FRO­NIUS Welducation Simulator User manual

Operating
Instructions
Welducation Simulator
Welducation Campus
42,0426,0444,EA 002-25102023
EN-US Operating instructions

Table of contents
Safety Instructions 5
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 10
Safety measures in normal operation 11
Commissioning, maintenance, and repair 11
Safety symbols 11
Data backup 11
Copyright 12
Disposal 12
General information 13
Important notes about this document 15
Purpose of the document 15
How information is presented in the document 15
FCC Compliance 15
Industry Canada Statement 17
Detachable Antenna Usage 17
Functional principle 19
Functional description of the Welducation Campus software 19
User concept 20
Target group 20
Terms and conditions of use 20
Data, security, and safety 22
Data storage 22
Data Privacy Statement 22
Safety Instructions 22
Intended use 22
Software updates 23
Training concept 24
Product concept 24
Interaction with the Welducation Campus software 25
Visualization 25
Objectives and features of the standard equipment 25
Optional accessories 31
Intended use 31
Warning notices on the device 32
Software and product updates 33
Operating controls and connections 34
Connections on the Welducation Simulator 34
Installation 37
IT settings 39
IT settings 39
Before installation and initial operation 40
Safety 40
Setup regulations 40
Waiting time until the power connection is established 41
3
EN-US

Mains connection 41
Installing basic system components 41
Table stand positions and setting options 41
Switching on, operation 43
Plugging in the mains cable and switching on the device 43
Operation 44
MIG/MAG 45
Commissioning 47
MIG/MAG welding commissioning 47
Laying the hosepacks correctly 49
Description of MIG/MAG Operating Modes 50
2-step mode 50
4-step mode 50
Special 4-step mode 51
Symbols and abbreviations 51
MIG/MAG Standard Manual Welding 53
General 53
Adjustable welding parameters for MIG/MAG standard manual 53
MIG/MAG standard manual welding 53
MIG/MAG synergic welding 55
MIG/MAG synergic welding 55
TIG 57
Commissioning 59
TIG welding commissioning 59
TIG welding 59
Laying the hosepacks correctly 61
Description of TIG Operating Modes 62
4-step mode 62
Symbols and explanations 62
Rod Electrode 65
Commissioning 67
MMA welding commissioning 67
MMA welding 67
Laying the hosepacks correctly 68
Support 69
Fronius Support team 71
Fronius Support team 71
Update 72
Software update 72
Troubleshooting, maintenance, and disposal 73
Troubleshooting 75
General 75
Safety 75
Troubleshooting 76
Maintenance and disposal 78
General 78
Safety 78
Maintenance at every start-up 78
Disposal 78
Technical data 79
Special voltage 79
Welducation Simulator 79
NEXT welding helmet 79
Standards 79
4

Safety Instructions
5

6

Safety Instructions
Explanation of
safety instruc-
tions
DANGER!
Indicates an immediate danger
▶Death or serious injury will result if appropriate precautions are not taken.
WARNING!
Indicates a potentially dangerous situation
▶Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a potentially harmful situation
▶Minor injury or damage to property may result if appropriate precautions are
not taken.
NOTE!
Indicates a possibility of flawed work results and possible damage to the equip-
ment
General The device has been manufactured in line with the state of the art and according
to recognized 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 Instruc-
tions
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 regula-
tions 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
-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 sec-
tion headed "General" in the Operating Instructions for the device.
Before switching on the device, eliminate any faults that could compromise
safety.
7
EN-US

Your personal safety is at stake!
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer accepts no liab-
ility 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: 0 °C to 40 °C (+32 °F to +104 °F)
-During transport and storage: -20 °C to +60 °C (-4 °F to +140 °F)
Relative humidity:
-Up to 93% at +40 °C (+104 °F), non-condensing
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
company
The operating company undertakes to
-Read and understand the Operating Instructions
The operating company must only allow persons to work with the device if they:
-Are familiar with the basic occupational safety and accident prevention regu-
lations 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 be-
fore beginning 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 connec-
tion
The mains voltage and mains frequency must match the specifications on the
rating plate.
The device must only be connected to a properly installed, secured, and groun-
ded 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 and qualified 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.
8

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 di-
mensioned. 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 grid and device supply lead regularly inspected by an electrician to en-
sure that the ground conductor is functioning properly.
Only operate the device on a grid with a ground conductor and a socket with a
ground conductor 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 manu-
facturer 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.
Only trained and qualified personnel may carry out repair work (e.g., open the
device). 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
This device is an emission class B device.
Devices in emission class B:
-are only intended for use in or in the immediate vicinity of residential, busi-
ness, and commercial 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
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 operating company is obliged to take appropriate ac-
tion to rectify the situation.
9
EN-US

Check and evaluate possible problems and the interference immunity of equip-
ment in the vicinity according to national and international regulations. For ex-
ample, of:
-Safety devices
-Grid power lines, signal lines, and data transfer lines
-IT and telecommunications equipment
-Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
a)Grid 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
grid filter).
b)No modifications to the device
-Modifications made to the device without prior agreement with the man-
ufacturer may result in loss of type approval.
c)If the device is suspected of interfering with the reception of television or ra-
dio signals or the operation of another device:
-Confirm the device as a source of interference by switching it on and off.
-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 af-
fected receiver use different circuits.
-Only connect the device to a grounded socket. Removing the grounding
may increase high-frequency emissions and cause an electric shock res-
ulting in death. Do not use AC adapter plugs or extension cables.
-If the above measures do not provide a sustainable solution, contact the
manufacturer or a trained radio and television technician.
Particular haz-
ard areas
Special regulations apply in areas at risk of fire or explosion.
- Follow the appropriate national and international regulations.
Always keep ventilation openings clear.
The ambient temperature must not exceed +40 °C (+104 °F).
Do not transport the device by crane.
Risk of personal injury and damage to property due to toppling of the device if
set up incorrectly. Only set up the device on a flat, stable surface with the help of
trained and qualified personnel.
Safety measures
at the setup loc-
ation and during
transport
Observe the applicable national and regional guidelines and accident prevention
regulations when transporting the device, especially guidelines concerning haz-
ards during transport and shipment.
Only carry out the transport in the original packaging or in the Toolcase provided
for this purpose. The original packaging or the appropriate Toolcase can be ob-
tained from the manufacturer.
Do not lift or transport any active devices. Switch off devices before transport or
lifting.
10

Use instructions and checks within the company to ensure that the vicinity of the
workplace is always clean and organized.
After transport and before installation and commissioning, it is essential to visu-
ally inspect the device for damage. Have trained and qualified personnel 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 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.
Ensure the safety of all persons before switching on the device.
The device must be examined at least once a week for externally detectable dam-
age and functionality of the safety devices.
Commissioning,
maintenance,
and repair
It is impossible to guarantee that third-party parts are designed and manufac-
tured to meet the demands made on them, and that they satisfy safety require-
ments.
-Use only original spare and wear parts (also applies to standard parts).
-Do not carry out any alterations, installations, or modifications to the device
without first obtaining the manufacturer's permission.
-Components that are not in perfect condition must be changed immediately.
-When ordering, specify the exact name and part number according to the
Spare Parts List, as well as the serial number of your device.
The housing screws provide the ground conductor connection for grounding the
housing parts.
Always use original housing screws in the appropriate quantity with the specified
torque.
Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directive (e.g., relevant product standards of
the EN 60 974 series).
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
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 manufacturer accepts no liability for any deleted personal settings.
11
EN-US

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 improvement, or can point out any mistakes that you
have found in the Operating Instructions, we will be most grateful for your com-
ments.
Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally sound manner in accordance with the European Dir-
ective and national law. Used equipment must be returned to the distributor or
through a local authorized collection and disposal system. Proper disposal of the
used device promotes sustainable recycling of material resources. Failure to ob-
serve this may lead to potential health/environmental impacts.
Packaging materials
Separate collection. Check your municipality’s regulations. Reduce the volume of
the box.
12

General information
13

14

Important notes about this document
Purpose of the
document
These Operating Instructions describe the functionality, installation, operation,
and maintenance of the Welducation Simulator and the Welducation Campus
software.
The document is aimed at all authorized teachers and trainees who are entrusted
with teaching or learning welding by means of the training concept consisting of
the Welducation Simulator and Welducation Campus software.
How information
is presented in
the document
The conventions regarding how information is presented in the document, which
are set out below, have been defined in order to increase the readability and
comprehensibility of the document. See the "Safety" chapter for the conventions
on presenting safety-related information. The conventions described here refer
to the way various types of information is presented, such as operational pre-
requisites, guidance, operator prompts, etc.
CAUTION!
Indicates a potentially harmful situation
▶Minor injury or damage to property may result if appropriate precautions are
not taken.
NOTE!
Indicates a possibility of flawed work results and possible damage to the equip-
ment
IMPORTANT! Indicates tips for correct operation and other particularly useful
information. It does not indicate a harmful or dangerous situation.
Emphasis
-Display texts are written in quotation marks.
FCC Compliance This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference, and
(2) this device must accept any interference received, including interference that
may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference in a residential in-
stallation.
This equipment generates, uses and can radiate radio frequency energy and, if
not installed and used in accordance with the instructions, may cause harmful in-
terference to radio communications. However, there is no guarantee that interfer-
ence will not occur in a particular installation.
15
EN-US

If this equipment does cause harmful interference to radio or television recep-
tion, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one of the following measures:
-Reorient or relocate the receiving antenna.
-Increase the separation between the equipment and receiver.
-Connect the equipment into an outlet on a circuit different from that to
which the receiver is connected.
-Consult the dealer or an experienced radio/TV technician for help.
FCC Caution:
Any changes or modifications not expressly approved by the party responsible
for compliance could void the user's authority to operate this equipment.
This transmitter must not be co-located or operated in conjunction with any oth-
er antenna or transmitter.
Radiation Exposure Statement:
This equipment complies with FCC radiation exposure limits set forth for an un-
controlled environment. This equipment should be installed and operated with
minimum distance 20 cm (7.87 in.) between the radiator & your body.
This device is intended only for OEM integrators under the following conditions:
1The antenna must be installed such that 20 cm (7.87 in.) is maintained
between the antenna and users.
2The transmitter module may not be co-located with any other transmitter or
antenna.
3Module approval valid only when the module is installed in the tested host or
compatible series of host which have similar RF exposure characteristic with
equal or larger antenna separation distance.
As long as 3 conditions above are met, further transmitter test will not be re-
quired. However, the OEM integrator is still responsible for testing their end-
product for any additional compliance requirements required with this module
installed.
IMPORTANT NOTE:
In the event that these conditions can not be met (for example certain laptop
configurations or co-location with another transmitter), then the FCC authoriza-
tion is no longer considered valid and the FCC ID can not be used on the final
product.
In these circumstances, the OEM integrator will be responsible for re-evaluating
the end product (including the transmitter) and obtaining a separate FCC au-
thorization.
End Product Labeling:
FOR MOBILE DEVICE USAGE > 20 cm (7.87 in.) / low power
This transmitter module is authorized only for use in device where the antenna
may be installed such that 20 cm (7.87 in.) may be maintained between the an-
tenna and users. The final end product must be labeled in a visible area with the
following: “Contains FCC ID: RYK-WPEQ261ACNIBT”. The grantee's FCC ID can
be used only when all FCC compliance requirements are met.
Manual Information To the End User:
The OEM integrator has to be aware not to provide information to the end user
regarding how to install or remove this RF module in the user’s manual of the
end product which integrates this module.
16

Industry Canada
Statement
This device complies with ISED’s licence-exempt RSSs. Operation is subject to
the following two conditions:
1This device may not cause harmful interference, and
2This device must accept any interference received, including interference
that may cause undesired operation.
FOR MOBILE DEVICE USAGE (> 20cm, 7.87 in. / low power)
Radiation Exposure Statement:
This equipment complies with ISED radiation exposure limits set forth for an un-
controlled environment. This equipment should be installed and operated with
greater than 20 cm (7.87 in.) between the radiator & your body.
This device is intended only for OEM integrators under the following conditions
(for module device use):
1The antenna must be installed and operated with greater than 20 cm (7.87
in.) between the antenna and users.
2The transmitter module may not be co-located with any other transmitter or
antenna.
3Module approval valid only when the module is installed in the tested host or
compatible series of host which have similar RF exposure characteristic with
equal or larger antenna separation distance.
As long as the 3 conditions above are met, further transmitter test will not be re-
quired. However, the OEM integrator is still responsible for testing his end-
product for any additional compliance requirements required with this module
installed. The end-user manual must include all required regulatory information
and warnings as specified in this manual.
Caution :
The user manual for devices in local area networks should contain detailed in-
structions on the restrictions mentioned above, in particular:
1The device for operation in the band 5150-5250 MHz is only for indoor use to
reduce the potential for harmful interference to co-channel mobile satellite
systems.
2For devices with detachable antenna(s), the maximum antenna gain permit-
ted for devices in the bands 5250-5350 MHz and 5470-5725 MHz shall be
such that the equipment still complies with the e.i.r.p. limit (detachable an-
tenna only).
3For devices with detachable antenna(s), the maximum antenna gain permit-
ted for devices in the band 5725-5850 MHz shall be such that the equipment
still complies with the e.i.r.p. limits as appropriate (detachable antenna only).
4Where applicable, antenna type(s), antenna models(s), and worst-case tilt
angle(s) necessary to remain compliant with the e.i.r.p. elevation mask re-
quirement set forth in section 6.2.2.3 shall be clearly indicated.
Detachable An-
tenna Usage
This radio transmitter (IC: 6158A-EQ261ACNIBT / Model: WPEQ-261ACNI(BT))
has been approved by ISED to operate with the antenna types listed below with
maximum permissible gain indicated. Antenna types not included in this list, are
having a gain greater than the maximum gain.
17
EN-US

The following antenna types are permissible:
-xxx
-xxx
-xxx
18

Functional principle
Functional de-
scription of the
Welducation
Campus soft-
ware
The Welducation Campus software is part of a virtual training concept for train-
ees to learn welding skills in a virtual environment. The training concept consists
of one or more Welducation Simulators and the separate Welducation Campus
software for managing courses and learning content. The AdminTool it contains is
used to process users, devices, and licenses.
Reserving the management as well as the theoretical study of the courses and
learning content for the Welducation Campus software results in the Welduca-
tion Simulators being used exclusively for specific welding tasks. The Welduca-
tion Campus software is intended for external end devices, such as the supplied
Fronius tablet or smartphones, notebooks, and PCs.
It is possible for the teachers to put together a training program tailored to the
needs of the trainees, with theory content and exercises on all 3 welding pro-
cesses: MIG/MAG, TIG, and MMA. The Welducation Campus software provides
an overview of the trainees' learning progress and supports evaluation and as-
sessment.
Trainees can study the learning content at any time and complete the practical
exercises assigned to them on the Welducation Simulator.
19
EN-US

User concept
Target group The training concept, consisting of the Welducation Campus software and the
Welducation Simulators, is aimed at all authorized teachers and trainees who are
involved in teaching or learning the 3 welding processes MIG/MAG, TIG, and
MMA. Another target group is those who have administrator rights and are in-
volved in the administration of the Welducation Campus software.
Terms and condi-
tions of use
Access to or use of the Welducation Campus software constitutes consent to ac-
cept and comply with the terms and conditions of use. If you do not agree to the
terms and conditions of use, you are not permitted to access the software.
The terms and conditions of use set out the responsibilities of Fronius Interna-
tional GmbH towards all persons using the software and identify the "dos" and
"don'ts" to be observed when using the software.
There is no entitlement to receive, use, or examine the machine code or source
code or any development documentation of the Welducation Campus software.
Fronius holds all rights to use and exploit the Welducation Campus software, all
software components, all further developments, improvements, and adaptations,
and all copies thereof.
It is not permitted to use the Welducation Campus software for purposes other
than those described in the order, to modify or adapt it, to link it with other pro-
grams, to translate it, to convert it into another programming language, to de-
compile it, or to create derivative works. In particular, it is not permitted to use
the Welducation Campus software other than within the contractual model.
User accounts and access data are not transferable and are limited to the agreed
contract period. Unless otherwise agreed in writing, maintenance (e.g., change of
rights) is the responsibility of the customer.
The Welducation Campus software is to be used exclusively for the contractual
purpose and only for the duration of the contract.
Fronius is not responsible for damage caused by the authorized persons or per-
sons who have unlawfully or accidentally gained access to the Welducation Cam-
pus software. Fronius is not liable for the risk of economic disadvantage or dam-
age, of whatever nature, resulting from the use of the Welducation Campus soft-
ware by such persons. Likewise, Fronius shall not be held liable for any lack of
training success.
Fronius shall be liable for damages demonstrably caused in connection with this
contract only in the case of intent or gross negligence. Liability for minor negli-
gence, lost profit, missed savings, compensation for consequential damages, lost
or altered data, indirect damages, and damages arising from claims of third
parties is excluded, unless contrary to mandatory law. Without limiting the fore-
going provisions, for each case of liability Fronius shall only be liable up to the
amount of the annual fee payable by the Customer.
The Internet connection between the end devices (e.g., tablets, smartphones,
notebooks, PCs) and the Welducation Simulators, including the hardware and
software required for this (e.g., mains connection, browser), is the responsibility
of the customer. It should therefore be acknowledged that Fronius does not con-
trol the transfer of data via communications equipment, including the Internet,
20