Production location

Head office

ration example

Example of network for management with Fronius Xplorer

Configuring network

General To configure the power source for network use, a connection must be established between

the power source and PC using a LocalNet/RS232 interface. The "Service module" software is also required to make the settings.

More information about configuring the Ethernet interface can be found in the "Ethernet" operating instructions.

(1) Wire-feed unit

(1)

(2)

(3)

(2) RCU 5000i remote control option (3) Power source (4) PC, laptop or touch screen with

Fronius Xplorer software

(5) LocalNet/RS232 interface

Assigning an IP address

Assigning a firewall IP address

(4) (5)

To identify a power source uniquely within a network, it must be assigned a numeric address (IP address).

IMPORTANT! The IP address must be different for each power source.

The IP address can be set using the RCU 5000i remote control, or by entering it in the "Overview" worksheet under "Options - General - Browser settings".

By assigning a firewall IP address, access to the power source can be restricted to one user (PC). The firewall IP address is the same as the IP address of the PC that is to be given access rights to the power source. The firewall IP address can be set using the RCU 5000i remote control, or by entering it in the "Overview" worksheet under "Options - Show connection data".

Fronius Xplorer overview

General

WARNING! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described until you have thoroughly read and understood the following documents:

- these operating instructions

- all the operating instructions for the system components, especially the safety rules

NOTE! Due to software updates, you may find that your device has certain functions that are not described in these operating instructions or vice versa. Individual illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

IMPORTANT! To ensure system stability, make sure that Windows updates are installed regularly (update.microsoft.com).

The symbols and buttons described in this section provide an initial overview of symbols and buttons used at the browser level. Detailed descriptions of symbols and buttons can be found in the relevant worksheet section.

IMPORTANT! Grey symbols indicate that the system is offline or that data traffic has been interrupted. Grey buttons indicate that this function cannot be performed at this particular moment for programming reasons.

Fronius Xplorer The user interface is divided into two main activity areas:

1. The browser level provides an overview of the location and status of the systems available on the network.

2. The work level – provides information about the welding system configuration – permits access to the operation of the power source, including background menu – displays a view of the saved jobs. If enabled, this can be changed and managed

(set value)

– if enabled: contains welding data documentation (actual value documentation)

if an RCU 5000i remote control is connected

– records parameter changes, change of user, firmware updates and any errors

that have occurred

– performs a statistical analysis of the welding parameters

IMPORTANT! To record the current welding system data, Fronius Xplorer must be activated during welding and the RCU 5000i remote control connected (data documentation can be enabled if required). Data that was recorded on the RCU 5000i remote control's SmartMedia card can, however, be loaded into the program at a later date.

Browser level overview

The browser level provides an overview of the status and location of the installed welding systems.

(1)

(2)

(3)

(6)

(A)

(B) (C) (D) (E)

(5)

(4)

TPS 5000

(10.4.2.120)

TPS 5000 CMT

(10.3.4.102)

TPS 4000

(10.2.2.220)

MW 4000

(10.5.2.010)

TIME 5000 Digital

(10.4.2.122)

DeltaSpot 1 (10.4.2.129)

DeltaSpot 2 (10.3.4.145)

DeltaSpot 3 (10.2.2.232)

DeltaSpot 4 (10.5.2.246)

DeltaSpot 5 (10.4.2.090)

TPS 5000 CMT

(10.4.146.244)

TIME 5000

(10.4.146.230)

DeltaSpot 1

(10.2.130.201)

DeltaSpot 4

(10.2.130.204)

Work level overview

Browser level

(1) Fronius Xplorer bar

Overview showing progress of opened folders

(2) Scroll bar

For moving the screen view where there are more systems installed than can be displayed on screen

(3) Subfolder overview

Overview of the systems in the open folder

(4) Status overview with buttons

Overview of the status of systems in the open folder (A) Installed systems: displays all installed systems (B) Ready: displays all ready systems (C) Errors: displays all systems on which an error has occurred (D) Warnings: displays all systems on which a warning has occurred (E) Unknown: displays all systems with an unknown status

(5) Selection bar

For storing frequently required welding systems, or those that have been allocated a particular type of job. Click the mouse to access the work level of the selected system.

(6) Browser button

Press the browser button to exit the work level and return to the browser level

The work level allows access to all welding system settings. Any deviations from normal operation can be seen immediately, and all settings can be corrected from the workplace. All work with and on the welding system can be recorded and archived.

Work level

(1)

(2)

(3)

(4)

(5)

TPS5000 (No:15440923)

FP25

VR7000 -CMT

Ethernet-Gate (No:15440923)

RCU5000i (No:15050216)

LN Router

TPS5000 (No:15440923)

POWERMAG-OS

4.2.4

Weld Process Regulator

5.0.100

DB 0503

5.0.95

UST2BV1.4B

1.4.1

BPS53 V0.3A

0.3.0.

FP25

FP25_OS

1.21.14

FP25 V1.6A

1.6.0

F5 F6 F7 F8

Overview

Place / ....

Panel

Jobs

Doku

LogBook Statistic Diagram

TPS 5000 CMT

(10.4.146.244)

TIME 5000

(10.4.146.230)

DeltaSpot 1

(10.2.130.201)

DeltaSpot 4

(10.2.130.204)

* Available depending on option pack

Buttons at the browser level

(1) Location path of welding system

Shows name and location of the selected welding system

(2) Close welding system button

By pressing the "Close welding system" button, the welding system is removed from the selection bar

(3) Licence manager

all the available system options are shown in the licence manager. Activated options are shown in green. Blocked options can be enabled by entering a code.

(4) Work level

For navigating and working in the available worksheets

(5) Activated welding system in the selection bar

By activating a welding system, the user is taken to the work level of the welding system

Browser button

For switching from the work level to the browser level

"Create new file" button

For creating a new file

"Open file" button

For opening Fronius Xplorer files (e.g. data from non-networked systems)

Symbols for power source location

Power source locations are defined using the following folder symbols:

Home symbol

The highest folder level: Home/

Production location symbol

The second folder level: Home/Production location/

Factory symbol

The third folder level: Home/Production location/Factory/

Production hall symbol

The fourth folder level: Home/Production location/Factory/Production hall/

Production cell symbol

The fifth folder level: Home/Production location/Factory/Production hall/Production cell/

The type and status of the welding system are shown in the lowest folder level

System component symbols

Power source symbol

Applies to all Fronius power sources from the digital series

Wire-feed unit symbol

Applies to all available Fronius wire-feed units

Remote control symbol

Applies to all available Fronius remote controls (except RCU 5000i)

RCU 5000i remote control symbol (system add-on)

Applies to the RCU 5000i remote control

Interface symbol (robot, Ethernet, etc.)

When using an interface

Gas sensor symbol

When using a gas sensor

Part counter symbol

When using a RCU 5000i remote control, the part counter is shown here

Serial interface symbol

When using the LocalNet/RS232 interface

DeltaSpot spot welding gun symbol

Applies to Fronius DeltaSpot spot welding guns

PC symbol

Displays various version numbers

WibuKey symbol

Indicates whether a WibuBox is connected to the PC

System status

(1)

F5 F6 F7 F8

(2)

Overview

Place / ....

Panel

Jobs

Doku

LogBook Statistic Diagram

TPS 5000 CMT

(10.4.146.244)

symbols

(1) System activity status symbol:

Welding active

Arc is burning

(1)

(2)

(2) System status symbol:

Status OK

System working properly

(3)

Warning

System displays a warning

Unknown status

System is currently unavailable (switched off or disconnected from mains)

System stop

System displays an error on the control panel and is not working properly

(3) System status symbol:

Welding system online

Connection to system established, data being retrieved

System available

System ready to establish a connection

No connection

The connection to the system is interrupted (e.g. system is switched off)

Symbols in the Jobs and Docu worksheets overview

(1) Symbols in Jobs worksheet

Jobs licence and access rights

The Jobs worksheet is available, jobs are available for editing

Jobs licence, but currently no access rights

The Jobs worksheet is available, but the job is currently locked for editing by another user

Jobs licence not available

The Jobs worksheet is not available

(2) Symbols in Docu worksheet

Data recording activated

Data recording is activated in the pull-down menu of the Docu worksheet

Data recording deactivated

Data recording is deactivated in the pull-down menu of the Docu worksheet

Menu - Tools

Options

General Browser settings

Searches can be performed automatically or manually. If a search is performed automatically, either the IP addresses of the required machines or the broadcast addresses are entered in the text box. In the case of broadcast addresses, the whole subnet is searched for machines. If a search is performed manually, only the IP addresses of the machines can be entered. The main difference between the two search options is that in the case of static (manual) IP addresses (machines), the browser level marks the not found IP addresses (machines) as unknown.

If the user puts a "#" in the text field before the text, this is automatically interpreted as a comment.

Language

The language for Fronius Xplorer can be set here.

Currency

The "Documentation" worksheet has an option for entering consumption figures. The currency to be displayed can be set in this menu.

Data directory

The document data and user data is saved by default in "My Documents\Fronius International\Fronius Xplorer". The user can select a preferred storage location in this menu. Select a network drive as the location so that the same data can be accessed from several PCs.

LocalNet serial ports

Licences A WibuBox/U+ (USB) or WibuBox/P+ (parallel port) can be used to enable various options

Serial interfaces

Fronius Xplorer can be connected to the welding system via a serial interface. A LocalNet/ RS232 interface is required. This menu is used to specify the serial interface used.

in the system. Simply "Browse" to the machine on which the options are to be enabled. After the machine has been selected, Fronius Xplorer and the LocalNet server must be restarted.

Only used for DeltaSpot applications.

Fronius Xplorer login

OPC login interface: login details, such as user name and rights, can be obtained via an OPC server. The OPC server defines a user level that is assigned to a user profile in Fronius Xplorer. The user level can be changed by the OPC server during operation. Fronius Xplorer does not need to be restarted. See the "Creating a login via OPC" chapter for creating an OPC login.

UsbKey login interface: a UsbKey can be set up on a USB stick, which enables the different functions of Fronius Xplorer. See the "Creating a login via a UsbKey" chapter for creating a UsbKey.

Creating a login

via OPC

Open the menu "Tools - Options - Login"

Activate the "OPC" login interface

Enter the OPC server address under "OPC server url" (if the Windows session ID is required in the URL, the placeholder {sessionid} can be used. This is replaced by the current Windows session ID later.)

Add required user levels

Enter admin level

Enter value for "Exit when level is <=" (Fronius Xplorer closes when a user level is "less than" a certain value.)

The OPC variables required by the server are "OPC_Fronius" (int) for the user level and "Username" (string) for the user name.

Once Fronius Xplorer has been restarted, you will find automatically created user profiles under "Tools -> User profiles". These correspond to the user levels specified previously. The "LoggedOut" user profile is activated as soon as an unknown user level is detected. All rights are deactivated in this profile.

As soon as the configuration is finished, the current username, user level and Windows session ID are displayed at the top of the Fronius Xplorer window.

Creating a login via the UsbKey

Fronius Xplorer can be assigned to a production area. A USB stick can be enabled for a number of production areas (Fronius Xplorer).

Open the menu "Tools - Options - Login"

Activate the "UsbKey" login interface

Enter the name of the production area under "Name"

Enter a password for the production area under "Password"

Enter the password that you have just entered again under "Repeat password" (to

avoid typing errors)

After Fronius Xplorer has been restarted, the UsbKey login is activated.

The following steps must be carried out to create a UsbKey on a USB stick:

Insert USB stick into the PC

Click the "UsbKey administration" menu item in the "Tools" menu

The "UsbKey administration" window opens

Select the desired USB stick under "Create or modify a UsbKey on the drive"

Select the desired production area under "For the production area"

Enter the password for the production area selected above under "Password"

Click "Edit" to enter other user information

Enter "User number"

Enter "Name"

Select "Profiles" (can be edited under "Tools - User profiles")

Enter "Pin"

Enter the "Master password" for the production area

Click "Save"

The UsbKey has been created. After Fronius Xplorer has been restarted, a valid UsbKey will be detected. Once you have entered the pin, the profile for the user in this production area is enabled. If the USB stick is disconnected, Fronius Xplorer immediately switches to observation mode.

User settings

User profiles

Administrator

Arc welding

DeltaSpot

New

Delete Rename

Userprofile 1

Options

New file

Open file

Edit users

Enable Automatic logoff

Automatic logoff in minutes:

Open/close machines

Delete machines from browser

Change password

Split

General In user management, various users can be assigned individual user profiles.

Permissions can be granted in the user profiles. User profiles can be created under "Tools

- User profiles".

The created profiles are assigned to the various users in the "Tools - User management" menu. The "User profiles" and "User management" menus can only be accessed by users with the "Administrator" user profile.

Creating a new user with a new user profile

Managing the user profiles

Open the "User profiles" menu ("Tools - User profiles")

Click the "New" button to create a user profile

Enter the name and press "Enter"

Grant the required permissions to the newly created user profile by checking or unchecking the box

In the next step, the user profile that you have just created will be assigned to a newly created user:

Open the "User management" menu ("Tools - User management")

Press the "New user" button to create a user

Enter the user name (= login name) and assign the user profile

The user profile menu can only be accessed by users with the administrator user profile.

The User profiles menu ("Tools - User profiles") allows you to:

- create

-delete

- rename

- and change user profiles

In addition, a time can be set after which a user profile is automatically logged out.

User manage-

ment

The User management menu can only be accessed by users with the administrator user profile.

The User management menu ("Tools - User management") allows you to:

- Create users

- Delete users

- Change or delete passwords (only the "Admin" user can change or delete passwords without having to enter the old password)

- To see who is logged in automatically when the program opens. This user does not need a password when the program starts.

Logging on and off automatically

Changing the user

Example of a user logging on and off automatically:

- The "Admin" user (user profile 1) logs on and carries out work on the system

- "Admin" forgets to log off

- Automatic log off is activated. "Admin" is automatically logged off the system after the specified time.

- Automatic log on is specified for the user "User 1"

- "User 1" is logged on to the system without being prompted to enter a password

Press the "Change user" button

Enter the user name and password

Press Enter

Splitting the window

TPS 5000 (No:15440923)

FP25

VR7000 -CMT

Ethernet-Gate (No:15440923)

RCU5000i (No:15050216)

LN Router

TPS5000 (No:15440923)

POWERMAG-OS

4.2.4

Weld Process Regulator

5.0.100

DB 0503

5.0.95

UST2BV1.4B

1.4.1

BPS53 V0.3A

0.3.0.

FP25

FP25_OS

1.21.14

FP25 V1.6A

1.6.0

Overview

Place / ....

Panel

Jobs

TIME 5000 (No:15440924)

VR7000 -CMT

Ethernet-Gate (No:15440924)

RCU5000i (No:15050217)

TPS5000 (No:15440924)

POWERMAG-OS

4.2.4

Weld Process Regulator

5.0.100

DB 0503

5.0.95

UST2BV1.4B

1.4.1

BPS53 V0.3A

0.3.0.

FP25

FP25_OS

1.21.14

FP25 V1.6A

1.6.0

Overview

Place / ....

Panel

Jobs

TPS 5000 CMT

(10.4.146.244)

TIME 5000

(10.4.146.230)

DeltaSpot 1

(10.2.130.201)

DeltaSpot 4

(10.2.130.204)

Splitting the window

If split window is enabled under "Tools - Split window", then as many worksheets as required can be displayed side by side/below one other. To show/hide the welding systems, click the relevant item in the selection list.

Windows displayed side by side

"Tools - Switch window split" allows you to switch between horizontal and vertical split.

Browser level

Ready

Errors

Warnings

General The browser is split into several folder levels. The welding systems are sorted into folder

levels according to their location and assignment. To access the next folder level, simply click on the folder button.

Navigation in browser

Folder structure:

Highest folder level: Home

Provides an overview of the production locations on the network.

Switching from browser view to status view

Company or production location folder level

Provides an overview of the production facilities at the production location.

Production facility folder level

Provides an overview of the production halls at the production facility.

Production hall folder level

Provides an overview of the welding cells in the production hall.

Welding cell folder level

Provides an overview of the welding systems in the cell.

Simply click the mouse to return to a higher-level folder at any time.

The browser view can be switched to a view that shows systems with the same status.

Press the relevant button for status view in the browser view

Systems with the same status are displayed in a table:

Installed units

Ready

Warnings

Offline

Errors 3

TPS 5000 CMT

(10.4.146.244)

TIME 5000

(10.4.146.230)

DeltaSpot 1

(10.2.130.201)

DeltaSpot 3 (11.4.22.298)

TPS 4000 (10.4.146.244)

TPS 5000 CMT (10.4.141.221)

/Path/...

/Path2/....

/Path3/...

TPS 5000

(10.4.2.120)

TPS 5000 CMT

(10.4.146.244)

TPS 4000

(10.2.2.220)

MW 4000

(10.5.2.010)

TPS 5000 CMT

(10.4.146.244)

Installed units

Ready 10

Errors 3

(2)

(1)

TPS5000 (No:15440923)

FP25

VR7000 -CMT

TPS5000 (No:15440923)

POWERMAG-OS

4.2.4

Weld Process Regulator

5.0.100

DB 0503

5.0.95

UST2BV1.4B

1.4.1

F5 F6 F7 F8

Overview

Place / ....

Panel

Jobs

Doku

LogBook Statistic Diagram

TPS 5000 CMT

(10.4.146.244)

TIME 5000

(10.4.146.230)

Click the mouse to open the relevant system, provided that the firewall IP address is configured for the PC trying to access it, or no firewall IP address is set and there are fewer than 4 users logged in.

Copying a welding system to the selection bar

Removing a welding system from the selection bar

To access the work level of a welding system, firstly copy the welding system to the selection bar. It is possible to copy as many welding systems to the selection bar as desired. This enables the status and availability of relevant welding systems to be seen at a glance.

To copy a welding system to the selection bar:

Access the folder level of the desired production cell

Click the mouse to copy the welding system to the selection bar

To copy more welding systems to the selection bar, repeat this process

Welding systems from various locations can be copied to the selection bar. Welding systems copied to the selection bar are retained, regardless of the current folder level.

Removing a welding system from the selection bar

Select the welding system that is to be removed from the selection bar (1)

Press the Close welding system button (2)

Alternatively, right-click on the welding system to be removed from the selection bar and confirm by clicking Close.

Worksheets

Worksheet overview

TPS5000 (No:15440923)

FP25

VR7000 -CMT

Ethernet-Gate (No:15440923)

RCU5000i (No:15050216)

LN Router

TPS5000 (No:15440923)

POWERMAG-OS

4.2.4

Weld Process Regulator

5.0.100

DB 0503

5.0.95

UST2BV1.4B

1.4.1

BPS53 V0.3A

0.3.0.

FP25

FP25_OS

1.21.14

FP25 V1.6A

1.6.0

F5 F6 F7 F8

Overview

Panel

Jobs

Doku

LogBook Statistic Diagram

Worksheet overview

The Worksheet overview provides information about:

- Welding system configuration

- Currently installed firmware versions

- Network connection used

To go to the work level, select the desired welding system on the selection bar.

To request information on a listed system component, activate the system component by clicking on it:

E.g.: system configuration with TPS 5000 power source

Buttons and symbols in the Worksheet overview

Refresh button

Updates system information

Undo button

The jobs on the machine are reset to their former status

Attach file button

Attaches a file to the job (e.g. photo of weld seam, etc.)

Maintenance panel button

Allows the maintenance counter of the:

- contact tip

- welding torch

- power source

- wire-feed unit

- and the hosepack to be read and reset

Backup options menu button

- for defining a master backup file

- for creating an automatic backup

- for opening the backup directory in Windows Explorer

- for showing an expanded view of all bus nodes

- for displaying connection data

- for configuring the system name and location

- for exporting the device configuration

- for configuring the field bus settings

Backing up and

Config automatic backup

Enable automatic backup

Next start time: Wednesday, 13 July 2011 13:00:00

Daily

Backup folder C:\users\administrator\Documents\Fro

...

Def

restoring data

The backup file contains all the welding system data. The backup path is specified and saved under the serial number of the power source (Mt Documents/Fronius International/ arc/specific/serial no./backup). It is, however, possible to specify the backup path individually.

Creating the backup:

Press the "Backup" button

Select the storage location and confirm by pressing the "Save" button

The backup is created

Restoring the backup:

Press the "Restore" button

Select the backup file and press the "Open" button

The backup is restored

NOTE! Restoring backed-up data will overwrite the latest data, which cannot be recovered.

Setting up automatic backup

The automatic backup backs up data at a defined interval.

Press the "Options" button

Press "Automatic backup settings"

Select the time, interval and backup path for the automatic update

Tip: select a network drive as the location so that the same data can be accessed from several PCs.

Defining and cancelling the master backup

It is possible to define a backup that will be restored automatically when the "Restore backup" button is pressed. This ensures that if data is lost or welding parameters are changed unintentionally, saved settings (jobs) are not lost.

Defining the master backup

Press the "Options" button

Press "Master backup"

Connection settings

IP address

Firewall IP Active connections 10.4.120.7

Default gateway

Subnet mask

Port number

10.4.146.246

0.0.0.0

10.4.146.245

255.255.248.0

Modbus firewall

Modbus UDP Fronius

170.170.170.170

Modbus port number

502

15001

MAC address

00-03-AC-03-43-02

10.4.146.245

Select master backup and confirm by pressing "Open"

Import master backup by pressing the "Restore backup" button

Cancelling the master backup

By cancelling the master backup option, a selection dialog box appears after pressing the "Restore backup" button.

Press the "Options" button

Press "Deactivate master backup"

Displaying connection status

Press the "Options" button

Press "Show connection settings"

IP address XX.X.XX.XX

Displays the current IP address

Firewall IP XX.X.XX.XX

Displays the IP addresses of the computers that have access to the power source. Setting 0.0.0.0 means that no access restrictions have been set, and up to 4 computers can access the power source.

Active connections XX.X.XX.XX

Displays the computers currently connected to the power source

Saving the device

Machine configuration

Machine path:

New folder

TPS 4000 (10.4.146.245)

configuration

When documenting data, the current device configuration can be exported and saved on the data medium as a text file.

Press the "Options" button

Press "Save device configuration"

Select the location and save the file

Configuring the system name and location

Press the "Options" button

Press "Machine configuration"

Press the "New folder" button

Enter a name for the location and confirm or press the "New folder" button repeatedly

until the desired folder structure is created

Fill in the field for "Machine name" and confirm details

IMPORTANT! The "Machine" is always saved in the highlighted folder. If there are subfolders with no machines under this highlighted folder, the subfolders are deleted automatically. The "Machine" can be moved to another folder at any time.

Control panel worksheet

Panel

(1)

(2)

Control panel worksheet

The control panel is modelled on the control panel of the connected power source. In addition, functions can be executed directly through shortcuts on the PC keyboard. The integrated adjusting dial (2) makes the touchscreen easy to use. Further information about the control panel function can be found in the power source operating instructions.

NOTE! If the RCU 5000i remote control is connected to the power source, operation via the Control panel worksheet is no longer available. The current parameter settings are displayed on the screen. The buttons on the control panel cannot be selected.

IMPORTANT! For safety reasons, the wire threading function is not available.

Operating the control panel using the keyboard

Example: Comfort/TPS 5000 power source control panel

(1) Control panel options menu

For selecting the control panel (e.g. TIG welding or US variant)

(2) Adjusting dial

For adjusting the currently selected welding parameter using the mouse or touchscreen

All welding parameters can be adjusted using shortcuts on the PC keyboard. Press the space bar to display the shortcuts available.

Example: displaying the shortcuts by pressing the space bar

Jobco

WFS

GAS

Trigger

Main

Accessing a power source set-up menu

To access a power source set-up menu:

Select and hold down the Setup button

Keep the left mouse button pressed down and move the cursor to Lock

Release left mouse button

The available set-up menus are displayed

Open the desired set-up menu

Alternatively, access the set-up menu by right-clicking.

rr.

Example: displaying available set-up menus

Jobs worksheet

(3)

(2)

(1)

(8)

(7)

(6)

(5)

(4)

Jobs worksheet The Jobs worksheet can be used to edit, copy and manage jobs. The locations are split

into groups of 10 jobs.

IMPORTANT! In order to use all the functions of the Jobs worksheet, the JobExplorer option must be enabled on the power source.

Connecting the RCU 5000i remote control increases the number of locations from 100 to

1000.

Jobs worksheet

(1) Buttons for confirming job changes

Select according to parameter changes

- Changes to power source or RC

- Undo changes

(2) Sizing bar

- Adjust window to desired size

- Double-click to change and adjust the view automatically

(3) Job/job groups scroll bar

The following is displayed in the bar

- White: free job spaces

- Blue: occupied job spaces

- Yellow: jobs with parameter changes

- Red: jobs with incorrect parameter settings

- Grey: jobs have not yet been synchronised with the power source

(4) Button bar

For selecting available functions

(5) Job groups

- Select all jobs in the group by clicking the mouse

- Double-click to edit job group names

(6) Jobs display field

- By selecting this, the parameter settings are shown in the parameter display (7)

- Double-click on job names to edit them

(7) Parameter display

- Shows current parameter settings and parameter changes

- Unconfirmed parameter changes are shown in yellow

(8) Welding parameter scroll bar

For scrolling in the parameter display

Buttons and symbols in the Jobs worksheet

Power source button

The jobs are transferred from the machine to Fronius Xplorer

Save job button

Confirm changes or newly created job

Undo button

The jobs on the machine are reset to their former status

Attach file button

Attaches a file to the job (e.g. photo of weld seam, etc.)

Copy job button

Copies selected jobs

"Delete job" button

Deletes selected jobs

Change job button

Changes selected jobs

History button

Provides an overview of the history of the selected job

File attachment button and symbol

- For opening an attached file

- Shows that a file is attached to the job

Change to job warning symbol

Means that there has been a job change on the

- power source

- RCU 5000i remote control

- Fronius Xplorer

E.g.: if the connection between an RCU 5000i remote control and Fronius Xplorer is interrupted, this is treated by the power source as a job change. Once the connection has been restored, the "Change to job warning symbol" appears next to the job that has been changed.

Job error button

Incorrect parameter settings, job cannot be carried out

Important! If a job is transferred that contains an option that is not available on the machine (e.g. spatter-free ignition), its status will be displayed as "Limited".

Job change conflict

Different job change on the RCU 5000i remote control and the power source during connection interruption.

Job options menu

For exporting and importing jobs

IMPORTANT! Jobs that have not yet been synchronised with the power source are iden-

tified by a grey dot.

Displaying job data

Copying and pasting jobs

Click mouse to select a job. Show data in the parameter display (7).

Copying a job, jobs or job group

Select a job, jobs or job group

Press the "Copy" button or Ctrl + C

Select location

Press the "Paste" button or Ctrl + V

Copying a job, jobs or job group from one power source to another

Select a job, jobs or job group

Press the "Copy" button or Ctrl + C

Exporting/importing jobs

Select a power source for pasting the jobs

Select location

Press the "Paste" button or Ctrl + V

IMPORTANT! Jobs can only be copied to another power source if the Job management option (JobExplorer) is enabled on the target power source. If the copied job cannot be carried out on the target power source, an error message appears.

Exporting a job, jobs or job group to data medium

Select a job, jobs or job group

Press the "Options" button

Press the "Export" option

Select storage location and save job(s)

Importing jobs from data medium

Select the desired paste location in the "Jobs" worksheet

Press the "Options" button

(1)

(2)

Press "Import"

Select job(s) and press "Open" to import

IMPORTANT! The file that is imported always contains the same number of jobs that were selected during the export:

- Single job

- Several highlighted jobs

- Job group

- Several job groups

Pasting job data into an external document

Attaching a file to a job/opening an attached file

Select jobs

Copy jobs to the clipboard by pressing the "Copy" button or Ctrl + C

Open a spreadsheet program, e.g. Excel, or a word processing program, e.g. Word,

a n d s e l e c t " P a s t e " f r o m t h e " E d i t " m e n u , o r p r e s s C t r l + V

Select job

Press the "Attach file" button

Select file from data medium and confirm

The Attach file symbol appears next to the job

The user can attach as many files as required to one job.

IMPORTANT! When pasting, the original file is not pasted into the program, a link to the file is created instead. If the file is removed from its original location, the program will no longer be able to find the file.

Opening a file attachment

Select job with file attachment

Select "Attach file" button (1) and click to open

If desired, remove attached file by selecting the "Remove attached file" button (2).

Deleting a job Select a job, jobs or job groups

Changing a job Select job

Job history A detailed view of the selected job can be called up under Job history. Any changes made

Press the "Delete" button

Press the "Change" button

Change welding parameters (see power source operating instructions)

to a job are recorded and shown here. Old versions of the job can be loaded onto the machine again.

Docu worksheet

dd.mm.yyy hh:mm:ss.x

KXX-XXXX

XXX,X

XXX

XX,X

dd.mm.yyy hh:mm:ss.x

KXX-XXXX

XXX,X

XXX

XX,X

dd.mm.yyy hh:mm:ss.x

KXX-XXXX

XXX,X

XXX

XX,X

dd.mm.yyy hh:mm:ss.x

KXX-XXXX

XXX,X

XXX

XX,X

dd.mm.yyy hh:mm:ss.x

KXX-XXXX

XXX,X

XXX

XX,X

dd.mm.yyy hh:mm:ss.x

KXX-XXXX

XXX,X

XXX

XX,X

Imin

Start Time

Seam

Partnumber

Arc Time

Imean Imax Umin Umean Umax Limit

wire

Gas

Welds

Docu

Docu worksheet The documented welding data is shown in the Docu worksheet:

-Welds

- Weld seam sections

- Set values of a weld seam (upslope, etc.)

- Actual values (only when RCU 5000i remote control is connected)

-Errors

- Consumption figures

Docu worksheet

Welding data currently in the memory is shown using the red power source symbol

Buttons and symbols in the Docu worksheet

The welding data remains in the memory for approx. 10 min. weld time. Fronius Xplorer then deletes the welding data from the detailed views. The welding data that is no longer in the detailed views can be displayed by clicking the grey power source symbol.

Welding data that is no longer in the detailed views can only be viewed in the Weld seams menu. Double-clicking on the grey power source symbol causes Fronius Xplorer to reload the welding data in the detailed views, and all the welding data can be viewed again:

Highlight welding data

Right-click and press "Load details"

Welds symbol

Documents the welding data (actual data) for the entire weld seam

Sections symbol

Documents the welding data (actual data) for individual sections of the weld seam

Set values symbol

Documents the specified set values

Actual values symbol

Documents the actual welded values. Records voltage (U), current (I) and weld time (arc time) every 100 ms.

Error symbol

Documents any errors that occur with a time stamp and in plain text.

Load welding data button

Displays and loads recorded welding data

Display current welding data button

Displays current welding data recording on the screen

Pause current screen view button

The current screen view stays on screen. Data continues to be recorded in the background. Activation takes place automatically when recorded welding data is opened.

Save welding data as Excel file button

The user can either export the highlighted welds to Fronius Xplorer (selected welds) or automatically save the selected FDO files (Fronius data format) in the background.

Online welding data symbol

Welding data that is currently in the memory is shown by the red power source symbol

Offline welding data symbol

Displays welding data that is no longer in the memory. Displayed using the grey power source symbol.

Docu data options menu

For selecting

- default settings for welding wire and shielding gas consumption figures

- data import

- country-specific settings

- Excel export

- switch data recording on/off (data receiver)

- time synchronisation

- diagram type

Limit exceed symbol

Limit exceed of upper/lower current or voltage limit

Applying the default settings for consumption figures

Error symbol

An error has occurred during welding

Press the "Options" button

Select "Consumption figures default settings"

Wire diameter in mm

For setting the wire diameter being used

Gas consumption in l/min

For setting the gas consumption. When using the GAS 30 I-kit, this option cannot be selected (preset by the sensor).

Welding speed in cm/min symbol

For setting the degree of efficiency

Degree of efficiency in % symbol

For setting the degree of efficiency

New wire button

For creating new wire material with a specific weight

Update wire material button

For updating existing wire material

Delete wire material button

For deleting wire material from the database

IMPORTANT! The currency can be set under "Tools - Options".

Automatic Excel export

Switching welding data recording on and off

Welding data can be saved automatically in an Excel file after every weld. The file location can be specified in the "Export wizard".

Press the "Options" button

Press "Excel export"

If "Excel export" is enabled, the data is saved in an Excel file after every weld.

"Data Receiver ON" must be enabled in the options menu to run the welding data documentation.

Press the "Options" button

Press "Data Receiver ON"

IMPORTANT! If the welding data documentation is disabled, no data is recorded in the worksheets, log book, statistics and graph.

Time synchronisation

A symbol in the Worksheet overview indicates whether the data receiver is enabled:

Data receiver enabled

Data receiver disabled

In order to obtain exact start and error times, synchronisation with the system time must be carried out. Synchronisation may be carried out automatically or manually.

Automatic time synchronisation

Press the "Options" button

Press "Automatic time synchronisation"

This setting is saved for each power source.

1212

If a RCU 5000i remote control is connected, then automatic time synchronisation is switched off as standard. If no RCU 5000i remote control is connected, then a prompt appears for automatic time synchronisation when the system is first opened.

Manual time synchronisation

Press the "Options" button

Press "Synchronise time now"

Displaying welds/ consumption figures menu

Completed welds are shown in the Welds menu. One weld seam consists of one or several weld seam sections and lasts from welding start to welding stop. The completed welds are numbered and listed consecutively (they may also be assigned to a part number).

Displaying consumption figures: the calculation is made using the default settings for the consumption figures.

Highlight one or more weld seams

Right-click and press "Consumption figures"

Consumption figures are shown

Welding parameter OK symbol