FRO­NIUS Virtual Welding 2.0 MobileCase User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0089,EN 011-13052020
Virtual Welding 2.0
[
Operating Instructions
Virtual welding system
EN

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Contents
Safety rules ................................................................................................................................................ 7
Explanation of safety notices ................................................................................................................ 7
General ................................................................................................................................................. 7
Environmental conditions...................................................................................................................... 7
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Dangers from mains current ................................................................................................................. 8
EMC device classifications ................................................................................................................... 9
Specific hazards.................................................................................................................................... 10
Safety measures at the installation location and during transport ........................................................ 10
Safety measures in normal operation ................................................................................................... 11
Commissioning, maintenance and repair.............................................................................................. 11
Safety symbols...................................................................................................................................... 11
Data protection...................................................................................................................................... 11
Copyright............................................................................................................................................... 12
Disposal ................................................................................................................................................ 12
General information 13
General ...................................................................................................................................................... 15
Device concept ..................................................................................................................................... 15
Intended use ......................................................................................................................................... 15
Warning notices on the device.............................................................................................................. 16
Software and product updates.............................................................................................................. 17
Scope of delivery and optional function packages..................................................................................... 18
Scope of supply .................................................................................................................................... 18
Function packages................................................................................................................................ 19
Controls, connections and mechanical components 21
Touchscreen and sensor ........................................................................................................................... 23
Touchscreen and sensor ...................................................................................................................... 23
Control elements and connections............................................................................................................. 24
Connection sockets on the StandUp Terminal...................................................................................... 24
Controls and connection sockets on the MobileCase........................................................................... 25
Location of the ventilation openings........................................................................................................... 27
Ventilation openings on the StandUp Terminal..................................................................................... 27
Ventilation openings on the MobileCase............................................................................................... 27
Installation 29
Before installation and commissioning....................................................................................................... 31
Safety.................................................................................................................................................... 31
Setup regulations .................................................................................................................................. 31
Installing the StandUp Terminal................................................................................................................. 33
Safety.................................................................................................................................................... 33
Screwing the mounting brackets to the StandUp Terminal................................................................... 33
Assembling the StandUp Terminal and tightening the screws.............................................................. 35
Waiting time until the power connection is established......................................................................... 38
Installing the MobileCase........................................................................................................................... 39
Safety.................................................................................................................................................... 39
Setting up the MobileCase, fitting the tool table.................................................................................... 39
Waiting time until the power connection is established......................................................................... 40
Fitting and connecting the system components......................................................................................... 41
Fitting and connecting the tool and other system components............................................................. 41
Switching on, getting started...................................................................................................................... 44
Connecting the mains cable and switching on the device .................................................................... 44
Getting started ...................................................................................................................................... 44

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Start-up 45
Training concept and commissioning sequence ........................................................................................ 47
Training concept ................................................................................................................................... 47
Commissioning sequence..................................................................................................................... 47
First step of commissioning: creating a curriculum .................................................................................... 48
General ................................................................................................................................................. 48
Configuring a USB flash drive............................................................................................................... 48
Creating a knowledge check (test)........................................................................................................ 49
Saving content to the USB flash drive .................................................................................................. 50
Importing content .................................................................................................................................. 51
Merging content into a curriculum......................................................................................................... 55
Second step of commissioning: creating a course..................................................................................... 63
Uses of a course ................................................................................................................................... 63
Creating a course.................................................................................................................................. 63
Third step of commissioning: assigning courses ....................................................................................... 66
Assigning courses to the Virtual Welding system ................................................................................. 66
Assigning courses to multiple terminals................................................................................................ 67
Fourth step of commissioning: activating course mode, preparing the system for users .......................... 68
Activating course mode......................................................................................................................... 68
Preparing the system for users ............................................................................................................. 68
Ghost 69
Explanation and configuration options ....................................................................................................... 71
Explanation ........................................................................................................................................... 71
Creating a variable Ghost ..................................................................................................................... 71
Available modes on the Virtual Welding system 75
Course mode ............................................................................................................................................. 77
Explanation ........................................................................................................................................... 77
Activating course mode......................................................................................................................... 77
Profile.................................................................................................................................................... 78
Description of rankings lists, exporting course data.............................................................................. 80
Open mode ................................................................................................................................................ 82
Explanation ........................................................................................................................................... 82
Enabling open mode ............................................................................................................................. 82
Showroom mode........................................................................................................................................ 83
Explanation ........................................................................................................................................... 83
Enabling showroom mode .................................................................................................................... 83
Calibration 85
System calibration...................................................................................................................................... 87
Function ................................................................................................................................................ 87
Performing system calibration............................................................................................................... 87
Room calibration ........................................................................................................................................ 89
Function ................................................................................................................................................ 89
Performing room calibration.................................................................................................................. 89
Component calibration ............................................................................................................................... 91
Function ................................................................................................................................................ 91
Performing component calibration ........................................................................................................ 91
Changing the camera settings ................................................................................................................... 93
Function ................................................................................................................................................ 93
Changing the camera settings .............................................................................................................. 93
Additional settings 95
Licence management................................................................................................................................. 97
Function ................................................................................................................................................ 97
Opening licence management (Licensemanager) ................................................................................ 97
Installing a licence................................................................................................................................. 97

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Changing the robot manufacturer .............................................................................................................. 98
Description ............................................................................................................................................ 98
Quiz............................................................................................................................................................ 99
Function ................................................................................................................................................ 99
Enabling/disabling or importing/exporting quizzes................................................................................ 99
Exporting a quiz .................................................................................................................................... 99
Creating a quiz...................................................................................................................................... 100
Importing a quiz .................................................................................................................................... 102
Setup menu 105
Permissions and opening the Setup menu ................................................................................................ 107
Different permissions ............................................................................................................................ 107
Access the Setup menu ........................................................................................................................ 107
Network menu item .................................................................................................................................... 108
Description ............................................................................................................................................ 108
Creating a cluster network .................................................................................................................... 108
Other settings menu item........................................................................................................................... 111
Viewing the licence list.......................................................................................................................... 111
Creating a backup (exporting data)....................................................................................................... 112
Management code ................................................................................................................................ 113
Language settings................................................................................................................................. 114
Importing data (only available to administrators) .................................................................................. 116
Viewing/changing country profiles (only available to administrators).................................................... 117
Restoring factory settings (only available to administrators)................................................................. 118
Performing sensor registration (only available to administrators) ......................................................... 119
Technical settings menu item .................................................................................................................... 122
Setting the time and date (only available to administrators) ................................................................. 122
Showing the NSB number..................................................................................................................... 122
Test screen (only available to administrators) ...................................................................................... 123
Setting the model .................................................................................................................................. 124
Enabling ScanDisk (only available to administrators) ........................................................................... 124
Performing touchscreen test (only available to administrators) ............................................................ 125
Adjusting the volume (only available to administrators)........................................................................ 126
Troubleshooting, maintenance and disposal 129
Troubleshooting ......................................................................................................................................... 131
General ................................................................................................................................................. 131
Safety.................................................................................................................................................... 131
Troubleshooting .................................................................................................................................... 131
Maintenance and disposal ......................................................................................................................... 134
General ................................................................................................................................................. 134
Safety.................................................................................................................................................... 134
Maintenance at every start-up .............................................................................................................. 134
Disposal ................................................................................................................................................ 134
Update 135
Updating the software ................................................................................................................................ 137
Preparing for the update ....................................................................................................................... 137
Updating the software ........................................................................................................................... 146
Technical data 149
Technical data............................................................................................................................................ 151
Special voltages.................................................................................................................................... 151
StandUp Terminal, MobileCase ............................................................................................................ 151
Standards.............................................................................................................................................. 151

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Safety rules
Explanation of
safety notices DANGER!
Indicates immediate danger.
► If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
► If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
► If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device has been manufactured in line with the state of the art and according to recog-
nised safety standards. If used incorrectly or misused, however, it can cause:
- Serious or fatal injury to the operator or third parties
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
All persons involved in commissioning, operating, maintaining and servicing the device
must:
- Be suitably qualified
- Have fully read, understood and precisely followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device:
- Must be kept in a legible state
- Must not be damaged/marked
- Must not be removed
- Must not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the "General" chap-
ter of the device Operating Instructions.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer shall not be held liable for any dam-
age arising from such usage.

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The device must only be installed and operated inside dry and enclosed premises.
Ambient temperature range:
- during operation: - 10 °C to + 35 °C (14 °F to 95 °F)
- during transport and storage: - 25 °C to + 55 °C (-13 °F to 131 °F)
Relative humidity:
- up to 50 % at 35 °C (95 °F)
- up to 90 % at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6500 ft)
Obligations of the
operator
The operator undertakes:
- To read and understand these Operating Instructions.
- To hand the key of the device only to persons who are familiar with the product
The operator must only allow persons to work with the device who:
- Are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- Have read and understood these Operating Instructions and have confirmed as much
with their signatures
- Are trained to produce the required results (live work or training)
Checks must be carried out at regular intervals to ensure that personnel are working in a
safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- To observe the basic instructions regarding safety at work and accident prevention
- To have read and understood these Operating Instructions
Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.
Mains connection The mains voltage and frequency must conform to the data on the rating plate.
The Virtual Welding system must be connected to a properly installed, fused and earthed
mains socket.
If the device is shipped without a standard domestic cable, fit and use a mains plug and
cable in accordance with local standards.
An electric shock is potentially life threatening and can be fatal. The mains plug must be
fitted and connected by trained personnel only.
Route the mains cable so as to avoid any risk of injury to persons (e.g. tripping) or damage
to the mains cable.
Dangers from
mains current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.

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EN
All cables and leads must be secured, undamaged, insulated and adequately dimen-
sioned. Loose connectors, scorched, damaged or inadequately dimensioned cables and
leads must be replaced immediately.
Do not wrap cables or leads around the body or parts of the body.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.
If the device is operated on a grid without a ground conductor and in a socket without a
ground conductor contact, this will be deemed gross negligence. The manufacturer shall
not be held liable for any damage arising from such usage.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-
one from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all components that store an electrical charge
- Ensure that all components in the device are de-energised.
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
Repairs (e.g. opening of the device) must only be carried out by suitably trained and qual-
ified personnel. In the event of a fault, disconnect the mains plug immediately and have
repairs carried out by trained and qualified personnel.
- The device must be disconnected from the power supply before carrying out repairs
- Use only original spare parts
- Switch off before removing the mains plug
EMC device clas-
sifications
Virtual Welding is an emission class A device.
Devices with emission class A
- Are only designed for use in an industrial setting
- Can cause conducted and emitted interference in other areas.
In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g. when there is sen-
sitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situ-
ation.

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Check for possible problems, and check and evaluate neighbouring devices' resistance to
interference according to national and international requirements. For example:
- Safety devices
- Network, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
a) Mains supply
- Use only with the power cable supplied
- If electromagnetic interference arises despite the correct mains connection, addi-
tional measures are necessary (e.g. use of a suitable line filter)
b) No changes to the device
- Changes made to the device without prior consent from the manufacturer may re-
sult in loss of type approval
c) If the device appears to be interfering with the reception of radio or TV signals or the
operation of other equipment:
- Turn the device on and off to confirm that it is a source of interference
- If this identifies the device as a source of interference, remedy the fault by the in-
terference suppression measures listed below
d) Interference suppression measures
- Shield other devices nearby
- Set up the device well away from the affected receiver
- Turn the device away from the affected receiver
- Turn the antenna of the affected receiver in a different direction
- Connect the device to a different AC socket so that the device and the affected
receiver use different circuits.
- Only connect the device to a socket that is earthed. Removing the earth can am-
plify high-frequency emissions and cause an electric shock with fatal conse-
quences. Do not use an AC adapter or extension cable
- If the measures described above do not resolve the problem, contact the manu-
facturer or a qualified radio and TV technician
Specific hazards Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
Always keep ventilation openings clear. For more details on the position of the ventilation
openings, see section Location of the ventilation openings from page 27.
The ambient temperature must not exceed 35 °C (95 °F).
The device must not be moved using a crane.
If the StandUp Terminal is set up incorrectly it could topple over, leading to injury and ma-
terial damage. The StandUp Terminal must only be set up by trained personnel on a firm,
horizontal surface and secured to the wall and the floor using the brackets provided.
For more details on installing the StandUp Terminal, see section Installing the StandUp
Terminal from page 33.
Safety measures
at the installation
location and dur-
ing transport
When transporting the device, ensure that the relevant national and local guidelines and
accident prevention regulations are observed. This applies especially to guidelines regard-
ing the risks arising during transport.
Transport the device only in the original packaging. The original packaging is available
from the manufacturer.

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EN
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Use internal directives and checks to ensure that the workplace environment is always
clean, organised and tidy.
After transport, before installation and commissioning, it is essential to visually inspect the
device for damage. Have a trained service technician repair any damage before installation
and commissioning.
Safety measures
in normal opera-
tion
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a risk of:
- Serious or fatal injury to the operator or third parties
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety
devices.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufac-
turer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 se-
ries).
Fronius International GmbH hereby declares that the device is compliant with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following
address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.

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Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the ba-
sis for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse af-
fects on the environment and your health!

General information

15
EN
General
Device concept
StandUp Terminal
Virtual Welding is used to teach welding in
a realistic environment. The following bene-
fits are provided by Virtual Welding:
- Very low cost of training No consuma-
bles are required (wire electrodes, wel-
ding gas, etc.)
- The trainees are not exposed to the
hazards of welding (heat, welding fu-
mes, welding spatter, noise, etc.)
- The learning progress of the trainees is
documented and can be compared
with each other
- The learning content can be adapted to
suit your needs
- Many different tasks can be simulated
with the help of the different welding
torches and workpieces
- etc.
Virtual Welding is available as a StandUp
Terminal for stationary applications and as
a MobileCase for portable use.
MobileCase
Intended use The device is to be used exclusively for its intended purpose.

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The device is intended for welding simulation only with the software and hardware supplied
by the manufacturer.
Any use above and beyond this purpose is deemed improper.
The manufacturer shall not be held liable for any damage arising from such usage.
Intended use also means:
- Fully reading and understanding all the instructions given in the Operating Instructions
- Fully reading and understanding all warning notices on the device
- Performing all stipulated inspection and servicing work
- Establishing the mains connection according to the specifications on the rating plate
- Setting up in a dry and enclosed environment
The device must never be:
- Modified without authorisation
- Handled improperly
- Operated with software other than that supplied by the manufacturer
- Operated, maintained or repaired without observing the Operating Instructions
The device is designed for use in a dry and enclosed environment. The manufacturer is not
liable for any damage caused by use in a different environment.
The manufacturer accepts no liability for inadequate or incorrect training results.
Warning notices
on the device
Warning notices and safety symbols are affixed to the StandUp Terminal and MobileCase.
These warning notices and safety symbols must not be removed or painted over. They
warn against incorrect operation, as this may result in serious injury and damage.

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EN
Incorrect operation or poorly executed work can cause serious injury or damage. The de-
vice may only be installed, repaired and maintained by trained and qualified personnel. The
following documents must be completely read and understood:
- These Operating Instructions
- All the Operating Instructions for the system components, especially the safety rules
Do not dispose of used devices with domestic waste. Dispose of them according to the sa-
fety rules.
Software and
product updates
Due to software updates, you may find that your device has certain functions that are not
described in these Operating Instructions or vice versa. Certain illustrations may also differ
slightly from the actual controls on your device, but these controls function in exactly the
same way.

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Scope of delivery and optional function packages
Scope of supply In addition to the StandUp Terminal or MobileCase, the following system components are
supplied:
Work table
Workpiece holder Single-V butt weld layer 1 (square butt weld) workpie-
ce
Single-V butt weld layer 2 and 3 (square butt weld)
workpiece
Fillet weld workpiece

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EN
Pipe workpiece 2 NFC keys
Supplied with the StandUp Terminal, but not shown:
- 3D glasses
- 4 keys
- 4 screws M8x80 mm with washers, for screwing together the upper and lower parts
- Mounting bracket including 4 screws M8x16 mm and washers
- This document
- Mains cable (for connecting to a power socket)
- Cable for 3D glasses
- Network cable
Supplied with the MobileCase, but not shown:
- 3D glasses
- 2 keys
- This document
- Mains cable (for connecting to a power socket)
- Cable for 3D glasses
- Network cable
Function packag-
es
The function packages are not included with the Virtual Welding system. At least one of the
following function packages must be ordered with the Virtual Welding system.
MIG/MAG function package TIG function package
Robotics function package

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Rod electrode function package