Lincoln Vrtex 360 Operator's Manual

VRTEX™360

IM10046-A

July, 2010

For use with machines having Code Numbers:

Safety Depends on You

Lincoln equipment is designed
an d bu ilt with sa fety in min d.
However, your overall safety can
be increased by proper installa­tion ... and thoughtful operation
on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, t hink before
you act and be careful.

AD1332-1 Software Version 1.0.7.7
AD1332-2

NOTICE

The VRTEX
tual reality arc welding
training machine only
and NOT a real arc
welder. When welding
with arc welding equip­ment, be aware of all
standard safety practices
associated with arc weld­ing. Some standard
warnings are included in
this manual.

TM

360 is a vir-

OPERATOR’S MANUAL

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.VRTEX360.com

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not ad d the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on con tac t with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In so me ca se s it may be ne ce ss ar y to remove safety

gu a rds to p erf o rm r equ ire d ma i nt e nan ce. Rem ove
guards only when necessary and replace them when the
ma i nte nan ce re q uir ing th ei r remo val is co mpl ete .
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flo wing thr ough any conductor caus es
localized Electri c and Mag netic Field s (EMF). Welding
current cre ates EMF fields aro und welding ca bles and
welding machines

2.b. EMF fields may interfere wi th so me pa ce makers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Nev er co il th e electr ode l ead around your body .

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

VRTEXTM360

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. We ar dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
mu st be perform ed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel , welding head , nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously t ou ch el ec tr ic al ly “hot” pa rt s of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Weldi ng may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. Wh en welding , k eep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

we lding with ele ctr odes wh ich req uir e sp eci al
ve nti lat ion such as sta inl ess or hard fac ing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum­st anc es, outdoors, a res pir ato r ma y be r equ ire d.
Additional precautions are also required when welding
on galvanized steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or deat h. Al wa ys use e nough ventil at ion,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t eri al safe ty da ta shee t ( MSD S) and fo llo w you r
employer’s safety practices. MSDS forms are available from
yo u r weld ing di str i but or or fro m th e manu fac tur er.

5.f. Also see item 1.b.

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iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Re m emb er t hat wel din g sp ark s an d hot
materials from welding can easily go through small cracks
an d open ings t o adj acent areas . Avo id w el ding n ear
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Stand ard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Co n tai ner s and Pip ing Th at Hav e Held Ha zar dou s
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase th e possibili ty of the welding current pas sing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from st arting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Us e onl y com pre sse d gas c yli nde r s
containing the correct shielding gas for the
pr o ces s us ed a n d pr ope rly o per ati ng
re g ula tor s d esi gne d f or th e g as an d

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Re ad and fo ll ow the in struction s on c om pressed ga s
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Ins tall equipment in ac cordance with the U.S. National
Electrical Co de, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

VRTEXTM360

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la mas se. Un court-circ uit ac cidental peut pro voquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’o pérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protége r l ’autre person nel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fu sion sont émise s de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

VRTEXTM360

v

SAFETY

v

WARNINGS

Do not place objects on the VR Table, Arm
or Weld Machine.

Handle the Face Mounted Display (FMD)
integrated helmet with care. When not in
use, the Helmet should be placed on the
helmet hanger peg. If you will not be
using the system for longer than 4 hours,
shut down your VRTEX(TM) 360 System.

Handle t h e VR SMAW device and V R
GMAW/FCAW gun with care. When not in
use, these items should be placed on the
appropriate holders located on the sides
of the VR machine. These devices are
customized and cannot be used on nor­mal welding machines.

Handle the VR Coupons with care. When
not in use, store them in the Coupon
Drawer at the b a c k o f the VR Weld
Machine.

During lightning storms, turn off the sys­tem and unplug it from the power outlet.

VRTEXTM360

vi

SAFETY

vi

Recycling Welding Equipment at End of Life

Waste Electrical and Electronic Equipment (WEEE)

Recycling

Recycling and reclamation of used electrical and electronic equipment is important to many nations and localities. Lincoln
Electric provides information to assist in the recycling of welding equipment.

This parts list contains a “WEEE” column. The WEEE column describes potential recyclable materials. Materials that
require selective treatment, according to national regulations, are also identified in the WEEE column.

The following table describes substances that are potentially recyclable. Components with high substance content are
identified within the parts list. Easily identified and common components such as steel screws, steel nuts, steel washers
and copper wire are not identified on the list, but are also recyclable. Some components may contain mixed substances.

Substance

Steel, Iron Fe

Aluminum

Copper

Recyclable Material

Identification

Al

Cu

WEEE in Europe

This instruction is mandatory for equipment in Europe that displays this symbol:

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE) and its imple­mentation in accordance with national law, electrical equipment that has reached the end of its life must be collected sep­arately and returned to an environmentally compatible recycling facility. As the owner of the equipment, you should get
information on approved collection systems from your local Lincoln representative. By applying this European Directive
you will protect the environment and human health!

The following components must be removed from the welding equipment and shall be selectively treated. They shall be
disposed of or recovered in compliance with Council Directive 75/442/EEC. They are identified within the parts pages:

Component

Selective Treatment

Identification

Printed circuit boards with surface greater than 10 square centimeters ST

Liquid crystal displays with surface greater than 100 square centimeters ST

External electric cables (not all external cables are shown on parts pages) ST

Electrolyte capacitors with height >25 mm and diameter >25 mm or proportionately
similar in volume

ST

VRTEXTM360

Thank You

viivii

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual Completely before attempting to use this equipment. Save this manual
and keep it handy for quick reference. Pay particular attention to the safety instructions we have pro­vided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

VRTEXTM360

viii

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Graphic Symbols ..................................................................................................................A-1

Technical Specifications.......................................................................................................A-2

Safety ...................................................................................................................................A-3

Location................................................................................................................................A-3

Environmental Area..............................................................................................................A-3

Stacking/Tilting/Lifting ..........................................................................................................A-3

High Frequency Interference Protection...............................................................................A-3

General Description..............................................................................................................A-4

Design Features ...................................................................................................................A-4

Hardware Uncrating & Set-up........................................................................................A-4/A-7

________________________________________________________________________________

Operation .........................................................................................................Section B

Product Description ..............................................................................................................B-1

User Interface Overview.......................................................................................................B-2

Hardware Specifications ................................................................................................B-3/B-5

Powering Up.........................................................................................................................B-6

Login Screen ........................................................................................................................B-7

Joint Configuration ...............................................................................................................B-8

Process Selection.................................................................................................................B-9

Stand Set-up ........................................................................................................................B-9

VR Coupons .........................................................................................................................B-9

Table/Arm Rotation ............................................................................................................B-10

Environment .......................................................................................................................B-11

VR Gas Set-up ...................................................................................................................B-11

Weld Machine Settings.......................................................................................................B-12

Push Buttons ......................................................................................................................B-13

Travel / Work Angle............................................................................................................B-14

Welders View .....................................................................................................................B-15

Instructors View..................................................................................................................B-15

LASER (Live Action Student Evaluation Report)................................................................B-15

Technique Parameters .......................................................................................................B-16

Position...............................................................................................................................B-17

Work/Travel Angle..............................................................................................................B-17

Pass Number, Travel Direction, Discontinuities .................................................................B-18

Instructor Mode ..................................................................................................................B-19

Updates ..............................................................................................................................B-19

Weldometer

Tolerance Editor .................................................................................................................B-21

Choosing Tolerance Set-up................................................................................................B-22

Choosing Tolerance To Load .............................................................................................B-22

Tolerances Screen(s) ................................................................................................B-22/B-25

Tolerances Whip & Travel Speed.......................................................................................B-26

Default Weld Processes Settings .......................................................................................B-27

________________________________________________________________________________

TM

.....................................................................................................................B-20

viii

Maintenance ....................................................................................................Section D

Cleaning & Maintenance .......................................................................................D-1

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide....................................................................................E-2/E-3

________________________________________________________________________

Wiring Diagrams..............................................................................................Section F

________________________________________________________________________

Parts Pages..............................................................................................................P638

VRTEXTM360

A-1

INSTALLATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

A-1

1

INPUT POWER

ON

OFF

CIRCUIT BREAKER

INPUT POWER

SINGLE PHASE
ALTERNATING CURRENT

READ THIS OPERATORS
MANUAL COMPLETELY

U

1

I

1

INPUT VOLTAGE

INPUT CURRENT

PROTECTIVE
GROUND

WARNING or CAUTION

Documentation must be con­sulted in all cases where this
symbol is displayed.

Explosion

Dangerous Voltage

USB

Shock Hazard

Shock Hazard

VRTEXTM360

A-2

INSTALLATION

TECHNICAL SPECIFICATIONS: AD1332-1 (STD. FREQ.) / AD1332-2 (ALT. FREQ.)

VRTEX™360 - VIRTUAL REALITY WELDING TRAINER

INPUT

MAKE/MODEL DESCRIPTION INPUT VOLTAGE INPUT CURRENT

+/- 10% (MAX.)

A-2

AD1332-1
AD1332-2

Standard Frequency 115-230 VAC (50-60 HZ) 4A-2A Single Phase
Alternate Frequency 115-230 VAC (50-60 HZ) 4A-2A Single Phase

WARNING

THIS PRODUCT INCORPORATES A PROTECTIVE EARTH IN THE AC POWER CORD. THE AC PLUG

SHOULD ONLY BE INSERTED INTO A SOCKET OUTLET PROVIDED WITH A

PROTECTIVE EARTH CONTACT.

TRACKING SYSTEM FREQUENCY

MAKE/MODEL DESCRIPTION OPERATING FREQUENCY

AD1332-1
AD1332-2

PHYSICAL DIMENSIONS (MACHINE W/MONITOR)

HEIGHT WIDTH DEPTH WEIGHT

71.0 in. 30.0 in. 50.0 in. 360 lbs.
1803 mm 762 mm 1270 mm 163 kg.

Standard Frequency HIGH
Alternate Frequency LOW

1

C

PHYSICAL DIMENSIONS (STAND)

HEIGHT WIDTH DEPTH WEIGHT

78.0 in. 39.0 in. 47.0 in. 102 lbs.
1981 mm 990 mm 1194 mm 46 kg.

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE

0

- 950F5

41

0

- 350C 320 - 1490F 00 - 650C

RELATIVE HUMIDITY OPERATING ALTITUDES

80% For Temperatures Up To 880F / 310C

50% @ 1040F / 400C 6562 Feet (2000 Meters)

ENVIRONMENT

This Product is Pollution Degree 1.

THIS PRODUCT HAS BEEN TESTED TO THE REQUIREMENTS OF CAN/CSA-C22.2 NO. 61010-1,
2ND EDITION, INCLUDING AMENDMENT 1, OR A LATER VERSION OF THE SAME STANDARD
INCORPORATING THE SAME LEVEL OF TESTING REQUIREMENTS.

VRTEXTM360

A-3

STRAPS

STRAPS

READ ENTIRE INSTALLATION SECTION BEFORE
STARTING INSTALLATION.

INSTALLATION

Safety Precautions

A-3

TILTING

Place the VRTEXTM360 directly on a secure, level sur­face.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should per­form this installation.

• Tur n the input p ower OFF and
unplug the machine from the recep­tacle before working on this equip­ment.



•



• Always connect the
ply grounded according to the National Electrical
Code and local codes.

------------------------------------------------------------

SELECT SUITABLE LOCATION

The machine will not operate in harsh environments.
It is important that simple preventative measures are
followed in order to assure long life and reliable opera­tion. This product is for INDOOR USE ONLY.

• Dirt and dust that can be drawn into the machine

should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.

• Do not locate where monitor is exposed to direct

sunlight.

VRTEXTM360

to a power sup-



If lifting the

rated for 500 pounds (226.8 kg) or more. Do not attempt to
lift the

VRTEXTM360

VRTEXTM360

is required, use two straps, each

with accessories attached to it.



• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when
lifting.

• Do not operate machine while
suspended or when lifting.

• Do not place equipment near radiant heat sources.

• Do not place in a confined space. Allow a minimum
of 3 feet of clearance around machine and stand at
all times. Adequate ventilation is necessary.

• The circuit breaker switch on the rear panel is the
input power disconnect device. Do not position the
equipment so that it is difficult to operate the circuit
breaker.

• Route and protect power cable to minimize exposure
to damage.

ENVIRONMENTAL AREA

Keep the machine inside and dry at all times. Do not
place it on wet ground or in puddles. Never place liq­uids on top of the machine.

STACKING

The VRTEXTM360 cannot be stacked.

FALLING EQUIPMENT can cause injury.

------------------------------------------------------------------------

HIGH FREQUENCY INTERFERENCE PRO­TECTION

CAUTION

USE CAUTION WHEN OPERATING THIS MACHINE
AROUND OTHER EQUIPMENT.

• Large equipment, such as cranes, may interfere
with the operation of this machine.

• This machine may interfere with the operation of
other equipment in work/training area.

VRTEXTM360

A-4

-1-2-1-2

-2-1-2-1

-1 -2 -1 -2

-2 -1 -2 -1

INSTALLATION

GENERAL DESCRIPTION

The VRTE XTM360 is a Virtual W elding Training
System and VRAW
Solution. This computer controlled interactive system
simulates arc welding through the use of realistic pud­dle graphics and sounds. This training system simu­lates multiple arc welding processes on a wide variety
of weld joint configurations. The VRTEX
sents the next generation of Virtual Reality (VR) weld­ing training.

TM

(Virtual Reality Arc Welding)

TM

360 repre-

DESIGN FEATURES

HARDWARE OVERVIEW:

• Virtual Welding Machine, including:
o Monitor
o Coupon Drawer (back drawer)
o VR GMAW/FCAW Gun
o VR SMAW Device
o VR GMAW/FCAW Gun Holder
o VR SMAW Device Holder
o VR Helmet w/Face Mounted Display (FMD)
o Five VR Coupons - Flat Plate

Tee Joint
Groove Joint
2” Pipe XXS
6” Pipe Schedule 40

• Stand, including:
o Post
o Arm
o Table
o Pins
o Base
o Weights

A-4

HARDWARE UNCRATING:

TOOLS NEEDED

3/8” (9.5 mm) Wrench
3/16” (4.8 mm) Allen Wrench
Phillips Screwdriver

1. Decide on a location for your unit.

NOTE: The system requires approximately 8’ L x 8’

D x 8’ H (2.4 m L x 2.4 m D x 2.4 m H) of
space. Keep at least 3 feet in all directions
of both the stand and VR weld machine free
from obstruction. In addition, be conscious
of where you are placing the unit to avoid
magnetic fields, conductive, and high fre­quency ob jects and processes. H aving
these types of objects in the area can cause
interference and result in increased jitter
and/or distortion in the motion tracking.

TM

For best results, do not install VRTEX
machine in the welding lab. Electrical inter­ference from power lines, though generally
small, can be present. Therefore all electri­cal power or lighting wiring within 50 feet of
the we lding area sha l l be e n closed in
grounded rigid metallic conduit. In the event
the VRTEX

TM

360 is affected by interference,

it is the user's responsibility to take steps to
isolate and/or eliminate the interference.

An uninterruptible power supply (UPS) may
be required for the protection of the system
from power irregularities or disruption.

MULTIPLE SYSTEM INSTALLATIONS

If multiple systems are required to operate together in
one location, a unique frequency transmitter can be
installed during the manufacturing process at Lincoln
Electric to reduce potential interference between sys­tems. AD1332-1 systems have a standard frequency
source installed. AD1332-2 systems have an alternate
frequency source installed. For multiple system installa­tions, alternate the -1 and -2 systems for best operation:

360

For Example: If 8 systems are to be installed in the VR
welding lab, the standard and alternate frequencies
should be positioned as seen below.

2. Using the 3/8” (9.5 mm) wrench, remove the screws
from the upper and lower front panels on the ship­ping crate.

NOTE: The rear of the crate is nailed on. Nail removal is

not required during the installation of this equip­ment.

VRTEXTM360

A-5

INSTALLATION

FRONT

(upper)

FRONT

(lower)

BOLTS

3. Remove the six 3/8” (9.5 mm) bolts (three on each
side) from the bottom of the crate assembly.

A-5

6. Remove the monitor from the back of the machine.

7. Using the 3/8” (9.5 mm) wrench, remove the two
screws from the rear base securing the unit to the
wooden crate.

4. Car efull y s lide the cra te assem bly from the

VRTEXTM360 towards the rear of the machine. Be
careful to avoid damaging the welding device hold­ers located on each side of the machine.

6. Carefu lly rem ove the po st (lo ng rectang ular
shaped cardboard box) from the crate.

5. Carefully cut and remove plastic wrapping from
the machine.

8. Remove the four screws from the wooden rear
cross brace.

9. Remove the wooden cross brace while ensuring
the unit is steady and secure.

10. Carefully roll the machine off the rear of the skid.

Ramping may be required.

11. Uncrate and unpack the table and table base.

VRTEXTM360

A-6

Table

Weights

Stand

Screws

Table

Weights

Stand

Screws

INSTALLATION

5. Obtain the three post collar pins from the factory

packaging of the VRTEXTM360.

A-6

TABLE & SWING ARM SET-UP:

1. Place counter weights on base.

2. Using the 3/16” (4.8 mm) allen wrench, remove the
two ¼” x 20 Allen-head screws from the base
assembly.

NOTE: The longer screw is in the top.

Swing Arm

Table

Collar
Pins

6. Insert one of the collar pins into the post at the #6
location.

7. From the top, slide the table onto the post letting it
rest on the collar pin inserted in previous step.

8. Insert the second collar pin into the post at the #13
position.

9. Obtain the swing-arm from the rear of the VRTEX
360 by removing the cable ties from the swing arm
and cable. Grey cable should remain connected to
the VRTEX

TM

360 (DO NOT CUT!).

Post

T Pin

TM

3. Insert red post into base assembly aligning the flat
on the pole with the hole.

NOTE: The post will only insert one way.

4. Using the 3/16” (4.8 mm) allen wrench, secure the
post into position by replacing and tightening the
screws.

Cable Tie

Grey Cable

(DO NOT CUT)

VRTEXTM360

A-7

SVGA Out

Audio Jack

Always i

n

the On posi

tion

Input Power

connection

SVGA Out

Audio Jack

Always i

n

the On posi

tion

Input Power

connection

INSTALLATION

A-7

9. Carefully slide swing-arm onto post with the letters
(on the collar) “ABC” up and the grey cable located
on the bottom of the swing arm assembly.

10. Insert a third collar pin at a convenient height for

holding the helmet.

MONITOR:
Note: always use the factory supplied
monitor with the VRTEX(TM) 360

1. Remove monitor from cardboard box.

MONITOR (Mounting Screws)

Screws

BACK OF MACHINE

3. External speakers may be connected using the

audio jack located on the back of the machine.

TRACKING SYSTEM FUNDAMENTALS:

The magnetic tracking system is composed of the
following:

Input

VGA

Power

2. Remo v e the cable ties from monito r cabl e s

secured to the monitor mounting post.

3. Using a Phillips-head screwdriver to carefully

mount the monitor onto the mounting post bracket.
Tighten the four Phillips-head screws securely.

4. Connect input power cable and VGA cable into the

monitor.

APPLY SYSTEM POWER:

1. Insert the input supply power cord into the back

of the VRTEXTM360 and into a standard electrical
outlet capable of 115 to 230 VAC at 4 to 2 Amps.

ADDITIONAL FEATURES:

• Control Unit (Inside VR Machine)
o Contains the hardware and software neces-

sary to compute position and orientation.

• Source (part of the Swing Arm)
o The source contains electromagnetic coils

enclosed in a plastic shell that emit a magnetic
field. The source is the system’s reference
frame for sensor measurements.

• Sensor (in the VR GMAW/FCAW gun, VR SMAW

device, and helmet)

o The sensor contains electromagnetic coils

enclosed in a plastic shell that detect the mag­netic fields emitted by the source. The sen­sor’s position and orientation are precisely
measured as it moves in reference to the
source. The sensor is completely passive,
having no active voltage applied to it.

1. The welding coupons are stored in the coupon
drawer in the rear of the machine.

2. The weld simulation can be displayed on an exter­nal monitor or projector by using the SVGA output
on the back of the machine. The external display

must support 1024x780 resolution.

VRTEXTM360

B-1

1

2

3

6

7

8

10

11

9

6

5

4

12

14

13

1

2

3

6

7

8

10

11

9

6

5

4

12

14

13

PRODUCT DESCRIPTION

OPERATION

B-1

The VRTEXTM360 is a virtual reality arc welding train­ing machin e only and NOT a real arc w elding
machine. Please be aware of all standard safety
practices associated with welding. Some standard
warnings are included in this manual.

If the equipment is used in a manner not specified by
the manufacturer, the protection provided to the
equipment and user may be impaired.

FRONT OF MACHINE

Access panels are not to be removed except by quali­fied service personnel due to risk of electric shock
from accessible live parts.

VRTEXTM360

B-2

OPERATION

B-2

USER INTERFACE OVERVIEW

The VRTEXTM360 is a virtual reality arc welding train­er. This computer based training system is an educa­tional tool designed to allow students to practice their
welding technique in a simulated environment. It pro­motes the efficient transfer of welding skills from the
classroom to the welding booth, while reducing mater­ial waste and energy consumption associated with tra­ditional welding training.

See figure on page B-1 for locations of operator con­trols and indicators.

1. The monitor allows the student to view the setup

screens and provides an active view of the actual
welding process for teachers and students. The
monitor can be rotated for ease of viewing. Make
certain the power button on the monitor is ON and
the green LED is lit.

2. Th e joys tic k allo ws the op erator to nav igate

through various options by moving the red highlight­ed box and zoom / r o tate the coupon in the
Instructor View.

3. The colored buttons on the front of the machine

correlate to the colored rectangles at the bottom of
the monitor screen when the simulation software is
running. These buttons perform various functions
depending upon the command shown in the corre­sponding box on the screen.

10. The key switch is located on the lower right of the

control panel. When the system is in the login
screen the instructor may insert the key shipped
with the system into the key lock and then rotate it
90 degrees to the right. This allows the instructor
to access the instructor mode which includes the
Weldometer
Update screens.

11 Pressing and holding the green circular button

for 3 seconds powers up the VRTEX

Note: The green power button does not power
down the system. Select Log Out and Shutdown
from the red menu to turn off the system

12. The red select button accepts (enters) the data

displayed or highlighted on the monitor.

13. VR GMAW/FCAW gun holder should be used to

store the VR GMAW/FCAW gun when not in use.

14. VR SMAW devi ce hold er sho uld be used t o

store the VR SMAW device when not in use.

TM

, Tolerance Editor, Options and

TM

360 system.

4. The wire feed speed/amperage dial allows the

user to input wire feed speed or amperage depend­ing on the VR welding process selected.

5. The voltage dial allows the user to input the weld-

ing voltage. This dial also allows input of trim val­ues when pulse process is in use.

6. The left and right white screen select arrows

allow the operator to cycle through various screens.

7. The process selector switch is used to selected

the virtual welding process. (GMAW, FCAW, or
SMAW)

8. The polarity selector switch is used to indicate

the welding polarity for any given process. (DC+,
DC-, or AC).

9. The USB port is used to upload software and

download user data from the system.

VRTEXTM360

B-3

OPERATION

B-3

HARDWARE SPECIFICS:

VR GMAW/FCAW GUN

The VR gun has a trigger that is used during the simu­lation of GMAW and FCAW processes to initiate and
main t ain the simul a ted weldin g a r c. T he V R
GMAW/FCAW gun should be placed on the round gun
holder on the right side when not in use.

VR GMAW/FCAW GUN

CAUTION

In order to strike an arc with the VR SMAW device,
strike or tap the tip of the rod (of the VR SMAW
device) on the coupon being welded. To break the
arc, move the VR SMAW device rod away from the
work piece.

CAUTION

Do not try to strike the arc with excessive force,
as the arc start is distance based. Excessive
force may result in da mage to the VR SM AW
device.

The angle of the rod can be changed by squeezing
the handle of the VR SMAW device. This allows the
rod to be moved into the 45 or 90 degree position.
Once the rod is at one of these angles, release the
handle. The rod should now be fixed in that position.

Do not change the rod angle while the rod is
extending or retracting.

VR SMAW DEVICE

Store gun as shown below to

avoid damage.

VR GMAW/FCAW GUN (Properly Stored)

VR SMAW DEVICE

The VR SMAW device has a rod that represents a
stick electrode. This rod retracts when a virtual arc is
struck to simulate the electrode burning off during the
virtual welding process. When the virtual electrode
burns down to a stub, the rod will stop retracting and
the user will no longer be able to weld. When the user
presses “new stick” in the orange actions menu but­ton, the rod extends out, simulating that a new elec­trode was put into the VR SMAW device. When not in
use, the VR SMAW device should be placed in the VR
SMAW holder on the left side of the VR weld machine.

CAUTION

Store device as shown below to

avoid damage.

VR SMAW DEVICE (Properly Stored)

VRTEXTM360

B-4

RATCHET KNOB

HEAD GEAR

FORE / AFT ADJUSTMENT
TILT ADJUSTMENT

CROWN

A

DJUSTMENT

PIN HOLES FOR

ADJUSTMENT

RATCHET KNOB

HEAD GEAR
FORE / AFT ADJUSTMENT

TILT ADJUSTMENT

CROWN
A

DJUSTMENT

PIN HOLES FOR
ADJUSTMENT

OPERATION

B-4

Helmet

Adjust the helmet so it fits comfortably. Adjustments
can be made by depressing and turning the knob at
the b ack of th e helm et unt il the de sired size i s
achieved. If necessary, the user may also have to
adjust the top crown adjustment to fit their head size.

HELMET FUNCTIONS

The helmet has an FMD (Face Mounted Display) on
the inside. These FMD lenses display the virtual envi­ronment to the user. Each lens can be shifted left or
right to align with the users eyes by applying gentle
pressure. In addition, the lenses can be lifted up and
down as well as shifted forward and back for the best
fit. The user should make sure the lenses are parallel
to their eyes. Keep the lenses clean at all times. See
Cleaning and Maintenance Section.

HELMET LENSES

Coupon Drawer

The coupon drawer houses the physical coupons.
When not in use, the coupons should be stored in the
drawer. To open the drawer, press the top indent
down, and slide the drawer out. Each coupon fits in
its own area defined by the foam locator in the draw­er.

COUPON DRAWER

Coupons

The coupons represent the various workpieces on
which the user can virtually weld. During the virtual
welding process, they provide physical feedback to
the student.

There are five VR Coupons:

1. Flat Plate

2. Tee Joint

3. 3/8” Groove Joint w/Backing Bar

4. 2” Diameter XXS Pipe

5. 6” Diameter Schedule 40 Pipe

LENSES

When not in use, the helmet should be hung from the
stand or placed in the right front drawer to avoid being
damaged.

EAR
BUDS

VRTEXTM360

VR COUPONS

5

2

4

1

The coupons along with the VR SMAW device and VR
GMAW/FCAW gun have been factory calibrated at
Lincoln Electric.

3

B-5

OPERATION

B-5

Stand

The stand is comprised of the post, arm, table, collar
pins, base and two weights. Users should position
themselves at the stand during virtual welding.

Post

The arm and table slide up and down and rest on the
collar pins that are inserted into the post. Hole num­bers 0 through 28 indicate position of welding for pro­gram accuracy. The position that the table or arm is
located is read by identifying the numbered hole that
the pin has been inserted into.

POST W/PIN INSERTED IN #18

SWING ARM ROTATION

POS. A

POS. B

POS. C

Table

The table can be used to gain stability and learn prop­er body positioning. The base supports the stand and
has weights on the back to maintain stability. The
table can be swung out of the way when not in use.

CAUTION

Do n ot us e the Stand/Table w ithou t the base
counter weights properly positioned.

___________________________________________

Coupon Positioning In Swing Arm

The coupons can be inserted into the arm to accom­modate flat, horizontal, vertical or overhead welding
positions. The knob on the front of the swing arm can
be pulled out for coupons to be inserted or removed
and pushed in for coupons to be secured. The front of
the swing arm can be rotated down at a 45 or 90­degree angle to allow 2G, 5G and 6G pipe welding
positions. The arm can also be rotated around the
post to comfortably accommodate left and right hand­ed welders or simulate specific welding applications.

COUPON INSERTION / REMOVAL

TABLE ROTATION



Do not use excessive force when inserting and
removing coupons into the arm.

VRTEXTM360

B-6

OPERATION

B-6

Powering Up Your System:

1. After you have set up the hardw are and have
become familiar with the user controls, you will be
ready to use your system.

2. Plug the power cord into a standard outlet.

3. Press and hold the green circular button on the
front panel until it lights up and you hear fans run­ning inside the machine. (approx. 3 seconds)

GREEN CIRCULAR BUTTON LOCATION

4. Your system will start up.

However, users can set and use their own tolerances
for teaching beginner welders. The tolerances also
determine how the user is scored on such parameters
as work angle, travel angle, travel speed, position,
and contact tip to work distance or arc length. The
software will step the user through the following setup
screens:

• Login

• Joint configuration selection

• Process selection

• Stand set up

• Environment

• Gas set up

• Weld machine settings

• Instructor’s view

• Welder’s view

• LASER (Live Action Student Evaluation Report)

The key provided with the system allows the user to
access the Instructor Mode with additional information
and set-up pages.

• Weldometer

TM

• Tolerance Editor

• Options

• Update

5. Wait a few minutes until your system displays the
login screen on your monitor.

LOGIN SCREEN

System Setup Information

When setting up the virtual equipment, the user must
set the welding parameters (e.g. wire feed speed for
VR GMAW) within the ranges set in the tolerance edi­tor. The system ships with Lincoln default tolerances.
Lincoln default tolerances can be reviewed in the tol­erance editor, or refer to the Default Weld Process
Settings Chart (if using the default settings) located at
the end of this OPERATION SECTION. The WPS’s
are also available on www.VRTEX360.com.

VRTEXTM360

B-7

OPERATION

B-7

Login Screen:

Overview

This page allows the user to:

• Enter Username

• Select Language Preference

• Select Imperial or Metric Units

• Shutdown System

• Continue to the next Setup Screen

1. On Screen Keyboard

The user enters their name by using the joystick and
red select button on the VR weld machine. The joy­stick allows the user to navigate the keyboard graphic
to highlight letters. Pressing the red select button
enters the letter highlighted into the enter name box
as indicated. The virtual keyboard starts with shift
enabled, so the first letter is automatically capitalized.
The user can select shift or lock (equivalent to caps
lock on a standard keyboard) at any time. If the user
makes a mistake, they can select the back arrow to

delete the last character entered.

LOGIN SCREEN

Press the red select button to accept.
Press the yellow button again to exit the language
menu. The system stores the language selection and
will automatically start up in the same language the

next time.

3. Measurement Units

The blue unit menu button brings up the measurement
system. Use the joystick to highlight the desired unit
of measurement. Press the red select button to
accept. Press the blue again to exit the measurement
unit menu. Selecting Metric or Imperial converts the
user interface into the corresponding measurement
system. The system stores the measurement selec­tion, so it will automatically start up in the same unit of
measurement the next time. The system uses the
units shown in Table B.1.

4. Menu

The red menu button allows the student to shut down
the system. If the user selects shutdown, a submenu
appears asking the user if they are sure that they want
to shut down the system. This prompt prevents the
user from accidentally shutting down the system. If
the user selects “Yes”, the VRTEX
down.

TM

360 will shut

2. Language

Selecting the yellow language menu button brings up
the list of languages the software supports. Use the
joystick to highlight the desired language.

TABLE B.1

CAUTION

THIS METHOD SHOULD ALWAYS BE USED TO
SHUT DOWN THE VRTEX
could cause damage to the system.

5. Continue

After the user enters their name and all selections
outlines above have been made

panel button is pressed to continue to set up process.

TM

360. Failure to do this

, the green

VRTEXTM360

B-8

OPERATION

B-8

Join t Confi gura tion Se lection
Screen:

Overview

The user selects which joint configuration they want to
virtually weld. First, the user selects the joint and
position. Using the joystick and the red select button,
the user highlights and selects the joint type and posi­tion in which to weld. A rotating view of the highlight­ed coupon shows in the upper area. For some config­urations, the user will be given the choice of material
thicknesses to choose from. The user selects materi­al thickness by using the joystick and red select but­ton. See Table B.2 for supported joint configurations.

JOINT CONFIGURATION SELECTION SCREEN

Menu

Selecting Logout takes the user to the login screen,
with the user’s name removed.

Back

Selecting Back takes the user back to the previous
screen.

TABLE B.2

VRTEXTM360

B-9

OPERATION

B-9

Process Selection Screen:

Overview

This screen allows the user to select the welding
processes. To change among VR GMAW, VR FCAW,
and VR SMAW, the user moves the process switch on
the front of the weld machine. See the joint configura­tion chart for available processes. If a process is not
supported for the selected material/thickness, it is
greyed out on this screen and cannot be selected. To
choose among different sub-processes, use the joy­stick and red select button or green continue button.

At the top of the screen, the user can see the coupon
position and thickness selected. As the user contin­ues to set up the simulation, additional information will
be added to the right of this readout, so that the user
can reference what has previously been selected.

PROCESS SELECTION SCREEN

Stand Set-Up Screen:

Overview

The correct VR stand information must be put into
the software for the VRTEX
erly in all virtual welding applications.

STAND SET-UP SCREEN

Coupon Insertion

Insert one of the VR coupons into the desired position
in the physical VR stand. Make sure the coupon is
fully seated into the track and then lock the coupon in
place by pushing in the knob at the end of the arm.
To release, pull the knob into the unlocked position
and remove the coupon. When the system is in use,
the coupon should always be lock ed in place to
assure system accuracy.

TM

360 to operate prop-

Menu

Selecting Logout brings the user back to the login
screen, with the user’s name removed.

Change Coupon Type

Selecting Change Coupon Type goes back to the
configuration selection screen.

Back

Selecting Back takes the user to the previous screen.

VRTEXTM360

VR COUPON (UNLOCKED POSITION)

B-10

OPERATION

B-10

Table/Arm Rotation

Move the physical VR table and arm to the desired
location for the position and joint configuration select­ed. To raise or lower the arm or table, hold the
arm/table in place and pull out the pin in the pole sup­porting it. Replace the pin in the hole that supports
th e arm/table at the proper height a nd res t the
arm/table on the pin. If the table is not needed,
swing the table to the left or right and out of the way.
The arm can also be rotated to the left (A), center (B)
or right (C) of the table.

SWING ARM ROTATION

POS. A

POS. B

POS. C

Pin Positions

When the physical stand is in the desired position,
proceed with the following: Use the joystick and red
select button to enter the numbers that appear next to
the pin positions for the table and arm height into the
stand setup screen. The image on the right side of
the stand setup screen moves to match the selections
entered on the left. If the table is in the “away” posi­tion, enter a table height value of 0. Next, enter the
arm rotation position A (left), B (center), or C (right).
The arm position letter aligns with the vertical pin
number sticker. An arm height of 18 and and arm
rotation of A are shown in the picture below.

PIN POSITIONS 18 A

TABLE ROTATION

Note: If the table height indicator in the software

cannot be moved to the pin height indicated
on the post, move the arm height indicator
in the software to a higher position and try
again. See Troubleshooting Guide if neces­sary.

VRTEXTM360

B-11

Indicate the coupon orientation used on the physical
stand in the coupon rotation area of the stand setup
screen. The red arrow indicates which side of the
coupon that the weld will be made. For pipe configu­rations, the coupon rotation is replaced with arm
angle. The arm angle can be adjusted by removing
the pin at the end of the arm, rotating the arm to 45 or
90 degrees from its original location, and reinserting
the pin. This is only used to accommodate 2G, 5G
and 6G pipe welding.

STAND SET-UP SCREEN (PIPE)

The physical stand should match the stand image
when these selections are completed. To continue,
press the green continue button. The stand setup ver­ification screen will be displayed. This screen serves
as a reminder to make sure VR stand components
match the screen. When verified, press the green
continue button again.

STAND SET-UP SCREEN OVERLAY

OPERATION

B-11

ENVIRONMENT SCREEN

Menu

Selecting Logout takes the user back to the login
screen, with the user’s name removed.

Back

Selecting Back takes the user to the previous screen.

Gas Set-Up Screen:

Overview

On this screen, the user selects the gas mixture and
gas flow rate. The correct gas mixture and flow rate
must be entered according to the tolerance editor. If
acceptable values are not entered, this will be indicat­ed on a later screen and the user may have to go
back and change the selection on this screen.

To select the gas mixture, use the joystick and the red
select button. The available gas mixtures are shown
on the gas set-up screen below.

To select the gas flow rate, use the joystick. Press
the red select button or green continue button to pro­ceed.

GAS SET-UP SCREEN

Back

Selecting Back takes the user to the previous screen.

Environment Screen:

Overview

The VRTEXTM360 comes pre-configured with a num­ber of different virtual welding environments. To
select an environment, the user moves the joystick left
or right and then presses the red select button or
green continue button to choose the environment.

Menu

Selecting Logout takes the user back to the login
screen, with the user’s name removed.

Back

Selecting Back takes the user to the previous screen.

VRTEXTM360

B-12

OPERATION

B-12

Weld Machine Settings Screen:

Overview

The user must enter the proper welding procedure
and process settings, including wire feed speed,
amperage, voltage, polarity, and trim where applica­ble. As in the gas setup screen, the user must enter
values within the acceptable range as governed by
the tolerance editor. If not, they will be notified by the
incorrect weld setting screen when the green check
settings button is pressed.

The user changes the wire feed speed or amperage
by rotating the wire feed speed/amperage dial. The
display above the dial indicates the setting.

The user changes the voltage by rotating the voltage
dial. The display above the dial indicates the setting.
Some processes may not allow the user to pre-set
the voltage, in which case the display will be blank.

WELD MACHINE SETTINGS SCREEN

Once the user has set the welding parameters, they
should press the green check settings button. If the
user has entered any settings outside the acceptable
range specified by the settings in the tolerance editor,
the incorrect weld setting screen will appear. The
user will then have to change any settings that are not
correct. If the settings are correct and the green
check settings button is pressed, the welder’s view
screen will appear on the monitor and in the helmet’s
stereo visor. The user will then be able to start virtual
welding.

THE INCORRECT WELD SETTINGS SCREEN

Polarity Selector

Change the polarity by rotating the polarity selector
switch. The user can select the following:

• AC

• DC+

• DC-

If default tolerances are being used, refer to the
Default Weld Process Settings included in this
manual.

Menu

Selecting Logout brings the user back to the login
screen, with the user’s name removed.

Back

Pressing Back goes back to the previous screen.

Virtual Welding Overview

Wh ile a user is welding, observers can see t he
Welder’s view, LASER screen, or Instructor’s view
displayed on the monitor. The Welder’s view shows
what the user with the helmet on is seeing through the
FMD. The LASER screen displays a real time graph
of the weld being made and gives a score when the
user selects “end pass”. The Instructor’s view allows
another user to zoom in/out and rotate the coupon to
view the weldment from different angles in real time.

VRTEXTM360

B-13

Distance)cue is only

Distance) cue is only

OPERATION

B-13

Upper Overlays

The welding technique set in the tolerance editor and
other process details are displayed on the upper right
portion of the screen.

Push Buttons

Menu

Selecting Logout brings the user back to the login
screen, with the user’s name removed.

Action Button

The orange action menu button has the following
options:

• Clean

• Trim

• Quench

• New Stick

These options are only available when applicable to
the welding process.

Clean removes the weld slag. Trim cuts back the VR
GMAW or VR FCAW wire. Quench simulates quickly
cooling the metal. New Stick extends the rod stick
out to a fixed length on the VR SMAW device to simu­late replacing the consumed rod.

Generally, these cues are color coded as well as sym­bolic. When cues are red, they indicate being out of
tolerance. Yellow cues indicate close to tolerance, but
not optimal. Green cues indicate being within toler­ance and close to optimal.

The “Cheater” Lens magnifies the image as seen by
the user in the helmet and in the welder’s view. The
user can toggle between Off, 1.25X, 1.5X, 1.75X, 2X
select their option with the red select button.

Travel Speed turns on the travel speed visual cue.
This cu e is lo cated on the si d e of th e VR
GMAW/FCAW Gun or VR SMAW device. This cue
uses the color coding position to indicate travel speed.

Note: The goal is to keep the arrow in the center of

the graph which will also keep it green.

TRAVEL SPEED VISUAL CUE

Visual Cues

The yellow visual cues menu button has the following
options:

• “Cheater” Lens – Off, 1.25X, 1.5X, 1.75X, 2X

• Travel Speed Visual Cue

• CTWD (Contact To Work Distance) Visual Cue

• Arc Length Visual Cue

• Travel/Work Angles Visual Cue

Visual cues are aids to help users learn faster. The
travel speed, CTWD, arc length, and travel/work angle
cues indicate whether the user is within the tolerances
set in the tolerances editor.

The CTWD (Contact To Work Distance) cue is only
available for VR GMAW and VR FCAW processes.
This cue uses color and position to indicate proper
CTWD. The goal is to get the tip of the green arrow
on the line of the “H” bar and keep the arrow color
green.

CTWD (Contact To Work Distance)

VRTEXTM360

B-14

OPERATION

B-14

The Arc Length cue is similar to the CTWD cue but
represents arc length distance for the VR SMAW
process. The goal is to get the tip of the arrow on the
line and keep the arrow color Green.

The Travel/Work Angle cue can be used with the
SMAW, GMAW or FCAW processes. The goal of this
cue is to center the circle in the cross hair and keep

the color green.

TRAVEL/WORK ANGLE

The Whip cue can be used with the E6010 VR SMAW
process. This cue helps the student use correct spac­ing between whipping motions, puddle time and whip
time. Correct whipping technique is indicated by a
green outter ring (spacing) with a green center (puddle
and whip timing).

Whip

The Aim cue can be used with the VR SMAW, VR
GMAW or VR FCAW processes. The goal of this cue
is to position the VR GMAW/FCAW Gun or VR SMAW
device so the aim cue is a thin green line. This indicat­ed that the weld is being made in the correct location
or position.

AIM

The Weave cue can be used with the VR SMAW, VR
GMAW or VR FCAW processes but is only available if
the technique identified in the Tolerance Editor is a
type of weave. The goal of this cue is to space the
weave so the outter ring is green (good weave spac­ing), set the width of the weave so line is green (good
weave width) and a green filled ring (good dwell time
on the toes of the previous weld).

Weave

VRTEXTM360

B-15

OPERATION

B-15

New Coupon

Pressing the blue new coupon menu button instantly
replaces the current coupon with a fresh, unwelded
coupon. Note that this is a quick way to start over on
the same configuration and process but that it will
remove all passes from the coupon and the graphs on
the LASER screen.

White Screen Select Arrows

Pressing the white screen select arrows allow the user
to rotate through the LASER screen, instructor’s view
and welder’s view.

Welder’s View screen

Overview

This screen shows the virtual view as seen by the
user wearing the helmet.

Instructor’s View screen

Overview

This screen shows the coupon and virtual weld in real
time. An observer can rotate and/or zoom in or out on
the co upon. T h is v iew also sh ows the VR
GMAW/FCAW gun or VR SMAW device being used.
Move the joystick to rotate the coupon. Press the red
select button to toggle the joystick from rotate to zoom
mode. Use the joystick to zoom in and out when in
zoom mode.

LASER SCREEN

(Live Action Student Evaluation Report)

Overview

This screen summarizes the student’s welding perfor­mance. Detailed information about the student’s
welding technique for each pass are displayed on this
screen.

LASER SCREEN (GOOD WELD)

LASER SCREEN (HORIZONTAL WELD)

NO WELD

NOTE: Changing views on the monitor does not

change the user’s view in the helmet.

INSTRUCTORS VIEW (POOR WELD)

LASER SCREEN (GOOD VERTICAL WELD)

VRTEXTM360

B-16

OPERATION

LASER SCREEN

(GRAPH, DEFECTS, DISCONTINUITIES, ETC.)

B-16

TECHNIQUE PARAMETERS

The upper left area of the screen shows the technique parameters being tracked and the graph of these parame­ters is located to the right. When the user welds, each parameter is graphed using a line that is of the same
color as the technique parameter box. For example, “position” is written in the blue box and indicated by the blue
line. The left side of the graph represents the left side of the coupon, and the right side represents the right side
of the coupon. For vertical welds, the graph is rotated so that it is vertical, with the bottom representing the bot­tom of the coupon and the top representing the top of the coupon. The graph also shows how close the parame­ter was to the ideal value. The ideal value is indicated by the red line located in the center of the graph. This
value is determined by the tolerance editor settings. The upper and lower white lines represent the acceptable
maximum and minimum values that the parameter should be within. These values are also determined by the
tolerance editor setting. Anything above the top white line or below the bottom white line is out of tolerance. The
closer the user is to the ideal line, the better the weld. Each parameter can be toggled on or off of the graph by
highlighting the parameter with the joystick and pressing the red select button. Whipping and weaving parame­ters are graphed when the system is set up to use these welding techniques (see tolerance editor section). The
following technique parameters are used (See Table B.3).

TABLE B.3

VRTEXTM360

B-17

OPERATION

B-17

Position is the user’s ideal weld root location. This
location can change with each pass. When weaving,
the ideal location is considered the centerline of the
weave.

Contact Tip to Work Distance (CTWD) (for VR
GMAW and VR FCAW) and Arc Length (for VR
SMAW) are the distances from the tip of the VR
GMAW/FCAW gun or VR SMAW device to a plane
going through the ideal position location.

Travel Angle is the angle between the electrode and
the workpiece in the direction of travel. The upper right
area of the screen displays if the user should be push­ing or dragging. If the user pushes when they should
be dragging, they will not receive maximum points. For
pipe welding, this is the angle between the electrode
and the tangent of the pipe at that point.

Work Angle is the angle between the electrode and
workpiece as seen in the work angle picture below.

VRTEXTM360

B-18

OPERATION

B-18

Travel Speed is how fast the electrode is traveling in
respect to the workpiece.

Dime Spacing is the distance from one solidified weld
puddle to the next. (whip technique only)

Whip Time is the time the user is in the whipping
motion, or not dwelling in the weld puddle. (whip tech­nique only)

Dwell Time is the time the user is dwelling, or keeping
the VR Stick electrode in the virtual puddle. (whip
technique only)

Width of Weave is the side-to-side distance of where
the VR GMAW/FCAW gun or VR SMAW device was
aimed when completing one weave cycle in a series
that make up a weld. (weave technique only)

Weave Timing is the time taken to complete one side
to side weaving motion. (weave technique only)

Weave Spacing is the distance in the overall direction
of travel between one weave cycle in a series that
make up a weld. (weave technique only)

Bead Render

An image of the completed pass appears in the mid­dle of the screen.

Discontinuity Indicator

The lower left side of the screen list potential disconti­nuities. When a student uses incorrect welding tech­niques, this causes specific weld discontinuities. A
line is drawn at the location indicating these disconti­nuities. For example, too long an arc length will cause
porosity.

Potential discontinuities include:

• Incomplete Fusion/Penetration

• Slag Inclusion

• Porosity

• Undercut

• Poor Bead Placement

• Wrong Weld Size

• Convex/Excessive Reinforcement

• Concave/Underfill

• Excess Spatter

• Melt Through/Blow Through

Pass number

The pass number is displayed on the left center of the
screen. To change the pass being viewed, use the
joystick to highlight the pass number and then joystick
left or right to change the pass number. For pipe, the
information is displayed in a similar manner on a 2D
screen as though the pipe is unraveled and put on a
flat surface. The user can choose between viewing
the whole pipe or one of the four quadrants of the
pipe. Use the joystick to highlight the pipe section
desired.

Travel Direction

The travel direction is located on the right side in the
middle of the screen. When the user first starts to
weld, a travel direction is sensed by the system and
an arrow indicating the direction is displayed. For
visual cues, the system assumes these directions.
The visual cues will automatically adapt to the travel
direction used when the arc is struck.

VRTEXTM360

B-19

OPERATION

B-19

End Pass

When the user presses the green “End Pass” menu
button, the pass is scored, a snapshot of the weld is
taken, and the percentages of the weld containing dis­continuities are calculated. If the user has inserted

a USB device, pressing “End Pass” also automati­cally saves a student report to the USB memory
device at the front of the weld machine. Allow 10

seconds after pressing the “End Pass” button to allow
time for the file to be saved. Student reports are not
saved internally on the VRTEX

saved on the USB device at the time of the weld, and
another weld is made, the previous weld data will be
lost.

TM

360. If the file is not

Score

On the upper right of the screen, a score for each
parameter is calculated. The closer each parameter
is to the ideal value, the higher the score will be (out
of 100). The total score at the bottom of the scoring
section is calculated as an average of each parame­ter. To achieve the maximum score, the weld must be
made on the entire length of the coupon.

Student Report

The student report is a PDF file that captures the
graph, discontinuities, bead render, score and other
information about the weld. This PDF can be printed
or archived from another computer to track student
progress.

Peak and Background Current

These welding parameters are shown on the LASER
screen when the student is using the STT welding
process. These settings cannot be modified but are
in dic ate d on the s yst em to allow the student t o
become familiar with the terms.

Instructor Mode

Overview

The Instructor Mode gives users the option of viewing
the WeldometerTM, using the tolerance editor and set­ting other preferences. In order to access instructor
mode, the user must first go back to the login screen.
This can be done on most screens by pressing menu,
logout, and selecting yes. Then the user must place
the key into the turn key slot at the front of the weld
machine and rotate the key 90 degrees to the right.
Selecting the orange back menu button brings the
system out of the instructor mode.

INSTRUCTOR MODE

Options

The options screen in the instructor mode allows the
user to change the volume of the user interface
sounds and welding sounds. Move the joystick left
and right and then hit the select button to choose the
volume. A volume of 0 will mute the sound, while a
volume of 10 is the loudest.

Update

Overview

The update screen in the instructor mode allows the
user to update their software or to update specific
configuration files from the USB memory device in the
front of the weld machine. Clicking on this brings up
two options:

Update Software
Update Configuration File

Software

Selecting this option loads a newer version of the soft­ware if one is available on the USB in the front of the
machine. Updating to a different version may shut
down or restart the system.

After updating, the system may need to be shut down
and restarted for changes to take effect.

Configuration File

Selecting this option loads any configuration changes
from the USB in the front of the machine. This is
used for part replacement.

Instructor mode includes the following:

• Options

• Update

• Weldometer

• Tolerances

TM

VRTEXTM360

B-20

OPERATION

B-20

Weldometer

TM

Overview

The WeldometerTMtracks virtual consumables, base material and gas usage. This information can be used to
track materials and cost savings incurred by the use of virtual welding training. The WeldometerTMtracks material
usage and arc time over a “trip” (since last reset) and over the VR system’s lifetime.

Arc Time keeps track of the amount of time (hours:min:seconds) students have a virtual arc struck with each
process.

Base Metal tracks how many virtual coupons have been used and their cumulative weight. Note that plate 3/8”
includes groove joints as well as tee joints, while plate 1/4" includes both tee joints and practice plates.

Gas tracks how much virtual gas was used.

Consumables tracks the cumulative weight of each type of virtual consumable used. It also displays how many

virtual SMAW electrodes are used.

At the bottom of the screen, the Simulated Welder Time keeps track of how long the unit has been on (time in
hours:minutes:seconds).

WELDOMETER

TM

VRTEXTM360

B-21

OPERATION

B-21

Reset Trip

Pressing Reset Trip zeroes out all items in the trip
column. This allows an instructor to track VR material
savings over a certain time period.

Save to File

If a USB memory device is in the front of the unit,
selecting “save to file” saves a file with all of the cur­rent WeldometerTMinformation. Once the file has
saved, the user can take the USB to a computer or
printer to print, email, copy, store or view the file.

Back

Pressing Back takes the user to the previous screen.

Tolerance Editor

Overview

The tolerance editor allows users to modify the sys­tem settings from the default to fit their curriculum.

TM

The VRTEX
parameters pre-installed. The parameters can be
modified by the instructor to reflect a specific welding
application or technique. The welding parameters that
can be modified include:

- WFS range

- Voltage range

- Amperage range

- Gas mixture

- Gas flow rate

The technique parameters ideal range values can also
be modified:

- Position

- CTWD/Arc length

- Work angle

- Travel angle

- Travel Speed

- Whip

- Weave

360 ships with Lincoln “default” welding

TOLERANCES

CAUTION

Changing the settings in the tolerance editor will
dramatically affect how the system runs, including
scoring, visual cues, and discontinuities. Take
care in changing the settings of the tolerance edi-

tor as not to reflect unrealistic welding situations.

VRTEXTM360

B-22

OPERATION

Choose Tolerance Set-up

This displays the list of all tolerance settings currently
stored on the unit. All units ship with default settings.
If the user creates multiple tolerance files, the file in
use is selected by pressing the red button. This
affects the visual cues, graphs, discontinuities and
score. The current tolerance settings in use are also
listed on this screen.

Choose Tolerance to Load

This displays the list of all tolerance sets currently
stored on the USB device. Files can be transferred to
and from a VRTEX

TM

360 with a USB memory device.

Back

Pressing back returns the system to the login screen.

B-22

USB Edit

This menu relates only to the files on the USB memo­ry device. If there is a file name currently listed in the
choose tolerance to load box, pressing the options on
the menu will take action on that file. This menu has
the following options:

• Copy to List

• Delete

• Rename

• Load from USB

Pressing Copy to List copies the file currently being
shown on the choose tolerance to load box and saves
it to the VRTEX

TM

360.

Edit

This menu button affects the file currently being
shown in the choose tolerance setup window. This
menu has the following options:

• Create New

• Save to File

• Copy

• Delete

• Rename

Pressing Create New creates a new file on the unit.
The file starts with the default settings. Pressing this
button takes the user to a keyboard screen so that a
new file name can be entered.

Pressing Save to File saves the current file to a USB
memory device if USB is inserted in the front of the
machine.

Pressing Copy makes a copy of the file currently
being shown on the choose tolerance setup window.
The copy is identified with the same name plus an
incremented number after it.

Pressing Delete brings up an “are you sure” dialogue.
Selecting yes deletes the file currently being shown on
the choose tolerance to load. This deletes the file
from the USB memory device. The user can also can­cel out by pressing no or pressing the back button.

Pressing Rename brings the user to a keyboard
screen where the name of the current file can be
changed.

Pressing Load loads the names of the files currently
on the USB memory device. The names show up in
the choose tolerance to load box. The user will need
to select this in order to see what is on their USB
memory device.

Tolerances Keyboard Screen

Overview

Allows the user to name or rename tolerance files.

TOLERANCES (KEYBOARD SCREEN)

Pressing Delete brings up an “are you sure” dialogue.
Selecting yes deletes the file currently shown. The
user can cancel out by pressing no or pressing the

back button.

Pressing Rename brings the user to a keyboard
screen where the name of the current file can be
changed.

VRTEXTM360

B-23

TOLERANCES SELECTED (DEFAULTS)

OPERATION

Back

Pressing back returns the user to the previous page
screen.

Continue

Pressing continue goes to the tolerance configuration
selection screen, unless the user was renaming a file,
in which case it goes back to the previous page.

B-23

Back

Pressing Back goes back to the previous screen.

Continue

Pressing Continue goes to the tolerance process
selection screen.

Tolerance s Proc ess Se lect ion
Screen

Overview

The user selects which process to modify.

TOLERANCES PROCESS SELECTION SCREEN

Tolerance s Joint C onfig urat ion
Selection Screen

Overview

The user selects which configuration to modify.

TOLERANCE CONFIGURATION SELECTION

Menu

Menu

Selecting Logout and then yes in the submenu brings
the user back to the login screen in welding mode.

Selecting Change Coupon Type takes the user back
to the tolerances configuration selection screen.

Back

Pressing Back goes back to the tolerance configura­tion selection screen.

Continue

Pressing Continue goes to the tolerance equipment
settings screen.

Selecting Logout and then yes in the submenu takes
the user back to the Login screen.

Selecting Change Process brings the user back to
the tolerances process selection screen.

VRTEXTM360

B-24

OPERATION

B-24

Modifying Tolerances

Overview

The user can modify the tolerance values. This is
done by:

1) Use the joystick to highlight the equipment setting

or parameter to change.

2) Press the red select button.

3) Use the joystick to change the value. Pressing the

green set tolerances button will save the changes.

The following screens are used to modify tolerances:

• Tolerances Equipment Settings screen

• Tolerances Gas screen

• Tolerances Welding Technique Parameters screen

• Tolerances Pattern and Aim screen

• Tolerances Whip and Travel Speed screen

• Tolerances Weave screen

Next & Previous

Use the arrow buttons to cycle through the tolerance
editor screens.

The configuration and process selected are shown at
the top of the screen.

In the upper right of the screen is the name of the tol­erance set being modified.

Ideal values represent the ideal weld technique para­meters. If the user welds using the technique listed as
ideal, they will get the best score. The ideal values
are represented by the red line on the LASER screen.
Changing the +/- changes the acceptable tolerance
indicated by the white lines on the LASER screen.
Any welding technique used within that +/- range is
acceptable but will be scored lower the further it is
from the ideal value. As an example, a work angle
with an ideal of 45 degrees and a +/- of 10 degrees
means that the user can use a work angle between 35
and 55 degrees and create an acceptable weld.

Next Pass

The next pass button changes the pass being modi­fied to the next pass in the series. If this is the last
pass, this option will not be available.

Tolera nces E quipment Sett ings
Screen

TOLERANCES EQUIPMENT SETTINGS SCREEN

Overview

This screen allows for the modification of the following
welding parameters:

• Wire Feed Speed

• Amperage

• Voltage

• Polarity

Tolerances Gas screen

Overview

This screen allows for the modification of:

• Gas Mixture Selected

• Gas Flow Rate

TOLERANCES GAS SCREEN

Settings that are non-applicable to the process select­ed are greyed out and cannot be changed.

Menu

This is the same as the tolerance configuration selec­tion screen.

Back

Pressing back goes to the previous screen without
saving changes.

Prev Pass

The previous pass button changes the pass being
modified. If this is the first pass, this option is not
available. The pass number currently being modified
is shown in the upper right of the screen.

VRTEXTM360

B-25

Z

Y

X

XX
X

Z

TEE PIPE GROOVE

Z

Y

X

XX

X

Z

TEE PIPE GROOVE

OPERATION

B-25

Tolerances Welding Technique
Parameters Screen

Overview

This screen allows the modification of:

• CTWD/Arc Length

• Work Angle

• Travel Angl

TOLERANCES WELDING

TECHNIQUE PARAMETERS

Tolerances Pattern and Aim Screen

Overview

This screen allows the user to change the type of pat­tern being used (stringer, box weave, straight weave,
whip, triangle weave) and the position of the root of
the weld. The X and Y values change the location of
where the weld bead should be placed. This affects
the position parameter on the LASER screen. The +/­determines how far off from the ideal position the stu­dent can place the electrode before it results in a mis­placed weld.

PATTERN & AIM SCREEN

Note: The travel angle for drag welding techniques

should always be less than 90 degrees. The
travel an gle for p ushi ng tec hnique sho uld
always be greater than 90 degrees.

COORDINATE CHART FOR WELD PLACEMENT (POSITION)

VRTEXTM360

B-26

OPERATION

Tolerances Whip and Travel Speed
Screen

Overview

This screen allows for the modification of technique
parameter relating to the whipping welding technique
and travel speed including:

• Dime Spacing

• Whip Time

• Puddle Time

• Travel Speed

WHIP & TRAVEL SPEED SCREEN

B-26

Tolerances Weave Screen

Overview

This screen allows for the modification of weaving
welding technique including:

• Width of Weave

• Weave Timing

• Weave Spacing

TOLERANCES WEAVE SCREEN

VRTEXTM360

B-27

SMAW1/8" E6010Fleetweld 5P+NANAFlat.25"90 (±5)NADC+

SMAW1/8" E6010Fleetweld 5P+NANA2F, 3F up, 4F.375"90 (±5)NADC+

SMAW1/8" E6010Fleetweld 5P+NANA1G, 2G, 3G up, 4G.375"90 (±5)NADC+

SMAW 1/8" E7018Excalibur 7018NANAFlat.25"125 (±5)NADC+

SMAW 1/8" E7018Excalibur 7018NANA2F, 3F up, 4F.375"125 (±5)NADC+

SMAW 1/8" E7018Excalibur 7018NANA1G, 2G, 3G up, 4G.375"125 (±5)NADC+

Root: 80 (±5)

Hot:100 (

+ 5)

Fill/Cap: 80 (±5)

Root: 80 (±5)

Hot:100 (

+ 5)

Fill/Cap: 80 (±5)

Root: 80 (±5)

Hot:100 (

+ 5)

Fill/Cap: 80 (±5)

1/8" E6010Fleetweld 5P+Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010Fleetweld 5P+Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010Fleetweld 5P+Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010Fleetweld 5P+Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010Fleetweld 5P+Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010Fleetweld 5P+Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

GTAW Root: NA

Fill/Cap: 80 (±5)

GTAW Root: NA

Fill/Cap: 80 (±5)

GTAW Root: NA

Fill/Cap: 80 (±5)

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 35Flat.25"

250 (

+ 5)18DC+

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 352F, 3F down.125"250 (+ 5) 18DC+

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 352F.25"375 (+ 5)20DC+

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 353F up.25"275 (+ 5)18DC+

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 354F.25"325 (+ 5)19DC+

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 351G.375"350 (+ 5)20DC+

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 352G.375"320 (+ 5)19.5DC+

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 353G up.375"

250 (

+ 5)17.9DC+

GMAW - S.035" ER70S-6SuperArc L-5675A/25C15 - 354G.375"

270 (

+ 5)18DC+

GMAW - Spray.045" ER70S-6SuperArc L-5690A/10C25-40Flat0.25

400 (

+ 5)27.1DC+

GMAW - Spray.045" ER70S-6SuperArc L-5690A/10C25-402F.375"

375 (

+ 5)26.5DC+

GMAW - Spray.045" ER70S-6SuperArc L-5690A/10C25-401G.375"

370 (

+ 5)26.5DC+

GMAW - Pulse.045" ER70S-6SuperArc L-5690A/10C25-402G.375"

130 (

+ 5).95(trim)DC+

GMAW - Pulse.045" ER70S-6SuperArc L-5690A/10C25-403G up.375"

130 (

+ 5).95(trim)DC+

GMAW - STT.045" ER70S-6SuperArc L-56100C15 - 352G Pipe

130 - 150NA

GMAW - Pulse.045" ER70S-6SuperArc L-5690A/10C25-402G Pipe125-130.95(trim)

GMAW - STT.045" ER70S-6SuperArc L-56100C15 - 355G Pipe down

130 to 150NA

GMAW - Pulse.045" ER70S-6SuperArc L-5690A/10C25-405G Pipe up125-130.95(trim)

GMAW - STT.045" ER70S-6SuperArc L-56100C15 - 356G Pipe down

130 to 150NA

GMAW - Pulse.045" ER70S-6SuperArc L-5690A/10C25-406G Pipe up125-130.95(trim)

FCAW - G.045" E71T-1UC 71A8575A/25C25-50Flat.25"

275 (

+ 5)25DC+

FCAW - G.045" E71T-1UC 71A8575A/25C25-502F, 3F up, 4F.375"

275 (

+ 5)25DC+

FCAW - G.045" E71T-1UC 71A8575A/25C25-501G, 2G, 3G up, 4G.375"

275 (

+ 5)25DC+

GMAW - STT.045" ER70S-6SuperArc L-56100C15-35

130 to 150NA

FCAW - G.045" E71T-1UC 71A8575A/25C25-50

275 (

+ 5)25

GMAW - STT.045" ER70S-6SuperArc L-56100C15-355G Pipe down

130 to 150NA

FCAW - G.045" E71T-1UC 71A8575A/25C25-505G Pipe up

275 (

+ 5)25

GMAW - STT.045" ER70S-6SuperArc L-56100C15-356G Pipe down

130 to 150NA

FCAW - G.045" E71T-1UC 71A8575A/25C25-506G Pipe up

275 (

+ 5)25

FCAW - S5/64" E71T-8NR- 232/233NANAFlat.25"14020DC-

FCAW - S5/64" E71T-8NR- 232/233NANA2F, 3F up.375"15521DC-

FCAW - S5/64" E71T-8NR- 232/233NANA4F.375"14520DC-

6"

DC+

DC+
6"6"DC+

NA

NA

NA
2"

DC+

DC+
NA

DC+
DC+

NA

NA

DC+

DC+

DC+

DC+

DC+NANA

NA

wfs (ipm) or amps

Voltage

NA

NA

Pol

VRTEX 360 - Default Weld Process Settings

Position

Mat'l (in)
VR Welding

Process
Consumable

Type
Gas Flow

(cfh)
NA

Excalibur 7018

NA

NA

Lincoln Brand

Gas Mixture

Excalibur 7018

NA

6"
Excalibur 7018

NA

Fleetweld 5P+6"6G Pipe up

6"

NA
Excalibur 7018NA3/32" E7018

SMAW
SMAW

3/32" E7018

3/32" E7018

SMAWNANA

SMAW
Excalibur 7018

Excalibur 7018

Excalibur 7018

NA
3/32" E7018

3/32" E7018

3/32" E7018

SMAW

SMAW
3/32" E7018

SMAW
3/32" E7018

6"

5G Pipe up

1/8" E6010

SMAW

6"
2G PipeNA2G Pipe

5G Pipe up

NA
5G Pipe up

6G Pipe up

NA
NA

SMAW

3/32" E7018

Excalibur 7018

NA

6"

DC+6"6"

DC+

DC+NADC+

DC+

NA

DC+
NA

6G Pipe up

2"2"2"

SMAW

1/8" E6010

Fleetweld 5P+

NANA2G Pipe

5G Pipe up2"2"

6G Pipe up

Fleetweld 5P+

1/8" E6010

SMAW

2G PipeNANA
Excalibur 7018

NA

SMAW6"2G PipeNANA

FCAW - S5/64" E71T-8NR- 232/233NANA1G,2G.375"13021DC-

FCAW - S5/64" E71T-8NR- 232/233NANA3G up.375"12519.5DC-

SMAW 1/8" E6010 Fleetweld 5P+ NA NA Flat .25" 90 (±5) NA DC+

SMAW 1/8" E6010 Fleetweld 5P+ NA NA 2F, 3F up, 4F .375" 90 (±5) NA DC+

SMAW 1/8" E6010 Fleetweld 5P+ NA NA 1G, 2G, 3G up, 4G .375" 90 (±5) NA DC+

SMAW 1/8" E7018 Excalibur 7018 NA NA Flat .25" 125 (±5) NA DC+
SMAW 1/8" E7018 Excalibur 7018 NA NA 2F, 3F up, 4F .375" 125 (±5) NA DC+
SMAW 1/8" E7018 Excalibur 7018 NA NA 1G, 2G, 3G up, 4G .375" 125 (±5) NA DC+

Root: 80 (±5)

Hot:100 (

+ 5)

Fill/Cap: 80 (±5)

Root: 80 (±5)

Hot:100 (

+ 5)

Fill/Cap: 80 (±5)

Root: 80 (±5)

Hot:100 (

+ 5)

Fill/Cap: 80 (±5)

1/8" E6010 Fleetweld 5P+ Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010 Fleetweld 5P+ Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010 Fleetweld 5P+ Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010 Fleetweld 5P+ Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010 Fleetweld 5P+ Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

1/8" E6010 Fleetweld 5P+ Root: 90 (±5)

Hot: 100 (±5)

Fill/Cap: 80 (

+ 5)

GTAW Root: NA

Fill/Cap: 80 (±5)

GTAW Root: NA

Fill/Cap: 80 (±5)

GTAW Root: NA

Fill/Cap: 80 (±5)

GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 Flat .25"

250 (

+ 5) 18 DC+

GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 2F, 3F down .125" 250 (+ 5) 18 DC+
GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 2F .25" 375 (+ 5) 20 DC+
GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 3F up .25" 275 (+ 5) 18 DC+
GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 4F .25" 325 (+ 5) 19 DC+
GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 1G .375" 350 (+ 5) 20 DC+
GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 2G .375" 320 (+ 5) 19.5 DC+
GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 3G up .375"

250 (

+ 5) 17.9 DC+

GMAW - S .035" ER70S-6 SuperArc L-56 75A/25C 15 - 35 4G .375"

270 (

+ 5) 18 DC+

GMAW - Spray .045" ER70S-6 SuperArc L-56 90A/10C 25-40 Flat 0.25

400 (

+ 5) 27.1 DC+

GMAW - Spray .045" ER70S-6 SuperArc L-56 90A/10C 25-40 2F .375"

375 (

+ 5) 26.5 DC+

GMAW - Spray .045" ER70S-6 SuperArc L-56 90A/10C 25-40 1G .375"

370 (

+ 5) 26.5 DC+

GMAW - Pulse .045" ER70S-6 SuperArc L-56 90A/10C 25-40 2G .375"

130 (

+ 5) .95(trim) DC+

GMAW - Pulse .045" ER70S-6 SuperArc L-56 90A/10C 25-40 3G up .375"

130 (

+ 5) .95(trim) DC+

GMAW - STT .045" ER70S-6 SuperArc L-56 100C 15 - 35 2G Pipe

130 - 150 NA

GMAW - Pulse .045" ER70S-6 SuperArc L-56 90A/10C 25-40 2G Pipe 125-130 .95(trim)

GMAW - STT .045" ER70S-6 SuperArc L-56 100C 15 - 35 5G Pipe down

130 to 150 NA

GMAW - Pulse .045" ER70S-6 SuperArc L-56 90A/10C 25-40 5G Pipe up 125-130 .95(trim)

GMAW - STT .045" ER70S-6 SuperArc L-56 100C 15 - 35 6G Pipe down

130 to 150 NA

GMAW - Pulse .045" ER70S-6 SuperArc L-56 90A/10C 25-40 6G Pipe up 125-130 .95(trim)

FCAW - G .045" E71T-1 UC 71A85 75A/25C 25-50 Flat .25"

275 (

+ 5) 25 DC+

FCAW - G .045" E71T-1 UC 71A85 75A/25C 25-50 2F, 3F up, 4F .375"

275 (

+ 5) 25 DC+

FCAW - G .045" E71T-1 UC 71A85 75A/25C 25-50 1G, 2G, 3G up, 4G .375"

275 (

+ 5) 25 DC+

GMAW - STT .045" ER70S-6 SuperArc L-56 100C 15-35

130 to 150 NA

FCAW - G .045" E71T-1 UC 71A85 75A/25C 25-50

275 (

+ 5) 25

GMAW - STT .045" ER70S-6 SuperArc L-56 100C 15-35 5G Pipe down

130 to 150 NA

FCAW - G .045" E71T-1 UC 71A85 75A/25C 25-50 5G Pipe up

275 (

+ 5) 25

GMAW - STT .045" ER70S-6 SuperArc L-56 100C 15-35 6G Pipe down

130 to 150 NA

FCAW - G .045" E71T-1 UC 71A85 75A/25C 25-50 6G Pipe up

275 (

+ 5) 25

FCAW - S 5/64" E71T-8 NR- 232/233 NA NA Flat .25" 140 20 DC­FCAW - S 5/64" E71T-8 NR- 232/233 NA NA 2F, 3F up .375" 155 21 DC-

6"

DC+

DC+

6"6"DC+

NA

NA

NA

2"

DC+

DC+NADC+
DC+

NA

NA

DC+

DC+

DC+

DC+

DC+NANA

NA

wfs (ipm) or amps

Voltage

NA

NA

Pol

VRTEX 360 - Default Weld Process Settings

Position

Mat'l (in)

VR Welding

Process

Consumable

Type

Gas Flow

(cfh)

NA

Excalibur 7018

NA

NA

Lincoln Brand

Gas Mixture

Excalibur 7018

NA

6"

Excalibur 7018

NA

Fleetweld 5P+

6"

6G Pipe up

6"

NA

Excalibur 7018

NA

3/32" E7018

SMAW
SMAW

3/32" E7018

3/32" E7018

SMAW

NANASMAW

Excalibur 7018

Excalibur 7018

Excalibur 7018

NA

3/32" E7018

3/32" E7018

3/32" E7018

SMAW

SMAW

3/32" E7018

SMAW

3/32" E7018

6"

5G Pipe up

1/8" E6010

SMAW

6"

2G Pipe

NA

2G Pipe

5G Pipe up

NA

5G Pipe up

6G Pipe up

NA
NA

SMAW

3/32" E7018

Excalibur 7018

NA

6"

DC+6"6"

DC+

DC+NADC+

DC+

NA

DC+

NA

6G Pipe up

2"

2"2"SMAW

1/8" E6010

Fleetweld 5P+

NANA2G Pipe

5G Pipe up

2"2"6G Pipe up

Fleetweld 5P+

1/8" E6010

SMAW

2G Pipe

NA

NA

Excalibur 7018

NA

SMAW6"2G Pipe

NA

NA

FCAW - S 5/64" E71T-8 NR- 232/233 NA NA 1G,2G .375" 130 21 DC­FCAW - S 5/64" E71T-8 NR- 232/233 NA NA 3G up .375" 125 19.5 DC-

OPERATION

B-27

VRTEXTM360

D-1

MAINTENANCE

CLEANING & MAINTENANCE

FMD

Taking pro per car e of the FMD (F ace Mou nted
Display) is important for optimal functioning of the
equipment. Occasionally, the FMD lens should be
wiped with the lint free lens wipe that is provided.
This can be done to remove fingerprints from the lens­es. You can also use a lens cloth (e.g., from a cam­era shop). Paper towels or household cloths may
scratch or damage the lenses and should not be used.
Avoid exposing the FMD to liquids. Cleaning solu­tions should not be used to clean the FMD. Do not
use Isopropyl alcohol or solutions containing alcohol
to clean the lenses or plastic parts on the FMD. You
can also use a camera pressure canister to occasion­ally blow out dirt.

You may want to clean the inside of the helmet occa­sionally. Be sure to do so without exposing the FMD
to any unacceptable materials, as explained above.

D-1

The FMD should be kept in a clean and dry location
out of direct sunlight. Avoid dirty or sandy environ­ments, as these can lead to scratching of optics and
damage the FMD mechanical adjustments.

Monitor

CAUTION

The monitor is not a touch screen and can be
damaged by touching or poking it with any object.
Use care when cleaning screen. Use only a soft
dry cloth (cotton or flannel). Avoid chemicals and
solvents (alcohol, benzine, acidic or alcazine sol­vent cleaners). Avoid granular or abrasive clean­ing agents.

VRTEXTM360

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action fo r the
Possible Cause.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact the
Lincoln Electric Automation Division: 22221 St. Clair
Ave. Cleveland, Ohio 44117-1199 U.S.A.

Phone: [phone]
Fax: [phone]

If the equipment is used in a manner not specified by
the manufacturer, the protection provided by the
equipment may be impaired.

VRTEXTM360

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-2

RECOMMENDED

COURSE OF ACTION

There is jitter, shake or wobble in the
Helmet display and Monitor.

The CPU constantly looses the cur­rent time and date. At initial boot-up
the monitor reads “CMOS” battery
failed.

As viewed through the helmet the
entire stand assembly appears in the
middle of the screen and the envi­ronment does not move.

The weld coupon image is a different
conf i gurat i o n than the physi c al
coupon.

Make sure the helmet is close to the
work piece. The further the helmet
is from the work piece the more jitter
there may be in the helmet display.

Local interference.

The internal battery in the CPU has
failed.

The leads to the Polhemus Interface
Module may be faulty or loose.

Either the wrong coupon is on the
stand or the wrong configuration as
been selected in the software.

Check for loose or faulty connections
between the Helmet/Monitor and the
VRT E X 3 60 m achin e. S ee the
wiring diagram.

Make sure t here ar e not o ther
objects or frequencies that are inter­fering with the system. See the
Installation Section of this manual.

A q u alifie d techn i cian ne eds t o
address this problem. (battery num­ber KTS CR2032)

Check all cables and leads to the
Polhemus Interface Module.

Press the menu button and select
change coupon type. Change the
soft w are sele c tions so th at the
im ages on the scr een m atch the
hardware you are using.

The arm and/or table are different
than the visuals in the software.

When the check settings are activat­ed the incorrect settings appear.

Holding the green button in does not
shut down the VRTEX
normal.

The students’ reports are not acces­sible.

TM

360. This is

The software information may be
incorrect. Press the menu button
and select change process. Make
sure th e images on the sc r een
match the hardware being used.

The settings in the Instructor Mode
are incorrect.

Holding the green button in does not
shut down the VRTEX
normal.

USB not in front of machine.

TM

360. This is

N/A

Make sure all of the settings in the
tolerance editor are correct for the
process and parameters being used.
Check for the acceptable ranges for
the Lincoln defaults.

TM

To shut down the VRTEX
select menu and then select shut­down. The green button is not used
for system shutdown.

The students’ reports can only be
saved via the USB port on the front
of the VRTEX
memory device into the front of the
machine. If a USB memory stick is
not plugged into the USB port or if
there is not available memory on the
USB stick the students’ reports will
not be saved.

TM

360. Plug in a USB

360

VRTEXTM360

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

RECOMMENDED

COURSE OF ACTION

E-3

Prev i ous w e l d pass data is no t
accessible on the LASER screen.

Some or none of the welding para­meters, defects, or discontinuities
are shown on the LASER screen
graph.

The user is not sure of which toler­ance set they are using.

The machine was shut down and will
not turn back on when the green cir­cular button is pressed.

“End Pass” must be activated before
star t ing a ne w pa s s. If a ne w
coupon is started the data will only
be available for the first pass. Again
“End Pass” must be pressed before
a new pass is started

These items may be “toggled” off.

The tolerance set displayed in the
tolerance editor is the one being
used.

The tolerance set can also be read
from the student report.

The system may still be in the shut
down mode.

Use the joystick to go to pass num­ber and change which pass data you
are looking for. Note that some con­figurations only have one pass capa­bilities. See the Lincoln default tol­erances.

Use t he joystic k t o high ligh t the
desired items and then press the red
select b utt on to toggle t hem on .
Also, make sure that you are on a
currently welded pass.

Go to the instructor mode to change
tolerances. Go to the login screen,
turn the key and select tolerances to
verify tolerance set.

See the Operation Section in this
manual.

Wait 20 seconds, then press and
hold the green circular button for 3
seconds to start the machine.

The use r ca n not weld a seco n d
pass.

The VR FCAW/GMAW or VR SMAW
device(s) location do not correspond
with the image shown in the FMD
(Face Mounted Display) device.

Not all of the buttons are lit on the
front of the machine.

TM

The VRTEX
when the green circular button is
pressed.

360 does not start up

The joint configuration may set up
for one pass only.

The system may be located to large
metal objects.

Only the buttons that are available
for use light up.

Make sure the correct input power is
being applied to the machine.

Check the tolerance editor to verify
the joint configuration allows for mul­tiple pass welding.

Move the system to a suitable loca­tion. See the Installation Section of
this manual.

N/A

Be sure to hold the green circular
button in for at least three seconds.

VRTEXTM360

F-1

USB

PORT

12V

SOURCE

SENSOR 2

PH.1

PH.2

15

COMPUTER ASSEMBLY

M22219-2

INPUT VOLTAGE
RANGE

115VAC-230VAC
50/60 Hz

SINGLE PHASE

HOT

NEUTRAL

TO EARTH GROUND PER
THE NATIONAL

ELECTRICAL CODE

10A

CB1

DISPLAY PCB
L11757-2

1J37
2J37
3

J37
4J37
5J37
6J37
7J37
8J37
9J37
10J37

202
213
212
211
210
216
214
201

USB INTERFACE
S28157-93

123456789

10

1112131415

16

GND

+5

CS3

CS2

CS1

CS0

SD0

SD1

SCLK

202

213

212

211

210

216

214

201

USB2

USB2

UPPER (AC)

TERMINAL BLOCKS

RED 1

RED 2

RED 3

GREY 1

GREY 2GREEN 1

GREEN 2

200

201

GND

CASEBACK

GND2
CASEFRONT

BASE

CONTROL

PANEL

GND3GND1

GND4

INPUT RELEAY
MCR1

101A

101A

103

103

L1

T1

ON SWITCH
GREEN

101B

103A

MONITOR

M22219-3

HOT

NEUTRAL

GROUND

MONITOR

HOT

NEUTRAL

G

ROUND

HOT

NEUTRAL

GROUND

COMPUTER

HOT

NEUTRAL

GROUND

5V POWER SUPPLY

12V POWER SUPPLY

NEUTRAL

HOT
0
+5V

NEUTRAL

HOT
0

103B
103C

103B103C

201

202

102A

102B

102A

102B

COMPUTER

GND4

GND6

GND5

GND5
GND6

A1

A2

BLACK

RED

USB1

USB1

USB INTERFACE
DIGITAL I/O

S28157-91

LOWER (DC)

TERMINAL BLOCKS

246

8

101214161820222426283032343638404244464850

13579

11

13

171921232527293133353739414345

47

INININININININININININININININ

IN

INININININININININININININININ

IN

DO NOT USE

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

P3.0

P3.1

P3.2

P3.3

P3.4

P3.5

P3.6

P3.7
P4.0

P4.1

P4.2

P4.3

P4.4

P4.5

P4.6

P4.7

P5.0

P5.1

P5.2

P5.3

P5.4

P5.5

P5.6

P5.7

GND

P0.0

P0.1

P0.2

P0.3

P0.4

P0.5

P0.6

P0.7

P1.0

P1.1

P1.2

P1.3

P1.4

P1.5

P1.6

P1.7

P2.0

P2.1

P2.2

P2.3

P2.4

P2.5

P2.6

P2.7

TRIANGULAR (LEFT)
WHITE

RECTANGULAR

GREEN

RECTANGULAR

BLUE

RECTANGULAR

YELLOW

RECTANGULAR

ORANGE

RECTANGULAR

RED

TRIANGULAR (RIGHT)
WHITE

JOYSTICK RIGHTJOYSTICK DOWN

JOYSTICK LEFT

JOYSITCK UP

BLUE 1

WHITE 1

WHITE 2

WHITE 3

81

81

BLUE 2

81B

81A

81A

81C

81D

81E

81F

81G

81H

50

50

50

50A

81A

81A
50A

50A

50B

RED CIRCLE

50C

50D

50E

50F

50H

50J

50K

50L50M

CLOCK

DIRECTION

RETRACTED

EXTENDED
90 DEG

45 DEG

JOYSTICK LEFT

JOYSTICK RIGHT

JOYSTICK UP

JOYSTICK DOWN

SELECT (RED) PB

GMAW

FCAW

SMAW

AC

DC+

DC-

KEY SWITCH (TEST MODE)
BLUE LIGHT

GREEN LIGHT

RIGHT WHITE LIGHT

SMAW RELAY

V ENCODER 2 CH A

V ENCODER 2 CH B

WFS ENCODER 1 CH A

WFS ENCODER 1 CH B

"SET" RELAY

"RST" RELAY

50V

2628303236384042444648

48

38

4042444636

32

30

28

26

7

5

3

31

WFS ENCODER 1

V ENCODER 2

1

2

3

1

2

3

47

50N
45

43

41

5

0P

50N

50P

3735

33

39
SWITCH 1

SWITCH 2

GMAW

FCAW

SMAW
AC

DC+

DC-

29

27

25

23

21

19

50Q

50R

50Q
50R

KEY SWITCH

(TEST MODE)

1750S

50S

SMAW DEVICE

GMAW TORCH

POLHEMUS CONTROL
S28157-121

HMD CONTROL AND
HEADGEAR

S28157-59

SENSOR

S28157-124

SENSOR

S28157-124

SENSOR

S28157-123

HELMET

STAND SOURCE
S28157-125

MOTOR

PCB

RELAY PCB

M22296-1

S28157-80

P50

1234567

8

10

1112131415

16

9

ORANGE

WHITE

YELLOW

GREEN

CABLE 1
CABLE 2

WHITE

BLACK

GREEN

RED

BLUE

BROWN

RED

BLACK

J50

2

4

6

8

50T

50T

1

J1
2J1
3J1
4J1
5J1
6J1
7J1
8J1

71
5

0U
81B
73
1
24
22

50U

50U

8

1B

81B

CABLE 2

CABLE 1

TRIGGOR

171921232527293133353739414345

47

49

1

357

2
4

6
8

20

24

22

18

SW1

SW2

SW3

SW4

BLACK

RED

BROWN

BLUE

WHITE

GREEN

YELLOW

ORANGE

M

71

50V

50T

50V

GREEN

+

-

-

+

RED

BLACK

WHITE

J3

J2

J4

SMAW

SENSOR 1

SEN1

SEN2

SOURCE

1

1

3

4

1

2

3

4

61

626364

61
62
63
64

50W

50W

50W

20

18

G
V+

73

72

72

AUDIO STYLE CONNECTOR

9899

MIG

VGA SPLITTER
S28157-33

VGA IN

VGA OUT 1

VGA OUT 2

+12V

0V

VGA IN

SPARE VGA ON CASEBACK

VGA1

USB4

VGA3

VGA4

VGA4

VGA3

VGA1

VGA1

VGA3

VGA4

VGA3

VGA4

VGA2

91

90

AUDIO INA1

A1

GREEN AUDIO OUT

+5V
0V

FMD POWER CABLE

FMD POWER CABLE

FMD POWER CABLE

FMD POWER CABLE

SPLITTER POWER CABLE

SPLITTER POWER CABLE

SPLITTER POWER CABLE

USB3

USB3

USB3

+

-

90

91

9091

+5V

0V

POWER CABLE

POWER CABLE

TRI. LEFT SW

RECT. GRN SW

RECT. BLUE SW

RECT. YEL. SW

RECT. ORANGE SW
RECT. RED SW

TRI. RIGHT SW

LEFT WHITE LIGHT

RED LIGHT

ORANGE LIGHT

YELLOW LIGHT

NO

ONON

NO

NO

+

-

+

-

+

-

+

-

+

-

+

-

+

-

NO

NONO

NONONONO

NO

L1

L1

L2

Cx

Cy
Cy

202

204

USB5

USB

PORT

LOCATED

ON CASE

FRONT

VGA 6

VGA 6

AUDIO OUT

LOCATED ON

CASE BACK

EMC FILTER

200A

204A

50E

50H

50G

50G

50F

INPUT

CONNECTOR

VRTEX 360 MACHINE SCHEMATIC

R

G3244-565
A.05

VIEW OF CONNECTOR ON PC BOARD

ELECTRICAL SYMBOLS PER E1537.

OHMS/WATTS

COMPONENT VALUE
UNITS:

RESISTORS:

MFD/VOLTS

CAPACITORS:

8

LATCH

0F CONNECTOR J5

EXAMPLE: THIS IS PIN 7

32

LEAD COLORING CODE:

B-BLACK

21

8

G-GREEN

O-ORANGE

R-RED

CONNECTOR PIN NUMBERS:

7

14

U-BLUE

Y-YELLOW

W-WHITE

1

3

J5
N- BROWN

ALL COMPONENTS VIEWED FROM REAR

PRINT ON E3269-9

SEN2

A1

USB5

USB4

USB2

USB2

USB4USB4

USB4

USB

PORT

12V

SOURCE

SENSOR 2

PH.1

PH.2

15

COMPUTER ASSEMBLY

M22219-2

INPUT VOLTAGE

RANGE

115VAC-230VAC

50/60 Hz

SINGLE PHASE

HOT

NEUTRAL

TO EARTH GROUND PER

THE NATIONAL

ELECTRICAL CODE

10A

CB1

DISPLAY PCB

L11757-2

1J37

2J37

3

J37

4J37

5J37

6J37

7J37

8J37

9J37

10J37

202

213

212

211

210

216

214

201

USB INTERFACE

S28157-93

1

2345678

9

10

1112131415

16

GND

+5

CS3

CS2

CS1

CS0

SD0

SD1

SCLK

202

213

212

211

210

216

214

201

USB2

USB2

UPPER (AC)

TERMINAL BLOCKS

RED 1

RED 2

RED 3

GREY 1

GREY 2 GREEN 1

GREEN 2

200

201

GND

CASEBACK

GND2

CASEFRONT

BASE

CONTROL

PANEL

GND3GND1

GND4

INPUT RELEAY

MCR1

101A

101A

103

103

L1

T1

ON SWITCH

GREEN

101B

103A

MONITOR

M22219-3

HOT

NEUTRAL

GROUND

MONITOR

HOT

NEUTRAL

G

ROUND

HOT

NEUTRAL

GROUND

COMPUTER

HOT

NEUTRAL

GROUND

5V POWER SUPPLY

12V POWER SUPPLY

NEUTRAL

HOT

0

+5V

NEUTRAL

HOT

0

103B

103C

103B 103C

201

202

102A

102B

102A

102B

COMPUTER

GND4

GND6

GND5

GND5

GND6

A1

A2

BLACK

RED

USB1

USB1

USB INTERFACE

DIGITAL I/O

S28157-91

LOWER (DC)

TERMINAL BLOCKS

2

468

10121416182022

24262830323436384042444648

50

1

357

9

11

13

171921

23252729313335373941434547

INININININININ

INININININININININ

INININININININININININININININ

IN

DO NOT USE

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

OUT

P3.0

P3.1

P3.2

P3.3

P3.4

P3.5

P3.6

P3.7

P4.0

P4.1

P4.2

P4.3

P4.4

P4.5

P4.6

P4.7

P5.0

P5.1

P5.2

P5.3

P5.4

P5.5

P5.6

P5.7

GND

P0.0

P0.1

P0.2

P0.3

P0.4

P0.5

P0.6

P0.7

P1.0

P1.1

P1.2

P1.3

P1.4

P1.5

P1.6

P1.7

P2.0

P2.1

P2.2

P2.3

P2.4

P2.5

P2.6

P2.7

TRIANGULAR (LEFT)

WHITE

RECTANGULAR

GREEN

RECTANGULAR

BLUE

RECTANGULAR

YELLOW

RECTANGULAR

ORANGE

RECTANGULAR

RED

TRIANGULAR (RIGHT)

WHITE

JOYSTICK RIGHTJOYSTICK DOWN

JOYSTICK LEFT

JOYSITCK UP

BLUE 1

WHITE 1

WHITE 2

WHITE 3

81

81

BLUE 2

81B

81A

81A

81C

81D

81E

81F

81G

81H

50

50

50

50A

81A

81A

50A

50A

50B

RED CIRCLE

50C

50D

50E

50F

50H

50J

50K

50L 50M

CLOCK

DIRECTION

RETRACTED

EXTENDED

90 DEG

45 DEG

JOYSTICK LEFT

JOYSTICK RIGHT

JOYSTICK UP

JOYSTICK DOWN

SELECT (RED) PB

GMAW

FCAW

SMAW

AC

DC+

DC-

KEY SWITCH (TEST MODE)

BLUE LIGHT

GREEN LIGHT

RIGHT WHITE LIGHT

SMAW RELAY

V ENCODER 2 CH A

V ENCODER 2 CH B

WFS ENCODER 1 CH A

WFS ENCODER 1 CH B

"SET" RELAY

"RST" RELAY

50V

2628303236384042444648

48

38

40 42 44 46 36

32

30

28

26

7

5

3

31

WFS ENCODER 1

V ENCODER 2

1

2

3

1

2

3

47

50N

45

43

41

5

0P

50N

50P

37 35

33

39

SWITCH 1

SWITCH 2

GMAW

FCAW

SMAW

AC

DC+

DC-

29

27

25

23

21

19

50Q

50R

50Q

50R

KEY SWITCH

(TEST MODE)

17 50S

50S

SMAW DEVICE

GMAW TORCH

POLHEMUS CONTROL

S28157-121

HMD CONTROL AND

HEADGEAR

S28157-59

SENSOR

S28157-124

SENSOR

S28157-124

SENSOR

S28157-123

HELMET

STAND SOURCE

S28157-125

MOTOR

PCB

RELAY PCB

M22296-1

S28157-80

P50

1

2345678

10

1112131415

16

9

ORANGE

WHITE

YELLOW

GREEN

CABLE 1

CABLE 2

WHITE

BLACK

GREEN

RED

BLUE

BROWN

RED

BLACK

J50

2

4

6

8

50T

50T

1

J1

2J1

3J1

4J1

5J1

6J1

7J1

8J1

71

5

0U

81B

73

1

24

22

50U

50U

8

1B

81B

CABLE 2

CABLE 1

TRIGGOR

171921232527293133353739414345

47

49

1

357

2

4

6

8

20

24

22

18

SW1

SW2

SW3

SW4

BLACK

RED

BROWN

BLUE

WHITE

GREEN

YELLOW

ORANGE

M

71

50V

50T

50V

GREEN

+

-

-

+

RED

BLACK

WHITE

J3

J2

J4

SMAW

SENSOR 1

SEN1

SEN2

SOURCE

1

1

3

4

1

2

3

4

61

626364

61

62

63

64

50W

50W

50W

20

18

G

V+

73
72

72

AUDIO STYLE CONNECTOR

98 99

MIG

VGA SPLITTER

S28157-33

VGA IN

VGA OUT 1

VGA OUT 2

+12V

0V

VGA IN

SPARE VGA ON CASEBACK

VGA1

USB4

VGA3

VGA4

VGA4

VGA3

VGA1

VGA1

VGA3

VGA4

VGA3

VGA4

VGA2

91

90

AUDIO INA1

A1

GREEN AUDIO OUT

+5V

0V

FMD POWER CABLE

FMD POWER CABLE

FMD POWER CABLE

FMD POWER CABLE

SPLITTER POWER CABLE

SPLITTER POWER CABLE

SPLITTER POWER CABLE

USB3

USB3

USB3

+

-

90

91

90 91

+5V

0V

POWER CABLE

POWER CABLE

TRI. LEFT SW

RECT. GRN SW

RECT. BLUE SW

RECT. YEL. SW

RECT. ORANGE SW

RECT. RED SW

TRI. RIGHT SW

LEFT WHITE LIGHT

RED LIGHT

ORANGE LIGHT

YELLOW LIGHT

NO

ONON

NO

NO

+

-

+

-

+

-

+

-

+

-

+

-

+

-

NO

NO NO

NO NO NO NO

NO

L1

L1

L2

Cx

Cy

Cy

202

204

USB5

USB

PORT

LOCATED

ON CASE

FRONT

VGA 6

VGA 6

AUDIO OUT

LOCATED ON

CASE BACK

EMC FILTER

200A

204A

50E

50H

50G

50G

50F

INPUT

CONNECTOR

VRTEX 360 MACHINE SCHEMATIC

R

G3244-565

A.05

VIEW OF CONNECTOR ON PC BOARD

ELECTRICAL SYMBOLS PER E1537.

OHMS/WATTS

COMPONENT VALUE

UNITS:

RESISTORS:

MFD/VOLTS

CAPACITORS:

8

LATCH

0F CONNECTOR J5

EXAMPLE: THIS IS PIN 7

32

LEAD COLORING CODE:

B-BLACK

21

8

G-GREEN

O-ORANGE

R-RED

CONNECTOR PIN NUMBERS:

7

14

U-BLUE

Y-YELLOW

W-WHITE

1

3

J5

N- BROWN

ALL COMPONENTS VIEWED FROM REAR

PRINT ON E3269-9

SEN2

A1

USB5

USB4

USB2

USB2

USB4 USB4

USB4

DIAGRAMS

F-1

VRTEXTM360

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

NOTES

VRTEXTM360

WARNING

Spanish

AVISO DE

PRECAUCION

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground.

• No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

• Aislese del trabajo y de la tierra.

• Keep flammable materials away.

• Mantenga el material combustible

fuera del área de trabajo.

• Wear eye, ear and body protection.

• Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

• Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

• Isolez-vous du travail et de la terre.

• Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

• Isolieren Sie sich von den

Elektroden und dem Erdboden!

• Não toque partes elétricas e electro-

dos com a pele ou roupa molhada.

• Isole-se da peça e terra.

• Gardez à l’écart de tout matériel

inflammable.

• Entfernen Sie brennbarres Material!

• Mantenha inflamáveis bem guarda-

dos.

• Protégez vos yeux, vos oreilles et

votre corps.

• Tragen Sie Augen-, Ohren- und Kör-

perschutz!

• Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU
SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT
ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO­DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing zone.

• Turn power off before servicing.

• Do not operate with panel open or

guards off.

WARNING

• Los humos fuera de la zona de res-

piración.

• Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

• Gardez la tête à l’écart des fumées.

• Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

• Vermeiden Sie das Einatmen von

Schweibrauch!

• Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

• Mantenha seu rosto da fumaça.

• Use ventilação e exhaustão para

remover fumo da zona respiratória.

• Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

• Débranchez le courant avant l’entre-

tien.

• Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)

•

Não opere com as tampas removidas.

•

Desligue a corrente antes de fazer
serviço.

•

Não toque as partes elétricas nuas.

• No operar con panel abierto o

guardas quitadas.

• N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

• Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

• Mantenha-se afastado das partes

moventes.

• Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com