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