FRO­NIUS Virtual Welding 2.0 User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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42,0426,0089,EA 011-29062020
Virtual Welding 2.0
[
Operating Instructions
Virtual welding system
EN-US

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Table of contents
Safety Instructions ..................................................................................................................................... 7
Explanation of Safety Instructions......................................................................................................... 7
General ................................................................................................................................................. 7
Environmental conditions...................................................................................................................... 8
Obligations of the operating company .................................................................................................. 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Danger from mains current ................................................................................................................... 9
EMC device classifications ................................................................................................................... 9
Particular hazard areas......................................................................................................................... 10
Safety measures at the setup location and during transport................................................................. 11
Safety measures in normal operation ................................................................................................... 11
Maintenance and repair ........................................................................................................................ 11
Safety Symbols ..................................................................................................................................... 11
Data backup.......................................................................................................................................... 12
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 supply and optional function packages....................................................................................... 18
Scope of supply .................................................................................................................................... 18
Function packages................................................................................................................................ 19
Operating controls, connections and mechanical components 21
Touch screen and sensor .......................................................................................................................... 23
Touch screen and sensor ..................................................................................................................... 23
Operating controls and connections .......................................................................................................... 24
Connections on the StandUp Terminal................................................................................................. 24
MobileCase operating controls and connections .................................................................................. 25
Position of the ventilation openings ........................................................................................................... 27
Ventilation openings on the StandUp Terminal..................................................................................... 27
Ventilation openings on the MobileCase............................................................................................... 27
Installation 29
Before installation and initial operation ...................................................................................................... 31
Safety.................................................................................................................................................... 31
Setup regulations .................................................................................................................................. 31
Installing the Standup Terminal ................................................................................................................. 33
Safety.................................................................................................................................................... 33
Screw the mounting bracket to the StandUp Terminal. ........................................................................ 33
Assemble and screw in the StandUp Terminal ..................................................................................... 35
Waiting time until the power connection is established......................................................................... 38
Installing the MobileCase........................................................................................................................... 39
Safety.................................................................................................................................................... 39
Setting up the MobileCase, mounting the tool table ............................................................................. 39
Waiting time until the power connection is established......................................................................... 40
Fitting/connecting the system components................................................................................................ 41
Installing and connecting the tool table and other system components................................................ 41
Powering on, initial steps ........................................................................................................................... 44
Plug in the mains cable and turn on the device .................................................................................... 44
Initial steps ............................................................................................................................................ 44

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Commissioning 45
Training concept and procedure for commissioning .................................................................................. 47
Training concept ................................................................................................................................... 47
Commissioning procedure .................................................................................................................... 47
First step of commissioning: Create a curriculum ...................................................................................... 48
General ................................................................................................................................................. 48
Configuring the USB thumb drive ......................................................................................................... 48
Creating a knowledge check................................................................................................................. 49
Saving content to the USB thumb drive................................................................................................ 50
Importing content .................................................................................................................................. 51
Merging content into a curriculum......................................................................................................... 55
Second step of commissioning: create a course ....................................................................................... 63
Using a course ...................................................................................................................................... 63
Creating a course.................................................................................................................................. 63
Third step of commissioning: assign courses ............................................................................................ 66
Assigning courses to the Virtual Welding system ................................................................................. 66
Assigning courses to multiple terminals................................................................................................ 67
Fourth step of commissioning: enable course mode, prepare the system for users.................................. 68
Activating course mode......................................................................................................................... 68
Preparing the system for the users ....................................................................................................... 68
Ghost 69
Explanation and configuration options ....................................................................................................... 71
Explanation ........................................................................................................................................... 71
Creating a variable Ghost .................................................................................................................... 71
Available modes on the Virtual Welding system 75
Course mode ............................................................................................................................................. 77
Explanation ........................................................................................................................................... 77
Activating course mode......................................................................................................................... 77
Profile.................................................................................................................................................... 78
Ranking list description, exporting course data .................................................................................... 80
Open mode ................................................................................................................................................ 82
Explanation ........................................................................................................................................... 82
Activating open mode ........................................................................................................................... 82
Showroom mode........................................................................................................................................ 83
Explanation ........................................................................................................................................... 83
Activating 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 setting ..................................................................................................................... 93
Function ................................................................................................................................................ 93
Changing the camera settings .............................................................................................................. 93
Other settings 95
License management................................................................................................................................. 97
Function ................................................................................................................................................ 97
Opening license management .............................................................................................................. 97
Installing a license................................................................................................................................. 97

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Changing the robot manufacturer .............................................................................................................. 98
Description ............................................................................................................................................ 98
Quiz............................................................................................................................................................ 99
Function ................................................................................................................................................ 99
Activating/deactivating a quiz, importing/exporting a quiz .................................................................... 99
Exporting a quiz .................................................................................................................................... 99
Creating a Quiz .................................................................................................................................... 100
Importing a quiz .................................................................................................................................... 102
Setup Menu 105
Permissions and accessing the Setup menu ............................................................................................. 107
Different permissions ............................................................................................................................ 107
Accessing the Setup menu ................................................................................................................... 107
Network menu item .................................................................................................................................... 108
Description ............................................................................................................................................ 108
Creating cluster networking .................................................................................................................. 108
Other settings menu item........................................................................................................................... 111
Displaying the license list...................................................................................................................... 111
Creating a backup (exporting data)....................................................................................................... 112
Management code ................................................................................................................................ 113
Language settings................................................................................................................................. 114
Importing data (only available to administrators) .................................................................................. 116
Displaying / changing country profiles (only available for administrators) ............................................ 117
Restoring factory settings (only available for administrators) ............................................................... 118
Performing sensor registration (only available for administrators)........................................................ 119
Technical settings menu item .................................................................................................................... 122
Setting the date and time (only available for administrators)................................................................ 122
Displaying the NSB number.................................................................................................................. 122
Test image (only available for administrators) ...................................................................................... 123
Defining the model ................................................................................................................................ 124
Activating the memory check (only available for administrators) .......................................................... 124
Performing the touch screen test (only available for administrators).................................................... 125
Setting the volume (only available for 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
Installing the Update .................................................................................................................................. 137
Preparation for the update .................................................................................................................... 137
Performing the update .......................................................................................................................... 146
Technical data 149
Technical data............................................................................................................................................ 151
Special voltage...................................................................................................................................... 151
StandUp Terminal, MobileCase ............................................................................................................ 151
Standards.............................................................................................................................................. 151

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Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured in line with the state of the art and according to recog-
nized safety standards. If work is carried out improperly or the device is used incorrectly or
misused, however, it can cause:
- Serious or fatal injury to the operator or third parties
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- Be suitably qualified
- Have fully read, understood, and precisely followed these Operating Instructions
The Operating Instructions must always be kept to hand wherever the device is being
used. In addition to the Operating Instructions, all applicable local rules and regulations re-
garding accident prevention and environmental protection must also be followed.
All safety and danger notices on the device:
- Must be kept in a legible state
- Must not be damaged/marked
- Must not be removed
- Must not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!

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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 accepts no liability for any damage
resulting from improper use.
Installation and operation may only take place within closed and dry rooms.
Temperature range of ambient air:
- During operation: - 10 °C to + 35 °C (14 °F to 95 °F)
- During transport and storage: - 25 °C to + 55 °C (- 13 °F to 131 °F)
Relative humidity:
- up to 50% at 35 °C (95 °F)
- up to 90% at 20 °C (68 °F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6500 ft.)
Obligations of the
operating compa-
ny
The operating company undertakes to
- Read and understand the Operating Instructions
- Only hand over the device keys to personnel who are familiar with the product
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions and have confirmed this with
their signature
- Are trained according to the requirements for the work and training results.
The safety-conscious work of the personnel must be checked regularly.
Obligations of
personnel
All persons who are instructed to work with the device must do the following before begin-
ning work:
- Follow the basic regulations for occupational safety and accident prevention
- Have read and understood these Operating Instructions.
Before leaving the workplace, ensure that no personal injury or property damage can occur
in their absence.
Mains connection The mains voltage and grid frequency must match the specifications on the rating plate.
The Virtual Welding system must only be connected to a properly installed, secured, and
grounded mains socket.
If the device is supplied without a country-specific cable, use the mains plug and cable in
accordance with local standards.
An electric shock can be fatal. Only trained personnel may install and connect the mains
plug.
Route the mains cable so that there is no risk of injury (risk of tripping, etc.) and damage
to the mains cable.

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EN-US
Danger from
mains current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
All cables and leads must be secured, undamaged, insulated, and adequately dimen-
sioned. Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.
Do not wrap cables or leads around your body or parts of the body.
Have the mains and device supply lead regularly inspected by an electrician to ensure that
the ground conductor is functioning properly.
Only operate the device on a grid with a ground conductor and a socket with a ground con-
ductor contact.
Operating the device on a grid without a ground conductor and on a socket without a
ground conductor contact is considered gross negligence. The manufacturer accepts no
liability for any damage resulting from improper use.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the mains plug.
Secure the device to prevent the mains plug from being connected and switched on again
by applying a clearly legible and understandable warning sign.
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply
If work is needed on voltage-carrying parts, bring in a second person who will switch off the
main switch at the correct time.
Repair work (e.g., opening the device) must only be carried out by qualified personnel
trained for this purpose. If a defect occurs, unplug the device immediately and have the
repair carried out by trained and qualified personnel.
- Repairs must only be carried out in a de-energized state
- Only use original spare parts
- Only unplug the device when it is switched off
EMC device clas-
sifications
The Virtual Welding system is an emission class A device
Devices in emission class A
- Are only designed for use in industrial areas
- Can cause wiring-related or radiated interference in other areas.
In certain cases, even though a device complies with the standard limit values for 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).

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If this is the case, then the operating company is obliged to take appropriate action to rectify
the situation.
Check and evaluate possible problems and the interference immunity of equipment in the
vicinity according to national and international regulations. For example, from:
- Safety devices
- Mains power lines, signal lines, and data transfer lines
- IT and telecommunications equipment
- Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
a) Mains power supply
- Use only the supplied power cables
- If electromagnetic interference occurs despite a mains connection that complies
with regulations, take additional measures (e.g., use a suitable mains filter).
b) No modifications to the device
- Modifications made to the device without prior agreement with the manufacturer
may result in loss of type approval
c) If the device is suspected of interfering with the reception of television or radio signals
or the operation of another device:
- Confirm the device by switching it on and off as a source of interference
- If this identifies the device as a source of interference, remedy the fault using the
anti-interference measures listed below
d) Anti-interference measures
- Shield other devices in the vicinity
- Place the device far away from the affected receiver
- Turn the device away from the affected receiver
- Adjust the antenna of the affected receiver
- Connect the device to another AC socket so that the device and the affected re-
ceiver use different circuits.
- Only connect the device to a grounded socket. Removing the grounding may in-
crease high-frequency emissions and cause an electric shock resulting in death.
Do not use AC adapter plugs or extension cables
- If the above measures do not provide a sustainable solution, contact the manu-
facturer or a trained radio and television technician
Particular hazard
areas
Special regulations apply in areas at risk of fire or explosion
–follow the appropriate national and international regulations.
Always keep ventilation openings clear. For more information on the position of the venti-
lation openings, see section Position of the ventilation openings from page 27.
The ambient temperature must not exceed 35 °C (95 °F).
The device must not be transported using a crane.
Risk of personal injury due to toppling of the StandUp Terminal if set up incorrectly. Only
set up the StandUp Terminal on a flat, stable surface and screw it to the wall and floor using
the supplied brackets with the help of trained personnel.
For more information on installing the StandUp Terminal, see section Installing the Stan-
dup Terminal from page 33.

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EN-US
Safety measures
at the setup loca-
tion and during
transport
Take care to ensure that the applicable national and regional guidelines and accident pre-
vention regulations are observed when transporting the device. especially guidelines con-
cerning hazards during transport and shipment.
Only carry out the transport in the original packaging. The original packaging is available
from the manufacturer.
Do not lift or transport any active devices. Switch off devices before transport or lifting.
Carry out internal instructions and checks to ensure that the vicinity of the workplace is al-
ways clean and organized.
After transport and before installation and commissioning, it is essential to visually inspect
the device for damage. Have a trained service technician repair any damage before instal-
lation 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 danger of:
- Serious or fatal injury to the operator or third parties
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
Safety devices that are not fully functional must be repaired before the device is switched
on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and
functionality of the safety devices.
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 label satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directive (e.g. relevant product standards of the EN 60974 se-
ries).
Fronius International GmbH declares that the device complies with Directive 2014/53/EU.
The full text of the EU Declaration of Conformity is available on the following website: http:/
/www.fronius.com

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Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings. The man-
ufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves the right to
make changes. The contents of the Operating Instructions shall not provide the basis for
any claims whatsoever on the part of the purchaser. If you have any suggestions for im-
provement, or can point out any mistakes that you have found in the Operating Instruc-
tions, we will be most grateful for your comments.
Disposal 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
be returned to your dealer, or you must locate the approved collection and recycling facil-
ities in your area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!

General information

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EN-US
General
Device concept
StandUp Terminal
Virtual Welding is used for the realistic lear-
ning of welding skills. Virtual Welding offers
the following benefits:
- Very low cost of training. No consuma-
bles are required (wire electrodes, wel-
ding fumes, etc.)
- The trainees are not exposed to the
dangers of welding (heat, welding fu-
mes, welding spatter, noise, etc.)
- The learning progress of the trainees is
documented and can be compared
- The learning content can be adapted to
suit individual needs
- With the help of the various welding
torches and workpieces, many diffe-
rent tasks can be simulated
- etc.
The Virtual Welding system is available as
a StandUp Terminal for stationary use and
as a MobileCase for mobile use.
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.
Utilization for any other purpose, or in any other manner shall be deemed improper.
The manufacturer shall not be liable for any resulting damage.
Intended use also means:
- Carefully reading and adhering to all instructions in these Operating Instructions
- Carefully reading and understanding all warnings on the device
- Carrying out all the specified inspection and maintenance work
- Establishing the mains connection according to the specifications on the rating plate
- Installation in closed and dry rooms
Never:
- Convert the device yourself
- Handle the device incorrectly
- Operate the device with programs other than the manufacturer's software
- Operate, service, or repair the device without observing the Operating Instructions
The device is designed for operation in closed and dry rooms. The manufacturer shall not
be liable for any damage resulting from use in other environments.
The manufacturer shall also not be liable for faulty or incorrect training success.
Warning notices
on the device
Warning notices and safety symbols can be found on the StandUp Terminal and Mobile-
Case. These warning notices and safety symbols must not be removed or painted over.
They warn against incorrect operation, as this may result in serious injury and property
damage.

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EN-US
Incorrect operation and incorrectly performed work can cause serious injury and property
damage. Installation, repair, and maintenance work may only be carried out by trained per-
sonnel. The following documents must be read in full and understood:
- These Operating Instructions
- All system component Operating Instructions, especially the safety rules
Dispose of old devices in accordance with safety rules and not in normal domestic waste.
Software and
product updates
Because of software updates, certain functions may be available for your device but not
described in these Operating Instructions or vice versa. In addition, individual figures may
also differ slightly from the operating controls of your device. However, these operating
controls function in exactly the same way.

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

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EN-US
Pipe workpiece 2 NFC keys
In addition to the supplied StandUp Terminal, but not shown:
- 3D glasses
- 4 keys
- 4 M8 x 80 mm screws with washers, for screwing together the upper and lower parts
- Mounting bracket including 4 M8x16 mm screws and washers
- This document
- Mains cable (for connecting to a socket)
- Cable for 3D glasses
- Network cable
In addition to the supplied MobileCase, but not shown:
- 3D glasses
- 2 keys
- This document
- Mains cable (for connecting to a socket)
- Cable for 3D glasses
- Network cable
Function packag-
es
The function packages are not included in the scope of supply of the Virtual Welding sys-
tem. At least one of the following function packages must be ordered with the Virtual Weld-
ing system.
MIG/MAG function package TIG function package

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Robotics function package
MMA function package