Reality Works guideWELD LIVE User manual

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Congratulations!
The guideWELD® LIVE real welding guidance system is a live welding training
and education tool that gives students instant feedback on core welding
techniques during live, arc-on welding.
System Includes:
1. Auto-darkening Welding Helmet with Guidance
Display and an SD card with 18 default Welding
Procedure Specications (WPS’s) in Helmet
2. Angle Sensor (connected to Helmet)
3. Stick Calibration Fixture
4. Speed Shield with Brackets
5. Screw knobs
6. Speed Sensor with base
7. Eight rechargeable batteries with battery charger
8. Accessories/supplies: screwdriver, arm band, extra
protective speed lens, helmet protective shield, helmet manual
9. Downloadable guideWELD® LIVE Curriculum
Additional Resources:
www.realityworks.com/guideweldlive-downloads
1. User Guide
2. guideWELD® LIVE Curriculum
3. Available Standard WPS Lists and WPS Editor
4. Product Support tutorials and documents
guideWELD® LIVE
Quick Start Guide
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ASSEMBLY INSTRUCTIONS
Speed Sensor and Speed Shield Assembly
Connect the Speed Sensor and Speed Shield to the base by attaching the two screw
knobs. Both sides of each have pre-drilled holes.
1. Position threaded holes on the Speed Sensor (orange arrows) to the inside of the
base arm (green arrows)
2. Position the threaded holes on Speed Shield Bracket (orange arrows) to the
outside of the base arm (blue arrows)
3. Line up the 2 screw knobs* to the outside of the Speed Shield Bracket to the base
arm (red arrows)
4. Screw until tight
* These knobs are also used for adjusting the alignment of the Speed Sensor.

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REFERENCE GUIDE TO SYSTEM PIECES
Use the images below as you walk through the set-up of your guideWELD LIVE Helmet
and the calibration process.
Speed Sensor
1. On/o button
(back of Speed Sensor)
2. Binding button
(back of Speed Sensor)
3. Calibration button
4. Battery compartment
(two AA batteries)
5. Alignment button
6. Arc-o speed indicators
7. Alignment lasers
(front of Speed Sensor)
Helmet and Display
guideWELD LIVE periphery guidance is
located inside the auto-darkening
Helmet using the chosen WPS
as the guide for each and
every weld.
1. Battery
compartment
(two AA batteries)
2. Work Angle
guidance indicator
3. Travel Angle
guidance indicator
4. Speed guidance
indicator
5. Helmet display
on/o button
6. Menu select button
7. Menu navigation
buttons
8. Menu display
9. SD card port
Work Angle (45)
Speed
Travel Angle (10)
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5
1 2
3
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5
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4
1
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HELMET SETUP
View Reference Guide to System Pieces
(page 3) for button positioning and
Helmet guides.
1. Turn on the Helmet and Speed Sensor
2. Look at the menu display, use naviga-
tion buttons to determine a choice on
each of the following screens
3. Choose WPS
Selection to start a
new WPS or choose
Weld with WPS,
which is the
previous WPS used.
Press the menu
select button
to conrm
4. Choose Process.
Press the menu
select button
to conrm
5. Choose Joint Type.
Press the menu
select button
to conrm
6. Choose Material.
Press the menu
select button
to conrm
7. Choose Thickness.
Press the menu
select button
to conrm
8. Choose WPS.
Press the menu
select button
to conrm*
9. Choose desired
Indicators to
display. Press the
menu select button
to conrm
10.Choose Starting
Position. Press the
menu select button
to conrm
* Only one option may be available based on previous selections.

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CALIBRATION PROCESS
NOTICE: The calibration process will need to
be completed before each weld!
The process includes Speed Sensor alignment and Angle Sensor calibration.
The process is the same for Stick or MIG welding except when of using the
Stick Calibration Fixture (for Stick welding only).
Speed Sensor Alignment
Joint/Coupon types
1. Tee (2F)
2. Lap (2F)
3. V-Groove (1G)
Based on chosen joint type, align Speed Sensor to welding coupon
4. Press the red alignment laser button and align laser dots to weld joint
Tee or
Lap Position
V-Groove or
Lap Position
Joint/Coupon Side Views
Tee Joint/Coupon Alignment*
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1 2
4
calibration continued on next page >
* Laser dots must be within 1/2 inch of
welding joint line (in front or behind)
for optimal speed feedback.

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CALIBRATION PROCESS (continued)
Angle Sensor Calibration
During calibration process and during weld, maintain a rm grasp on welding gun and
Angle Sensor. For best results, keep Angle Sensor in the same location (between palm of
hand/glove and welding gun) without movement.*
1. Tighten the Angle Sensor straps to the
palm of your hand. Cover your hand and
the Angle Sensor with a welding glove
OR
Cover your hand with the welding glove,
then tighten the Angle Sensor straps to
the palm of the glove-covered hand
2. Determine if welding left- or right-handed--use left side calibration xture for
left-handed users, or right side for right-handed users
3. Determine if calibrating for MIG
or Stick process
a.For MIG, insert the welding
gun into the calibration xture
b.For Stick, insert the welding
gun into the Stick
Calibration Fixture
4. Tighten the small screw knob
a.For MIG, tighten so the
welding gun nozzle can just
slide in and out of the xture
with minimal clearance
b.For Stick, tighten on Stick
Calibration Fixture so it cannot
be easily be removed
MIG Calibration Setup Stick Calibration Setup
*Angle Sensor must be on palm side during
welding for accurate guidance feedback.

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5. Grasp the welding gun in the desired holding position, pivot handle down and hold
6. Press and release the calibration button on the Speed Sensor. The calibrating screen will
display in the Helmet. Wait for rst part of the calibration to complete before continuing
7. Pivot the welding gun handle up and hold
8. Press and release the calibration button on the Speed Sensor, the calibrating screen will
display in the Helmet. Wait for rst part of the calibration to complete before continuing
9. When calibration has completed, the in-helmet
indicators will display*
10. Remove the welding gun and start the weld without
adjusting the position of the Angle Sensor on
the welding gun
* The Speed Guidance Display will not show until a weld has started.
The Speed Sensor needs to detect an arc before turning on
speed guidance.
Work Angle (45)
Speed
Travel Angle (10)
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www.realityworks.com | 800.830.1416
© 2016 Realityworks, Inc. All rights reserved.
1032220-05 | 7/2016
NEED MORE HELP?
Battery Installation
The Helmet and Speed Sensor require two AA batteries. Each unit is shipped with
rechargeable batteries installed. Four additional rechargeable batteries and a battery
charger are included.
Additional Help and Information
Notice: From the factory, the guideWELD LIVE Helmet and Speed Board are bound
together. If using multiple units and/or Helmet and Speed Sensor combinations have
changed, a binding process is necessary. Find process in Complete User Guide.
Visit: www.realityworks.com/guideweldlive-downloads
1. Complete User Guide
2. guideWELD® LIVE curriculum
3. Available Standard WPS Lists and WPS Editor
4. Product Support tutorials and documents
Online Product Support
We’re here to help! Our online Product Support features video tutorials, downloadable
documents, frequently asked questions and product notices, all of which make it easy
for you to get support for products, software and more, day or night. Find our online
product support area here: www.realityworks.com/support/
Online Store
Supplies, accessories, select simulators, curriculum and more are
available for purchase from our online store 24 hours a day!
Find our online store here: http://store.realityworks.com
Helmet batteries Speed Sensor Batteries