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

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

Before installation and initial operation 40

Safety 40

Setup regulations 40

Waiting time until the power connection is established 41

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

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

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

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.

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.

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.

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.

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