FRO­NIUS Virtual Welding User manual

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/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0089,EN 001-04112019
Virtual Welding Operating Instructions
Training
EN

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EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety symbols DANGER!
Indicates immediate and real danger.
If it is not avoided, death or serious injury will result.
WARNING!
Indicates a potentially dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
If it is not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.

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EN
Contents
Safety rules ................................................................................................................................................ 9
General ................................................................................................................................................. 9
Proper use ............................................................................................................................................ 10
Environmental conditions...................................................................................................................... 10
Obligations of the operator.................................................................................................................... 11
Obligations of personnel ....................................................................................................................... 11
Mains connection .................................................................................................................................. 11
Dangers from mains current ................................................................................................................. 12
EMC device classifications ................................................................................................................... 13
Specific hazards.................................................................................................................................... 14
Safety measures at the installation location and during transport ........................................................ 14
Safety measures in normal operation ................................................................................................... 15
Commissioning, maintenance and repair.............................................................................................. 16
Disposal ................................................................................................................................................ 16
Safety symbols...................................................................................................................................... 16
Data protection...................................................................................................................................... 16
Copyright............................................................................................................................................... 17
General information 19
General ...................................................................................................................................................... 21
Device concept ..................................................................................................................................... 21
Application ............................................................................................................................................ 21
Proper use ............................................................................................................................................ 22
Warning notices on the device.............................................................................................................. 22
System components ............................................................................................................................. 23
Controls, connections and mechanical components 27
Touchscreen and sensor ........................................................................................................................... 29
General ................................................................................................................................................. 29
Touchscreen and sensor ...................................................................................................................... 29
Control elements and connections............................................................................................................. 30
StandUp terminal controls and connection sockets .............................................................................. 30
Controls and connection sockets on the MobileCase ........................................................................... 31
Mains switch with mains connection ..................................................................................................... 32
Installation and commissioning 33
Before installation and commissioning....................................................................................................... 35
Safety.................................................................................................................................................... 35
Setup regulations .................................................................................................................................. 35
Installation.................................................................................................................................................. 37
StandUp terminal: Installation and fixing............................................................................................... 37
StandUp terminal: Installing system components ................................................................................. 38
MobileCase: Setting up......................................................................................................................... 39
MobileCase: Installing system components.......................................................................................... 40
Connecting the VR glasses................................................................................................................... 41
Connect the mains cable and switch on the device .............................................................................. 42
Display types.............................................................................................................................................. 44
Display types: Overview........................................................................................................................ 44
Display types: Connection diagram ...................................................................................................... 44
Display types: External monitor or projector ......................................................................................... 44
Start-up ...................................................................................................................................................... 46
Enabling the licence.............................................................................................................................. 46
Step one................................................................................................................................................ 46
Terminal management 49
Accessing "Terminal management" ........................................................................................................... 51

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Access .................................................................................................................................................. 51
Overview ............................................................................................................................................... 52
Curriculum.................................................................................................................................................. 53
Curricula................................................................................................................................................ 53
Creating a new curriculum .................................................................................................................... 53
MIG/MAG tasks..................................................................................................................................... 55
Rod electrode tasks .............................................................................................................................. 56
TIG tasks............................................................................................................................................... 58
Robotics tasks....................................................................................................................................... 59
For all training courses.......................................................................................................................... 59
Courses...................................................................................................................................................... 62
Courses................................................................................................................................................. 62
Creating a new course .......................................................................................................................... 62
Ghost ......................................................................................................................................................... 64
Ghost .................................................................................................................................................... 64
Creating a Ghost................................................................................................................................... 64
Ghost: Defining the record grid and welding speed .............................................................................. 66
Ghost: Executing reference welding ..................................................................................................... 67
Ghost: Defining the optimal oscillation.................................................................................................. 68
Ghost: Adjusting the number of movement steps and welding speed .................................................. 70
Ghost: Preview...................................................................................................................................... 71
Ghost: Setting the stick-out and tilt angle ............................................................................................. 71
Closing the Ghost ................................................................................................................................. 73
Terminals ................................................................................................................................................... 75
Terminals .............................................................................................................................................. 75
Terminals - Training administration....................................................................................................... 75
Terminal management - Additional settings 77
Additional settings - Overview.................................................................................................................... 79
Additional settings - Overview............................................................................................................... 79
Settings ...................................................................................................................................................... 81
Settings - activating modes................................................................................................................... 81
Settings - activating VR glasses ........................................................................................................... 81
Course mode ............................................................................................................................................. 82
General ................................................................................................................................................. 82
Training ................................................................................................................................................. 82
Ranking list ........................................................................................................................................... 86
Profile.................................................................................................................................................... 88
Log-in and registration .......................................................................................................................... 89
Select language .................................................................................................................................... 91
Showroom mode........................................................................................................................................ 93
General ................................................................................................................................................. 93
Try out now ........................................................................................................................................... 93
Training ................................................................................................................................................. 94
Open mode ................................................................................................................................................ 95
General ................................................................................................................................................. 95
Open training ........................................................................................................................................ 95
Calibration.................................................................................................................................................. 98
Calibration - system calibration............................................................................................................. 98
Calibrating the MIG/MAG welding torch................................................................................................ 99
Note on calibrating a TIG welding torch................................................................................................ 99
Calibrating camera settings .................................................................................................................. 100
Calibrating the hemisphere tracking ..................................................................................................... 101
Miscellaneous ............................................................................................................................................ 103
Licensemanager ................................................................................................................................... 103
Quiz - overview ..................................................................................................................................... 104
Activate / deactivate available quiz ....................................................................................................... 104
Change active quiz ............................................................................................................................... 104
Administrate quiz .................................................................................................................................. 104
Change robot manufacturer .................................................................................................................. 108
Setup settings 111

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EN
The Setup menu ........................................................................................................................................ 113
Overview ............................................................................................................................................... 113
Overview of buttons .............................................................................................................................. 113
Accessing the Setup menu ................................................................................................................... 113
Network menu item .................................................................................................................................... 116
Cluster network ..................................................................................................................................... 116
Other settings menu item........................................................................................................................... 120
Overview ............................................................................................................................................... 120
Licence list ............................................................................................................................................ 120
Exporting............................................................................................................................................... 121
Management code ................................................................................................................................ 123
Importing ............................................................................................................................................... 124
Language settings................................................................................................................................. 125
Country profiles..................................................................................................................................... 126
Reset..................................................................................................................................................... 127
Sensor registration................................................................................................................................ 128
Technical settings menu item .................................................................................................................... 131
Overview ............................................................................................................................................... 131
Setting the date and time ...................................................................................................................... 131
Showing the NSB number..................................................................................................................... 132
Test screen ........................................................................................................................................... 133
Brightness of glasses............................................................................................................................ 134
Choosing the model .............................................................................................................................. 134
ScanDisk............................................................................................................................................... 135
Calibrating the touchscreen .................................................................................................................. 136
Touchscreen test .................................................................................................................................. 137
Adjusting the volume............................................................................................................................. 138
Troubleshooting and maintenance 141
Troubleshooting ......................................................................................................................................... 143
General ................................................................................................................................................. 143
Safety.................................................................................................................................................... 143
Fault diagnosis...................................................................................................................................... 144
Care, maintenance and disposal ............................................................................................................... 147
General ................................................................................................................................................. 147
Safety.................................................................................................................................................... 147
Every start-up........................................................................................................................................ 147
Every 6 months ..................................................................................................................................... 147
Disposal ................................................................................................................................................ 147
Update ....................................................................................................................................................... 148
Installing/updating the software ............................................................................................................ 148
Appendix 151
Technical data............................................................................................................................................ 153
Special voltages.................................................................................................................................... 153
Virtual Welding terminal and MobileCase ............................................................................................. 153
Standards.............................................................................................................................................. 153
Spare parts list: Virtual Welding................................................................................................................. 154
Glossary..................................................................................................................................................... 162
ADSL..................................................................................................................................................... 162
APN....................................................................................................................................................... 162
AT commands....................................................................................................................................... 162
B-channel for ISDN ............................................................................................................................... 162
DHCP.................................................................................................................................................... 162
DSL ....................................................................................................................................................... 162
DSL modem .......................................................................................................................................... 162
Ethernet ................................................................................................................................................ 162
Gateway................................................................................................................................................ 162
GPRS.................................................................................................................................................... 163
HSDPA.................................................................................................................................................. 163
IP address............................................................................................................................................. 163
ISDN ..................................................................................................................................................... 163

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LAN ....................................................................................................................................................... 163
PIN ........................................................................................................................................................ 163
Point-to-Point Protocol .......................................................................................................................... 163
PPPoE .................................................................................................................................................. 163
PPTP..................................................................................................................................................... 163
Protocol................................................................................................................................................. 163
RAM ...................................................................................................................................................... 164
S0 bus for ISDN .................................................................................................................................... 164
Server ................................................................................................................................................... 164
SIM card................................................................................................................................................ 164
Splitter................................................................................................................................................... 164
Subnet mask ......................................................................................................................................... 164
TCP/IP .................................................................................................................................................. 164
UMTS.................................................................................................................................................... 164
WCDMA ................................................................................................................................................ 164
WEP...................................................................................................................................................... 165

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EN
Safety rules
General The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operat-
ing company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualified,
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- 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, rectify any faults that could compromise safe-
ty.
This is for your personal safety!

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Proper use
Environmental
conditions
The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the simulation of manual MIG/MAG
welding and manual metal arc welding using the hardware and software pro-
vided by the manufacturer.
Any use above and beyond this purpose is deemed improper. The manufac-
turer shall not be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating
instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work
- connection to the mains power supply according to the values shown on
the rating plate
- setting up in a dry and enclosed environment
- steady mounting on a firm and horizontal surface using the holders pro-
vided
The device should 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 instruc-
tions
The device is designed for use in a dry and enclosed environment. The man-
ufacturer is not liable for any damage caused by use in a different environ-
ment.
The manufacturer likewise accepts no liability for inadequate or incorrect train-
ing results.
Operation or storage of the device outside the stipulated area will be deemed
as not in accordance with the intended purpose. The manufacturer shall not
be held liable for any damage arising from such usage.
The device must only be installed and operated inside dry and enclosed prem-
ises.
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 sub-
stances, etc.
Can be used at altitudes of up to 2000 m (6500 ft)

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EN
Obligations of the
operator
Obligations of
personnel
Mains connection
The operator undertakes:
- to read the 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 the "Safety rules" section and warning notices
in these operating instructions and signed them to confirm this
- are trained to produce the required working or training results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident
prevention
- to read and observe the "Safety rules" section and the warning notices in
these operating instructions.
Before leaving the work area, ensure that people or property cannot come to
any harm in your absence.
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 has been supplied without the cable normally employed in your
country, bring the mains plug and cable into line with national standards.
An electric shock can be fatal. The mains plug must be fitted and connected
by trained personnel.
Route the mains cable so as to avoid any risk of injury to persons or damage
to the mains cable.
Do no connect the mains cable until the device has been set up. The Virtual
Welding terminal requires at least four hours to acclimatise.

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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.
All cables and leads must be secured, undamaged, insulated and adequately
dimensioned. Loose connections, scorched, damaged or inadequately dimen-
sioned cables and leads must be repaired/replaced immediately.
Do not sling 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 mains without a ground conductor and in a sock-
et 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 anyone from plugging the mains plug back in and switching it on
again.
After opening the device:
- discharge all live components
- 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.
Any repairs (e.g. opening of the terminal) must only be carried out by suitably
trained and qualified personnel. In the event of a fault, disconnect the mains
plug immediately and have repairs carried out by trained and qualified person-
nel.
- 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

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EN
EMC device clas-
sifications Virtual Welding is an emission class A device:
- It is only designed for use in an industrial setting
- It can cause conducted and emitted interference in other areas.
In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rec-
tify the situation.
Check for possible problems, and check and evaluate neighbouring devices'
resistance to interference according to national and international require-
ments:
- Safety devices
- Power, 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 correct mains connec-
tion, additional measures are necessary (e.g. use of a suitable line
filter).
b) No changes to the device
- Changes made to the device without the agreement of the manufac-
turer may lead to withdrawal of the operating licence.
c) If the device appears to interfere with 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 the device is responsible for the interference, eliminate the interfer-
ence using one or more of the following interference suppression
measures
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 conductor can amplify high frequency emissions and cause
electric shock with fatal consequences. Do not use an AC adapter or
extension cable.
- If the measures described above do not resolve the problem, consult
the manufacturer or a qualified radio and TV technician.

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Specific hazards
Safety measures
at the installation
location and dur-
ing transport
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
Make sure ventilation slots are not obstructed. The ambient temperature must
not exceed 35 °C (95 °F).
Use only suitable load-carrying equipment when transporting devices by
crane.
- Hook chains or ropes onto all of the provided suspension points of the
suitable load-carrying equipment.
- Chains/ropes must be at the smallest angle possible to the vertical.
If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, forklift
or other mechanical hoist.
If the Virtual Welding terminal is set up incorrectly it could topple over, leading
to injury and damage. The Virtual Welding terminal must only be set up by
trained personnel on a firm, horizontal surface and fastened to the wall or an-
chored to the floor using the holders provided.
A device that topples over can easily kill someone. Set up the device in a dry
and enclosed environment on a firm, supportive, horizontal surface, making
sure it is stable. Trained personnel must fasten the Virtual Welding terminal to
the wall or anchor it firmly to the floor using the holders provided.
It is strictly forbidden to install the Virtual Welding terminal in a damp or wet
environment or on a surface that is not horizontal or firm. This could lead to
accidents such as electric shock or the device could topple over.
Before installing, make sure that the following conditions are met:
- dry and enclosed premises
- firm, horizontal and supportive surface
- unobstructed access to the Virtual Welding terminal
- all-round clearance of 0.5 m (1 ft. 7.69 in.) around the device
- the Virtual Welding terminal is free from transport damage and is in fault-
free condition
There must be no metallic objects in the immediate vicinity of the Virtual Weld-
ing terminal. Other Virtual Welding terminals with the same sensor frequency,
located in the immediate vicinity, can cause frequency interference on the sys-
tems concerned.
Do not set up the Virtual Welding terminal ...
.. close to vital facilities such as:
- emergency exits
- fire extinguishers
- first-aid cabinets

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EN
Safety measures
in normal opera-
tion
... close to heat sources such as:
- radiators
- air-conditioning units
- sun terraces
- strong sunlight
... in areas subject to heavy environmental stress, such as:
- smoke and dirt
- rain and moisture
- strong magnetism or radio waves
- heat - ambient temperature above 35 °C (95 °F)
- cold
Special regulations apply in rooms at risk of fire or explosion.
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protec-
tion shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) around the Virtual Welding terminal so that cooling air can enter
and exit unhindered.
When transporting the device, observe the relevant national and local guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
Transport the device only in the original packaging. The packaging has the fol-
lowing item numbers:
- 42,0411,0090 MobileCase packaging
- 42,0411,0104 Terminal packaging
After transporting the device, the device must be visually inspected for dam-
age before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Only operate the device when all protection devices are fully functional. If the
protection devices are not in full working order, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operator,
- 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 protection 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 func-
tioning of safety devices.

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Commissioning,
maintenance and
repair
Disposal
Safety symbols
Data protection
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made of them, or that they satisfy safety require-
ments.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.
- Components that are not in perfect condition must be replaced immedi-
ately.
- 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.
Do not dispose of this device with normal domestic waste! To comply with the
European Directive on Waste Electrical and Electronic Equipment and its im-
plementation as national law, electrical equipment that has reached the end of
its life must be collected separately and returned to an approved recycling fa-
cility. 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 affects on
the environment and your health!
Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (e.g. relevant product standards
of the EN 60 974 series).
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 rele-
vant standards for Canada and the USA.
The user is responsible for the safekeeping of any changes made to the fac-
tory settings. The manufacturer accepts no liability for any deleted personal
settings.

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EN
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 basis for any claims whatsoever on the part of the pur-
chaser. 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.

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General information