Lincoln Electric VRTEXTM 360 SVM200-A User manual

SVM200-A
April, 2010
SERVICE MANUAL
or use with machine code number: AD1332-1
AD1332-2
VRTEX
™
360
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] AX: 216.383.8823 WEB SITE: www.VRTEX360.com
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
Safety Depends on You
incoln equipment is designed
and built with safety in mind.
However, your overall safety can
be increased by proper installa-
tion ... and thoughtful operation
on your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
E UIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
NOTICE
The VRTEXTM 360 is a virtu-
al reality arc welding
training machine only
and NOT a real arc
welder. When welding
with arc welding equip-
ment, be aware of all
standard safety practices
associated with arc weld-
ing. Some standard warn-
ings are included in this
manual.
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VRTEX TM 360
SAFETY
i i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refueling
to prevent spilled fuel from vaporizing on con-
tact with hot engine parts and igniting. Do not
spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi-
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts when
starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler by
pushing on the throttle control rods while the
engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
incoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURETHAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-
FORMED ONLY BY UALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
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SAFETY
ii ii
VRTEX TM 360
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PE
and ACGIH T V limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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VRTEX TM 360
SAFETY
iii iii
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA,1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. a
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. e dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
SAFETY
iv iv
VRTEX TM 360
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. es circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue ou
les vétements mouillés. Porter des gants secs et sans trous
pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au soudage
à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
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SAFETY
v v
VRTEX TM 360
Do not place objects on the Table Arm or
Weld Machine.
andle the Face Mounted Display (FMD)
integrated helmet with care. When not in
use, the elmet should be placed some-
where where it will not fall down or be
harmed. If you will not be using the sys-
tem for longer than 4 hours, shut down
your unit.
andle the VR SMAW device and VR
GMAW/FCAW gun with care. When not in
use, these items should be placed in the
appropriate holders. These devices are
customized and cannot be used on normal
welding machines.
andle the Coupons with care. When not
in use, store them in the Coupon Drawer at
the back of the Weld Machine.
During lightening storms, turn off the sys-
tem and unplug it from any power outlets.
WARNINGS
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SAFETY
vi vi
VRTEX TM 360
Recycling Welding Equipment at End of Life
Waste Electrical and Electronic Equipment (WEEE)
Recycling
Recycling and reclamation of used electrical and electronic equipment is important to many nations and localities.
Lincoln Electric provides information to assist in the recycling of welding equipment.
This parts list contains a “WEEE” column. The WEEE column describes potential recyclable materials. Materials that
require selective treatment, according to national regulations, are also identified in the WEEE column.
The following table describes substances that are potentially recyclable. Components with high substance content are
identified within the parts list. Easily identified and common components such as steel screws, steel nuts, steel washers
and copper wire are not identified on the list, but are also recyclable. Some components may contain mixed substances.
EEE in Europe
This instruction is mandatory for equipment in Europe that displays this symbol:
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE) and its imple-
mentation in accordance with national law, electrical equipment that has reached the end of its life must be collected sep-
arately and returned to an environmentally compatible recycling facility. As the owner of the equipment, you should get
information on approved collection systems from your local Lincoln representative. By applying this European Directive
you will protect the environment and human health!
The following components must be removed from the welding equipment and shall be selectively treated. They shall be
disposed of or recovered in compliance with Council Directive 75/442/EEC. They are identified within the parts pages:
Component Selective Treatment
Identification
Printed circuit boards with surface greater than 10 square centimeters ST
Liquid crystal displays with surface greater than 100 square centimeters ST
External electric cables (not all external cables are shown on parts pages) ST
Electrolyte capacitors with height >25 mm and diameter >25 mm or proportionately
similar in volume ST
Substance Recyclable Material
Identification
Steel, Iron e
Aluminum Al
Copper Cu
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
I I
VRTEX TM 360
Page
Safety ...........................................................................i-vi
Installation..................................................................SectionA
Operation ..................................................................SectionB
Maintenance ................................................................SectionD
TheoryofOperation ..........................................................SectionE
TroubleshootingandRepair ...................................................SectionF
ElectricalDiagrams ..........................................................SectionG
PartsManual ...................................................................P-638
RETURN TO MAIN INDEX

TABLE OF CONTENTS - INSTALLATION SECTION
A-1 A-1
VRTEX TM 360
Installation...........................................................................................................Section A
Graphic Symbols ..................................................................................................................A-2
Technical Specifications .......................................................................................................A-3
Safety....................................................................................................................................A-4
ocation ................................................................................................................................A-4
Environmental Area ..............................................................................................................A-4
Stacking/Tilting/ ifting ...........................................................................................................A-4
High Frequency Interference Protection ...............................................................................A-4
General Description..............................................................................................................A-5
Design Features ...................................................................................................................A-5
Hardware Uncrating & Set-up ........................................................................................A-5/A-8
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INSTALLATION
A-2 A-2
VRTEX TM 360
INPUT POWER
ON
OFF
CIRCUIT BREAKER
INPUT POWER
SINGLE P ASE
ALTERNATING CURRENT
READ THIS OPERATORS
MANUAL COMPLETELY
INPUT VOLTAGE
INPUT CURRENT
PROTECTIVE
GROUND
WARNING or CAUTION
Documentation must be con-
sulted in all cases where this
symbol is displayed.
Explosion
Dangerous Voltage
Shock azard
GRAP IC SYMBOLS T AT APPEAR ON
T IS MAC INE OR IN T IS MANUAL
U1
I1
1
Shock azard
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INSTALLATION
A-3 A-3
VRTEX TM 360
TEC NICAL SPECIFICATIONS: AD1332-1 (STD. REQ.) / AD1332-2 (ALT. REQ.)
VRTEX
™™
360 - VIRTUAL REALITY WELDING TRAINER
MAKE/MODEL DESCRIPTION INPUT VOLTAGE INPUT CURRENT
+/- 10% (MAX.)
AD1332-1 Standard Frequency 115-230 VAC (50-60 Z) 4A-2A Single Phase
AD1332-2 Alternate Frequency 115-230 VAC (50-60 Z) 4A-2A Single Phase
INPUT
EIG T WIDT DEPT WEIG T
71.0 in. 30.0 in. 50.0 in. 360 lbs.
1803 mm 762 mm 1270 mm 163 kg.
P YSICAL DIMENSIONS (MAC INE W/MONITOR)
C
1T IS PRODUCT AS BEEN TESTED TO T E REQUIREMENTS OF CAN/CSA-C22.2 NO. 61010-1,
2ND EDITION, INCLUDING AMENDMENT 1, OR A LATER VERSION OF T E SAME STANDARD
INCORPORATING T E SAME LEVEL OF TESTING REQUIREMENTS.
EIG T WIDT DEPT WEIG T
78.0 in. 39.0 in. 47.0 in. 102 lbs.
1981 mm 990 mm 1194 mm 46 kg.
P YSICAL DIMENSIONS (STAND)
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
410 - 950F5
0 - 350C 320 - 1490F 00 - 650C
TEMPERATURE RANGES
80% For Temperatures Up To 880F / 310C
50% @ 1040F / 400C 6562 Feet (2000 Meters)
RELATIVE UMIDITY OPERATING ALTITUDES
This Product is Pollution Degree 1.
ENVIRONMENT
MAKE/MODEL DESCRIPTION OPERATING FREQUENCY
AD1332-1 Standard Frequency IG
AD1332-2 Alternate Frequency LOW
TRACKING SYSTEM FREQUENCY
WARNING
T IS PRODUCT INCORPORATES A PROTECTIVE EART IN T E AC POWER CORD. T E AC PLUG
S OULD ONLY BE INSERTED INTO A SOCKET OUTLET PROVIDED WIT A
PROTECTIVE EART CONTACT.
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INSTALLATION
A-4 A-4
VRTEX TM 360
TILTING
Place the VRTEXTM 360 directly on a secure, level sur-
face.
IG FREQUENCY INTERFERENCE PRO-
TECTION
READ ENTIRE INSTALLATION SECTION BEFORE
STARTING INSTALLATION.
Safety Precautions
------------------------------------------------------------
SELECT SUITABLE LOCATION
The machine will not operate in harsh environments. It
is important that simple preventative measures are fol-
lowed in order to assure long life and reliable opera-
tion. This product is for INDOOR USE ONLY.
• Dirt and dust that can be drawn into the machine
should be kept to a minimum. ailure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.
• Do not locate where monitor is exposed to direct sun-
light.
• Do not place equipment near radiant heat sources.
• Do not place in a confined space. Allow a minimum
of 3 feet of clearance around machine at all times.
Adequate ventilation is necessary.
• The circuit breaker switch on the rear panel is the
input power disconnect device. Do not position the
equipment so that it is difficult to operate the circuit
breaker.
• Route and protect power cable to minimize exposure
to damage.
ENVIRONMENTAL AREA
Keep the machine inside and dry at all times. Do not
place it on wet ground or in puddles. Never place liq-
uids on top of the machine.
STACKING
The VRTEXTM 360 cannot be stacked.
ELECTRIC S OCK can kill.
• Only qualified personnel should per-
form this installation.
• Turn the input power OFF and unplug
the machine from the receptacle
before working on this equipment.
•
Insulate ourself from the work and ground.
• Always connect the VRTEXTM 360 to a power sup-
ply grounded according to the National Electrical
Code and local codes.
WARNING
CAUTION
USE CAUTION W EN OPERATING T IS MAC INE
AROUND OT ER EQUIPMENT.
• Large equipment, such as cranes, may interfere
with the operation of this machine.
• This machine may interfere with the operation of
other equipment in work/training area.
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when
lifting.
• Do not operate machine while
suspended or when lifting.
FALLING EQUIPMENT can cause injury.
------------------------------------------------------------------------
WARNING
LIFTING
If lifting the VRTEXTM 360 is required, use two straps, each
rated for 500 pounds or more. Do not attempt to lift the
VRTEXTM 360 with accessories attached to it.
STRAPS
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INSTALLATION
A-5 A-5
VRTEX TM 360
GENERAL DESCRIPTION
The VRTEXTM 360 is a Virtual Welding Training
System. This computer controlled interactive system
simulates arc welding through the use of realistic pud-
dle graphics and sounds. This training system is capa-
ble of simulating multiple arc welding processes on a
wide variety of weld joint configurations. The VRTEXTM
360 represents the next generation of Virtual Reality
(VR) welding training.
DESIGN FEATURES
ARDWARE OVERVIEW:
• Virtual Welding Machine, including:
o Monitor
o Coupon Drawer (back drawer)
o VR GMAW/ CAW Gun
o VR SMAW device
o VR GMAW/ CAW Gun holder
o VR SMAW device holder
o VR Helmet w/ ace Mounted Display ( MD)
o ive VR Coupons - lat Plate
Tee Joint
Groove Joint
2” Pipe XXS
6” Pipe Schedule 40
• Stand, including:
o Post
o Arm
o Table
o Pins
o Base
o Weights
ARDWARE UNCRATING:
TOOLS NEEDED
3/8” Wrench
3/16” Allen Wrench
Phillips Screwdriver
1. Decide on a location for your unit.
NOTE: The unit will take up approximately 8’ L x 8’
D x 8’ . Keep approximately 3 feet in all
directions of both the stand and VR weld
machine free from obstruction. In addition,
be conscious of where you are placing the
unit to avoid magnetic fields, conductive,
and high frequency objects and processes.
aving these types of objects in the area
can cause interference and result in
increased jitter and/or distortion in the
motion tracking.
For best results, do not install VRTEXTM 360
machine in the welding lab. Electrical
interference from power lines, though gen-
erally small, can be present. Therefore all
electrical power or lighting wiring within 50
feet of the welding area shall be enclosed
in grounded rigid metallic conduit. In the
event the VRTEXTM 360 is affected by inter-
ference, it is the user's responsibility to
take steps to isolate and/or eliminate the
interference.
An uninterruptible power supply (UPS)
may be required for the protection of the
system from power irregularities or disrup-
tion.
MULTIPLE SYSTEM INSTALLATIONS
If multiple units are required to operate together a
unique frequency transmitter can be installed during
the manufacturing process at Lincoln Electric to reduce
potential interference between systems. AD1332-1
systems have a standard frequency source installed.
AD1332-2 systems have an alternate frequency
source installed. or multiple system installations,
alternate the -1 and -2 systems for best operation:
For Example: If 8 systems are to be installed in the VR
welding lab, the standard and alternate frequencies
2. Using the 3/8” wrench, remove the screws from the
upper and lower front panels on the shipping crate.
NOTE: The rear of the crate is nailed on. Do not
remove at this time.
-1 -2 -1 -2
-2 -1 -2 -1
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INSTALLATION
A-6 A-6
VRTEX TM 360
10. Remove the four screws from the wooden rear
cross brace.
11. Remove the wooden cross brace while ensuring
the unit is steady and secure.
12. Carefully roll the machine off the rear of the skid.
Ramping may be required.
13. Uncrate and unpack the table and table base.
9. Using the 3/8” wrench, remove the two screws from
the rear base securing the unit to the wooden crate.
8. Remove the monitor from the back of the machine.
4. Carefully slide the crate assembly from the
VRTEXTM 360.
5. Slide towards the rear of the machine. Be careful to
avoid damaging the welding device holders located
on each side of the machine.
6. Carefully remove the post (long rectangular
shaped cardboard box) from the crate.
7. Carefully cut and remove plastic wrapping.
3. Remove the six 3/8” bolts (three on each side) from
the bottom of the crate assembly.
FRONT
(upper)
BOLTS
FRONT
(lower)
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INSTALLATION
A-7 A-7
VRTEX TM 360
14. Insert the input supply power cord into the back of
the VRTEXTM 360 and into a standard electrical
outlet capable of 115 to 230 VAC at 4 to 2 Amps.
TABLE & SWING ARM SET-UP:
1. Using the 3/16” allen wrench, remove the two ¼” x
20 Allen-head screws from the base assembly.
NOTE: The longer screw is in the top.
2. Insert red post into base assembly aligning the flat
on the pole with the hole.
NOTE: The post will only insert one way.
3. Using the 3/16” allen wrench, secure the post into
position and tighten.
5. Insert one of the collar pins into the post at the #6
location.
6. rom the top, slide the table onto the post letting it
rest on the collar pin inserted in previous step.
7. Insert the second collar pin into the post at the #13
position.
8. Obtain swing-arm from the rear of the VRTEXTM 360
by removing the cable ties from the swing arm and
cable. Grey cable should remain connected to the
VRTEXTM 360 (DO NOT CUT!).
Collar
Pins
4. Obtain the three post collar pins from the factory
packaging of the VRTEXTM 360.
Cable Tie
Swing Arm
Table Post
T Pin
Grey Cable
(DO NOT CUT)
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INSTALLATION
A-8 A-8
VRTEX TM 360
9. Carefully slide swing-arm onto post with the letters
(on the collar) “ABC” up and the grey cable located
on the bottom of the swing arm assembly.
10. Insert a third collar pin at a convenient height for
holding the helmet.
MONITOR:
1. Remove monitor from cardboard box.
2. Remove the cable ties from monitor cables secured
to the monitor mounting post.
3. Using a Phillips-head screwdriver, carefully mount
the monitor onto the mounting post bracket. Tighten
the four Phillips-head screws securely.
4. Install input power cable and VGA cable into the
monitor.
ADDITIONAL FEATURES:
1. The welding coupons are stored in the coupon
drawer in the rear of the machine.
2. The weld simulation can be displayed on an exter-
nal monitor or projector by using the SVGA output
on the back of the machine. The external display
must support 1024x780 resolution.
3. External speakers may be connected using the
audio jack located on the back of the machine.
TRACKING SYSTEM FUNDAMENTALS:
The magnetic tracking system is composed of the
following:
• Control Unit (Inside VR Machine)
o Contains the hardware and software neces-
sary to compute position and orientation.
• Source (part of the Swing Arm)
o The source contains electromagnetic coils
enclosed in a plastic shell that emit a magnetic
field. The source is the systemʼs reference
frame for sensor measurements.
• Sensor (in the VR GMAW/ CAW gun, VR SMAW
device, and helmet)
o The sensor contains electromagnetic coils
enclosed in a plastic shell that detect the mag-
netic fields emitted by the source. The sensorʼs
position and orientation are precisely mea-
sured as it moves in reference to the source.
The sensor is completely passive, having no
active voltage applied to it.
MONITOR (Mounting Screws)
Screws
Input
Power
VGA
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NOTES
A-9 A-9
VRTEX TM 360
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TABLE OF CONTENTS - OPERATION SECTION
B-1 B-1
VRTEX TM 360
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Product Description ...............................................................................................B-2
User Interface Overview ........................................................................................B-3
Hardware Specifications .................................................................................B-4/B-5
Powering Up ..........................................................................................................B-7
ogin Screen...................................................................................................B-7/B-8
Joint Configuration.................................................................................................B-9
Process Selection ................................................................................................B-10
Stand Set-up........................................................................................................B-10
VR Coupons ........................................................................................................B-10
Table/Arm Rotation...............................................................................................B-11
Environment.........................................................................................................B-12
VR Gas Set-up ....................................................................................................B-12
Weld Machine Settings ........................................................................................B-13
Push Buttons........................................................................................................B-14
Welders View .......................................................................................................B-15
Instructors View....................................................................................................B-15
ASER ( ive Action Student Evaluation Report) .................................................B-16
Technique Parameters .........................................................................................B-16
Position ................................................................................................................B-17
Work/Travel Angle ................................................................................................B-18
Pass Number .......................................................................................................B-19
Timing/Direction/Discontinuities...........................................................................B-19
Instructor Mode....................................................................................................B-20
Updates ...............................................................................................................B-20
WeldometerTM .......................................................................................................B-21
Tolerance Editor...................................................................................................B-22
Choosing Tolerance Set-up .................................................................................B-23
Choosing Tolerance To oad ...............................................................................B-23
Tolerances Screen(s) ..................................................................................B-23/B-26
Tolerances Whip & Travel Speed .........................................................................B-27
Default Weld Processes Settings.........................................................................B-28
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OPERATION
B-2 B-2
VRTEX TM 360
FRONT OF MAC INE
1
2
3
6
7
8
10
11
9
6
5
4
12
14 13
PRODUCT DESCRIPTION
The VRTEXTM 360 is a virtual reality arc welding train-
ing machine only and NOT a real arc welding machine.
Please be aware of all standard safety practices asso-
ciated with welding. Some standard warnings are
included in this manual.
If the equipment is used in a manner not specified by
the manufacturer, the protection provided to the equip-
ment and user may be impaired.
Access panels are not to be removed except by quali-
fied service personnel due to risk of electric shock
from accessible live parts.
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