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TÄYDELLISTÄ HITSAUSTA

FRONIUS EXPLORER/ Operating Instructions

v.01/2012 ENG

EN

Dear reader,

Introduction Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer. This will allow you to make full use of its advantages.

Please also note the safety rules to ensure greater safety when using the product. Careful handling of the product will repay you with years of safe and reliable operation. These are essential prerequisites for excellent results.

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Contents

General 5

General ...................................................................................................................................................... 7Principle ................................................................................................................................................ 7Fronius Xplorer function packs ............................................................................................................. 7Application areas .................................................................................................................................. 7

System requirements ................................................................................................................................. 8PC system requirements....................................................................................................................... 8Welding system requirements............................................................................................................... 8Firmware versions................................................................................................................................. 8System configuration example.............................................................................................................. 9

Configuring network ................................................................................................................................... 10General ................................................................................................................................................. 10Assigning an IP address ....................................................................................................................... 10Assigning a firewall IP address ............................................................................................................. 10

Fronius Xplorer overview 11

Fronius Xplorer overview ........................................................................................................................... 13General ................................................................................................................................................. 13Fronius Xplorer ..................................................................................................................................... 13Browser level overview ......................................................................................................................... 13Work level overview .............................................................................................................................. 14Buttons at the browser level.................................................................................................................. 15Symbols for power source location ....................................................................................................... 15System component symbols ................................................................................................................. 16System status symbols ......................................................................................................................... 17Symbols in the Jobs and Docu worksheets overview ........................................................................... 17

Menu - Tools 19

Options....................................................................................................................................................... 21General ................................................................................................................................................. 21LocalNet serial ports ............................................................................................................................. 21Licences................................................................................................................................................ 21Login ..................................................................................................................................................... 21Creating a login via OPC ...................................................................................................................... 22Creating a login via the UsbKey............................................................................................................ 22

User settings .............................................................................................................................................. 24General ................................................................................................................................................. 24Creating a new user with a new user profile ......................................................................................... 24Managing the user profiles.................................................................................................................... 24User management ................................................................................................................................ 25Logging on and off automatically .......................................................................................................... 25Changing the user................................................................................................................................. 25

Splitting the window ................................................................................................................................... 26Splitting the window .............................................................................................................................. 26

Browser level 27

Browser level ............................................................................................................................................. 29General ................................................................................................................................................. 29Navigation in browser ........................................................................................................................... 29Switching from browser view to status view.......................................................................................... 29Copying a welding system to the selection bar..................................................................................... 30Removing a welding system from the selection bar.............................................................................. 30

Worksheets 33

3

Worksheet overview................................................................................................................................... 35Worksheet overview.............................................................................................................................. 35Buttons and symbols in the Worksheet overview ................................................................................. 35Backing up and restoring data .............................................................................................................. 36Setting up automatic backup................................................................................................................. 36Defining and cancelling the master backup .......................................................................................... 36Displaying connection status ................................................................................................................ 37Saving the device configuration ............................................................................................................ 38Configuring the system name and location........................................................................................... 38

Control panel worksheet ............................................................................................................................ 39Control panel worksheet ....................................................................................................................... 39Operating the control panel using the keyboard ................................................................................... 39Accessing a power source set-up menu ............................................................................................... 40

Jobs worksheet .......................................................................................................................................... 41Jobs worksheet ..................................................................................................................................... 41Buttons and symbols in the Jobs worksheet......................................................................................... 42Displaying job data................................................................................................................................ 43Copying and pasting jobs...................................................................................................................... 43Exporting/importing jobs ....................................................................................................................... 43Pasting job data into an external document.......................................................................................... 44Attaching a file to a job/opening an attached file .................................................................................. 44Deleting a job ........................................................................................................................................ 45Changing a job...................................................................................................................................... 45Job history............................................................................................................................................. 45

Docu worksheet ......................................................................................................................................... 46Docu worksheet .................................................................................................................................... 46Buttons and symbols in the Docu worksheet ........................................................................................ 46Applying the default settings for consumption figures........................................................................... 47Automatic Excel export ......................................................................................................................... 48Switching welding data recording on and off ........................................................................................ 48Time synchronisation ............................................................................................................................ 48Displaying welds/consumption figures menu ........................................................................................ 49Showing as a graph .............................................................................................................................. 49Weld seam sections menu.................................................................................................................... 50Parameter set values menu .................................................................................................................. 51Actual welding parameter values menu ................................................................................................ 51Errors menu .......................................................................................................................................... 52Loading and displaying recorded welding data..................................................................................... 52Saving welding data as an Excel file..................................................................................................... 53Importing welding data.......................................................................................................................... 53Documented welding data .................................................................................................................... 54

Log book worksheet................................................................................................................................... 57Log book worksheet.............................................................................................................................. 57Buttons and symbols in the Log book worksheet.................................................................................. 57Loading and displaying log book data................................................................................................... 57Saving log book data as an Excel file ................................................................................................... 58

Statistics worksheet ................................................................................................................................... 59Statistics worksheet .............................................................................................................................. 59Buttons and symbols in the Statistics worksheet .................................................................................. 59Creating a new statistics bar................................................................................................................. 60

Graph worksheet........................................................................................................................................ 61Graph worksheet................................................................................................................................... 61Buttons and symbols in the Graph worksheet ...................................................................................... 61Creating a new job graph...................................................................................................................... 62Hiding/showing jobs .............................................................................................................................. 62Zoom..................................................................................................................................................... 62

Importing data from systems not in the network ........................................................................................ 63General ................................................................................................................................................ 63Adding a welding system ...................................................................................................................... 63

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General

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General

Principle The Fronius Xplorer software is a virtual control station for networked welding systems in automated production areas. The graphical user interface, with its self-explanatory sym-bols, facilitates the clear and simple management of any number of welding systems that form part of a networked production line.The location and status of each welding system can be seen at a glance. Tried and tested settings can be copied easily from one system to another. The software also has touch-screen capability for faster operation.

Fronius Xplorer function packs

Fronius Xplorer is available with different function packs and associated options:

* Welds, sections

Application areas The application area encompasses all digital devices from the Fronius product family in au-tomated and manual applications- MIG/MAG welding and brazing (CMT)- TIG welding- DeltaSpot - spot welding- Plasma welding

(1) Power source + Fronius Xplorer (basic package)

(2) Power source + Fronius Xplorer + Docu

(3) Power source + Fronius Xplorer + JobExplorer + Docu (optional)

(4) Power source + Fronius Xplorer + RCU 5000i remote control

Function packs (1) (2) (3) (4)

All systems in the network can be seen X X X X

Monitoring the current operating status X X X X

Backup/restore functions X X X X

Remote control of the power source using PC X X X -

Documentation of set values - - X X

Documentation of changes to set values - - X X

Attaching documents or images as information - - X X

Copying jobs from one power source to another - - X X

Documentation of weld seam actual values (with part number as option)

- * * X

Limit monitoring of current and voltage - - - X

Motor current monitoring - - - X

Log book/graph/statistics - - - X

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System requirements

PC system re-quirements

The system requirements of the computer depend on the number of connected welding systems for which data documentation is to be carried out. The following information re-lates to a system with 16 welding systems whose data is to be documented on the compu-ter:- 3 GHz CPU- 2 GB RAM- WinXP, Win7 or WinServer2008 operating system + latest service packs- Microsoft.NET Framework 2.0 (on "ToolsCD" CD-ROM or via internet)- Screen resolution of at least 1024 x 768- One free serial interface (for configuring the network)- At least 100 Mbit network connection- No hub in network

Welding system requirements

- Digital power source- Free LocalNet connection with "Ethernet" option on the power source

If no LocalNet connection is free:- LocalNet passive distributor

For retrospective evaluation of welding data:- RCU 5000i remote control- or enabling of data documentation (Docu)

To use the log book, graph and statistics functions, an RCU 5000i remote control must be connected to the respective power source.

Firmware ver-sions

The device firmware must be kept up-to-date in order to be able to use all Fronius Xplorer functions without any restrictions.

Minimum requirements:TS 4000 / 5000, TPS 2700 / 3200 / 4000 (CMT) / 5000 (CMT) / 7200 / 9000 - Power source firmware: OFFICIAL UST V3.32.30 or higher

OFFICIAL UBST V1.4.31 or higher- Wire-feed unit firmware: OFFICIAL SR 4X A V2.1.27 or higher- RCU 5000i firmware: OFFICIAL RCU V1.13.7 or higher

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System configu-
ration example

Example of network for management with Fronius Xplorer

Welding cell

Production hall

Welding cell

Production hall

Production location

Head office

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Configuring network

General To configure the power source for network use, a connection must be established between the power source and PC using a LocalNet/RS232 interface. The "Service module" soft-ware is also required to make the settings.

More information about configuring the Ethernet interface can be found in the "Ethernet" operating instructions.

(1) Wire-feed unit

(2) RCU 5000i remote control option

(3) Power source

(4) PC, laptop or touch screen with Fronius Xplorer software

(5) LocalNet/RS232 interface

Assigning an IP address

To identify a power source uniquely within a network, it must be assigned a numeric ad-dress (IP address).

The IP address can be set using the RCU 5000i remote control, or by entering it in the "Overview" worksheet under "Options - General - Browser settings".

Assigning a fire-wall IP address

By assigning a firewall IP address, access to the power source can be restricted to one user (PC). The firewall IP address is the same as the IP address of the PC that is to be given access rights to the power source. The firewall IP address can be set using the RCU 5000i remote control, or by entering it in the "Overview" worksheet under "Options - Show connection data".

(1)

(2)

(3)

(4) (5)

IMPORTANT! The IP address must be different for each power source.

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Fronius Xplorer overview

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Fronius Xplorer overview

General

The symbols and buttons described in this section provide an initial overview of symbols and buttons used at the browser level. Detailed descriptions of symbols and buttons can be found in the relevant worksheet section.

Fronius Xplorer The user interface is divided into two main activity areas:1. The browser level provides an overview of the location and status of the systems avail-

able on the network.2. The work level

– provides information about the welding system configuration– permits access to the operation of the power source, including background menu– displays a view of the saved jobs. If enabled, this can be changed and managed

(set value)– if enabled: contains welding data documentation (actual value documentation)

if an RCU 5000i remote control is connected– records parameter changes, change of user, firmware updates and any errors

that have occurred– performs a statistical analysis of the welding parameters

Browser level overview

The browser level provides an overview of the status and location of the installed welding systems.

WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:- these operating instructions- all the operating instructions for the system components, especially the safe-

ty rules

NOTE! Due to software updates, you may find that your device has certain func-tions that are not described in these operating instructions or vice versa. Individ-ual illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

IMPORTANT! To ensure system stability, make sure that Windows updates are installed regularly (update.microsoft.com).

IMPORTANT! Grey symbols indicate that the system is offline or that data traffic has been interrupted. Grey buttons indicate that this function cannot be performed at this particular moment for programming reasons.

IMPORTANT! To record the current welding system data, Fronius Xplorer must be activat-ed during welding and the RCU 5000i remote control connected (data documentation can be enabled if required). Data that was recorded on the RCU 5000i remote control's Smart-Media card can, however, be loaded into the program at a later date.

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Browser level

(1) Fronius Xplorer bar

Overview showing progress of opened folders

(2) Scroll bar

For moving the screen view where there are more systems installed than can be displayed on screen

(3) Subfolder overview

Overview of the systems in the open folder

(4) Status overview with buttons

Overview of the status of systems in the open folder(A) Installed systems: displays all installed systems(B) Ready: displays all ready systems(C) Errors: displays all systems on which an error has occurred(D) Warnings: displays all systems on which a warning has occurred(E) Unknown: displays all systems with an unknown status

(5) Selection bar

For storing frequently required welding systems, or those that have been allocated a particular type of job. Click the mouse to access the work level of the selected system.

(6) Browser button

Press the browser button to exit the work level and return to the browser level

Work level over-view

The work level allows access to all welding system settings. Any deviations from normal operation can be seen immediately, and all settings can be corrected from the workplace. All work with and on the welding system can be recorded and archived.

(1)

(2)

(3)

(6)

(A)(B)(C)(D)(E)

(5)

(4)

?

!

TPS 5000(10.4.2.120)

TPS 5000 CMT(10.3.4.102)

TPS 4000(10.2.2.220)

MW 4000(10.5.2.010)

TIME 5000 Digital(10.4.2.122)

DeltaSpot 1(10.4.2.129)

DeltaSpot 2(10.3.4.145)

DeltaSpot 3(10.2.2.232)

DeltaSpot 4(10.5.2.246)

DeltaSpot 5(10.4.2.090)

TPS 5000 CMT(10.4.146.244)

TIME 5000 (10.4.146.230)

DeltaSpot 1(10.2.130.201)

DeltaSpot 4 (10.2.130.204)

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Work level

* Available depending on option pack

(1) Location path of welding system

Shows name and location of the selected welding system

(2) Close welding system button

By pressing the "Close welding system" button, the welding system is removed from the selection bar

(3) Licence manager

all the available system options are shown in the licence manager. Activated op-tions are shown in green. Blocked options can be enabled by entering a code.

(4) Work level

For navigating and working in the available worksheets

(5) Activated welding system in the selection bar

By activating a welding system, the user is taken to the work level of the welding system

Buttons at the browser level

Symbols for pow-er source location

Power source locations are defined using the following folder symbols:

(1) *

(2)

(3)

(4)

(5)F2

TPS5000 (No:15440923)FP25

VR7000 -CMT

Ethernet-Gate (No:15440923)

RCU5000i (No:15050216)

LN Router

TPS5000 (No:15440923)

POWERMAG-OS 4.2.4

Weld Process Regulator 5.0.100

DB 0503 5.0.95

UST2BV1.4B 1.4.1

BPS53 V0.3A 0.3.0.

FP25

FP25_OS 1.21.14

FP25 V1.6A 1.6.0

F3 F4 F5 F6 F7 F8

Overview

Place / ....

Panel Jobs Doku LogBook Statistic DiagramTPS 5000 CMT(10.4.146.244)

TIME 5000 (10.4.146.230)

DeltaSpot 1(10.2.130.201)

DeltaSpot 4 (10.2.130.204)

Browser buttonFor switching from the work level to the browser level

"Create new file" buttonFor creating a new file

"Open file" buttonFor opening Fronius Xplorer files (e.g. data from non-networked systems)

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The type and status of the welding system are shown in the lowest folder level

System compo-nent symbols

Home symbolThe highest folder level: Home/

Production location symbolThe second folder level: Home/Production location/

Factory symbolThe third folder level: Home/Production location/Factory/

Production hall symbolThe fourth folder level: Home/Production location/Factory/Production hall/

Production cell symbolThe fifth folder level: Home/Production location/Factory/Production hall/Pro-duction cell/

Power source symbolApplies to all Fronius power sources from the digital series

Wire-feed unit symbolApplies to all available Fronius wire-feed units

Remote control symbolApplies to all available Fronius remote controls (except RCU 5000i)

RCU 5000i remote control symbol (system add-on)Applies to the RCU 5000i remote control

Interface symbol (robot, Ethernet, etc.)When using an interface

Gas sensor symbolWhen using a gas sensor

Part counter symbolWhen using a RCU 5000i remote control, the part counter is shown here

Serial interface symbol When using the LocalNet/RS232 interface

DeltaSpot spot welding gun symbol Applies to Fronius DeltaSpot spot welding guns

PC symbol Displays various version numbers

WibuKey symbol Indicates whether a WibuBox is connected to the PC

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System status
symbols

Symbols in the Jobs and Docu worksheets over-view

(1)

(2)

(3)

(1) System activity status symbol:

Welding activeArc is burning

(2) System status symbol:

Status OKSystem working properly

WarningSystem displays a warning!

Unknown statusSystem is currently unavailable (switched off or disconnected from mains)

System stopSystem displays an error on the control panel and is not working properly

(3) System status symbol:

Welding system onlineConnection to system established, data being retrieved

System availableSystem ready to establish a connection

No connectionThe connection to the system is interrupted (e.g. system is switched off)

?

(1) Symbols in Jobs worksheet

Jobs licence and access rightsThe Jobs worksheet is available, jobs are available for editing

Jobs licence, but currently no access rightsThe Jobs worksheet is available, but the job is currently locked for editing by an-other user

Jobs licence not availableThe Jobs worksheet is not available

(2) Symbols in Docu worksheet

Data recording activatedData recording is activated in the pull-down menu of the Docu worksheet

Data recording deactivatedData recording is deactivated in the pull-down menu of the Docu worksheet

(1)

F2 F3 F4 F5 F6 F7 F8

(2)

Overview

Place / ....


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Menu - Tools

EN

Options

General Browser settingsSearches can be performed automatically or manually. If a search is performed automatically, either the IP addresses of the required machines or the broadcast addresses are entered in the text box. In the case of broadcast addresses, the whole subnet is searched for machines.If a search is performed manually, only the IP addresses of the machines can be entered.The main difference between the two search options is that in the case of static (manual) IP addresses (machines), the browser level marks the not found IP addresses (machines) as unknown.

If the user puts a "#" in the text field before the text, this is automatically interpreted as a comment.

LanguageThe language for Fronius Xplorer can be set here.

CurrencyThe "Documentation" worksheet has an option for entering consumption figures. The cur-rency to be displayed can be set in this menu.

Data directoryThe document data and user data is saved by default in "My Documents\Fronius Interna-tional\Fronius Xplorer". The user can select a preferred storage location in this menu. Se-lect a network drive as the location so that the same data can be accessed from several PCs.

LocalNet serial ports

Serial interfacesFronius Xplorer can be connected to the welding system via a serial interface. A LocalNet/RS232 interface is required. This menu is used to specify the serial interface used.

Licences A WibuBox/U+ (USB) or WibuBox/P+ (parallel port) can be used to enable various options in the system. Simply "Browse" to the machine on which the options are to be enabled. Af-ter the machine has been selected, Fronius Xplorer and the LocalNet server must be re-started.

Login Automatic Windows loginOnly used for DeltaSpot applications.

Fronius Xplorer login

OPC login interface:login details, such as user name and rights, can be obtained via an OPC server. The OPC server defines a user level that is assigned to a user profile in Fronius Xplorer. The user level can be changed by the OPC server during operation. Fronius Xplorer does not need to be restarted.See the "Creating a login via OPC" chapter for creating an OPC login.

UsbKey login interface:a UsbKey can be set up on a USB stick, which enables the different functions of Fronius Xplorer. See the "Creating a login via a UsbKey" chapter for creating a UsbKey.

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Creating a login via OPC

Open the menu "Tools - Options - Login"

Activate the "OPC" login interface

Enter the OPC server address under "OPC server url" (if the Windows session ID is required in the URL, the placeholder {sessionid} can be used. This is replaced by the current Windows session ID later.)

Add required user levels

Enter admin level

Enter value for "Exit when level is <=" (Fronius Xplorer closes when a user level is "less than" a certain value.)

The OPC variables required by the server are "OPC_Fronius" (int) for the user level and "Username" (string) for the user name.

Once Fronius Xplorer has been restarted, you will find automatically created user profiles under "Tools -> User profiles". These correspond to the user levels specified previously.The "LoggedOut" user profile is activated as soon as an unknown user level is detected. All rights are deactivated in this profile.

As soon as the configuration is finished, the current username, user level and Windows session ID are displayed at the top of the Fronius Xplorer window.

Creating a login via the UsbKey

Fronius Xplorer can be assigned to a production area. A USB stick can be enabled for a number of production areas (Fronius Xplorer).

Open the menu "Tools - Options - Login"

Activate the "UsbKey" login interface

Enter the name of the production area under "Name"

Enter a password for the production area under "Password"

Enter the password that you have just entered again under "Repeat password" (to avoid typing errors)

After Fronius Xplorer has been restarted, the UsbKey login is activated.

The following steps must be carried out to create a UsbKey on a USB stick:

Insert USB stick into the PC

Click the "UsbKey administration" menu item in the "Tools" menu

The "UsbKey administration" window opens

Select the desired USB stick under "Create or modify a UsbKey on the drive"

Select the desired production area under "For the production area"

Enter the password for the production area selected above under "Password"

Click "Edit" to enter other user information

Enter "User number"

Enter "Name"

Select "Profiles" (can be edited under "Tools - User profiles")

Enter "Pin"

Enter the "Master password" for the production area

Click "Save"

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456

12345

12

345

123456

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EN

The UsbKey has been created. After Fronius Xplorer has been restarted, a valid UsbKey will be detected. Once you have entered the pin, the profile for the user in this production area is enabled.If the USB stick is disconnected, Fronius Xplorer immediately switches to observation mode.

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User settings

General In user management, various users can be assigned individual user profiles. Permissions can be granted in the user profiles. User profiles can be created under "Tools - User profiles". The created profiles are assigned to the various users in the "Tools - User management" menu.The "User profiles" and "User management" menus can only be accessed by users with the "Administrator" user profile.

Creating a new user with a new user profile

Open the "User profiles" menu ("Tools - User profiles")

Click the "New" button to create a user profile

Enter the name and press "Enter"

Grant the required permissions to the newly created user profile by checking or un-checking the box

In the next step, the user profile that you have just created will be assigned to a newly cre-ated user:

Open the "User management" menu ("Tools - User management")

Press the "New user" button to create a user

Enter the user name (= login name) and assign the user profile

Managing the user profiles

The user profile menu can only be accessed by users with the administrator user profile.

The User profiles menu ("Tools - User profiles") allows you to:- create- delete- rename- and change user profiles

In addition, a time can be set after which a user profile is automatically logged out.

1234

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User profiles

Administrator

Arc welding

DeltaSpot

New Delete Rename

Userprofile 1

Options

New file

Open file

Edit users

Enable Automatic logoff

Automatic logoff in minutes:

Open/close machines

Delete machines from browser

Change password

Split

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User manage-
mentThe User management menu can only be accessed by users with the administrator user profile.

The User management menu ("Tools - User management") allows you to:- Create users- Delete users- Change or delete passwords (only the "Admin" user can change or delete passwords

without having to enter the old password)- To see who is logged in automatically when the program opens. This user does not

need a password when the program starts.

Logging on and off automatically

Example of a user logging on and off automatically:- The "Admin" user (user profile 1) logs on and carries out work on the system- "Admin" forgets to log off- Automatic log off is activated. "Admin" is automatically logged off the system after the

specified time.

- Automatic log on is specified for the user "User 1"- "User 1" is logged on to the system without being prompted to enter a password

Changing the user

Press the "Change user" button

Enter the user name and password

Press Enter

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Splitting the window

Splitting the win-dow

If split window is enabled under "Tools - Split window", then as many worksheets as re-quired can be displayed side by side/below one other. To show/hide the welding systems, click the relevant item in the selection list.

Windows displayed side by side

"Tools - Switch window split" allows you to switch between horizontal and vertical split.

F2

TPS 5000 (No:15440923)FP25

VR7000 -CMT


RCU5000i (No:15050216)

LN Router

TPS5000 (No:15440923)

POWERMAG-OS 4.2.4


DB 0503 5.0.95

UST2BV1.4B 1.4.1

BPS53 V0.3A 0.3.0.

FP25

FP25_OS 1.21.14

FP25 V1.6A 1.6.0

F3 F4

Overview

Place / ....

Panel Jobs DF2

TIME 5000 (No:15440924)

VR7000 -CMT


RCU5000i (No:15050217)

TPS5000 (No:15440924)

POWERMAG-OS 4.2.4


DB 0503 5.0.95

UST2BV1.4B 1.4.1

BPS53 V0.3A 0.3.0.

FP25

FP25_OS 1.21.14

FP25 V1.6A 1.6.0

F3 F4

Overview

Place / ....

Panel Jobs DTPS 5000 CMT(10.4.146.244)

TIME 5000 (10.4.146.230)

DeltaSpot 1(10.2.130.201)

DeltaSpot 4 (10.2.130.204)

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Browser level

EN

Browser level

General The browser is split into several folder levels. The welding systems are sorted into folder levels according to their location and assignment. To access the next folder level, simply click on the folder button.

Navigation in browser

Folder structure:

Simply click the mouse to return to a higher-level folder at any time.

Switching from browser view to status view

The browser view can be switched to a view that shows systems with the same status.

Press the relevant button for status view in the browser view

Highest folder level: HomeProvides an overview of the production locations on the network.

Company or production location folder levelProvides an overview of the production facilities at the production location.

Production facility folder levelProvides an overview of the production halls at the production facility.

Production hall folder levelProvides an overview of the welding cells in the production hall.

Welding cell folder levelProvides an overview of the welding systems in the cell.

1

!

Ready

Errors

Warnings

10

1

1

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Systems with the same status are displayed in a table:

Click the mouse to open the relevant system, provided that the firewall IP address is configured for the PC trying to access it, or no firewall IP address is set and there are fewer than 4 users logged in.

Copying a weld-ing system to the selection bar

To access the work level of a welding system, firstly copy the welding system to the selec-tion bar. It is possible to copy as many welding systems to the selection bar as desired.This enables the status and availability of relevant welding systems to be seen at a glance.

To copy a welding system to the selection bar:

Access the folder level of the desired production cell

Click the mouse to copy the welding system to the selection bar

To copy more welding systems to the selection bar, repeat this process

Welding systems from various locations can be copied to the selection bar. Welding sys-tems copied to the selection bar are retained, regardless of the current folder level.

Removing a weld-ing system from the selection bar

Removing a welding system from the selection bar

Select the welding system that is to be removed from the selection bar (1)

Press the Close welding system button (2)

Installed units

Ready

Warnings

Offline

10

15

1

2

Errors 3

?

!

TPS 5000 CMT(10.4.146.244)

TIME 5000 (10.4.146.230)

DeltaSpot 1(10.2.130.201)

DeltaSpot 3 (11.4.22.298)

TPS 4000 (10.4.146.244)

TPS 5000 CMT (10.4.141.221)

/Path/...

/Path2/....

/Path3/...

2

12

TPS 5000(10.4.2.120)

TPS 5000 CMT(10.4.146.244)

TPS 4000(10.2.2.220)

MW 4000(10.5.2.010)

TPS 5000 CMT(10.4.146.244)

Installed units

Ready 10

15

Errors 3

3

(2)

(1)F2

TPS5000 (No:15440923)FP25

VR7000 -CMT

TPS5000 (No:15440923)

POWERMAG-OS 4.2.4


DB 0503 5.0.95

UST2BV1.4B 1.4.1

F3 F4 F5 F6 F7 F8

Overview

Place / ....


TIME 5000 (10.4.146.230)

12

30

EN

Alternatively, right-click on the welding system to be removed from the selection bar and confirm by clicking Close.

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Worksheets

EN

Worksheet overview

Worksheet over-view

The Worksheet overview provides information about:- Welding system configuration- Currently installed firmware versions- Network connection used

To go to the work level, select the desired welding system on the selection bar.

To request information on a listed system component, activate the system component by clicking on it:

E.g.: system configuration with TPS 5000 power source

Buttons and sym-bols in the Work-sheet overview

F2

TPS5000 (No:15440923)FP25

VR7000 -CMT


RCU5000i (No:15050216)

LN Router

TPS5000 (No:15440923)

POWERMAG-OS 4.2.4


DB 0503 5.0.95

UST2BV1.4B 1.4.1

BPS53 V0.3A 0.3.0.

FP25

FP25_OS 1.21.14

FP25 V1.6A 1.6.0

F3 F4 F5 F6 F7 F8

Overview Panel Jobs Doku LogBook Statistic Diagram

Refresh buttonUpdates system information

Undo buttonThe jobs on the machine are reset to their former status

Attach file buttonAttaches a file to the job (e.g. photo of weld seam, etc.)

Maintenance panel buttonAllows the maintenance counter of the: - contact tip- welding torch- power source- wire-feed unit- and the hosepack to be read and reset

Backup options menu buttonfor defining a master backup file- for creating an automatic backup- for opening the backup directory in Windows Explorer- for showing an expanded view of all bus nodes- for displaying connection data- for configuring the system name and location- for exporting the device configuration- for configuring the field bus settings

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Backing up and restoring data

The backup file contains all the welding system data. The backup path is specified and saved under the serial number of the power source (Mt Documents/Fronius International/arc/specific/serial no./backup). It is, however, possible to specify the backup path individ-ually.

Creating the backup:

Press the "Backup" button

Select the storage location and confirm by pressing the "Save" button

The backup is created

Restoring the backup:

Press the "Restore" button

Select the backup file and press the "Open" button

The backup is restored

Setting up auto-matic backup

The automatic backup backs up data at a defined interval.

Press the "Options" button

Press "Automatic backup settings"

Select the time, interval and backup path for the automatic update

Tip: select a network drive as the location so that the same data can be accessed from sev-eral PCs.

Defining and can-celling the master backup

It is possible to define a backup that will be restored automatically when the "Restore back-up" button is pressed. This ensures that if data is lost or welding parameters are changed unintentionally, saved settings (jobs) are not lost.

Defining the master backup


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NOTE! Restoring backed-up data will overwrite the latest data, which cannot be recovered.

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Config automatic backup

Enable automatic backup

Next start time: Wednesday, 13 July 2011 13:00:00

Daily

Backup folder C:\users\administrator\Documents\Fro ... Def

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EN

Press "Master backup"

Select master backup and confirm by pressing "Open"

Import master backup by pressing the "Restore backup" button

Cancelling the master backupBy cancelling the master backup option, a selection dialog box appears after pressing the "Restore backup" button.


Press "Deactivate master backup"

Displaying con-nection status


Press "Show connection settings"

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IP address XX.X.XX.XX

Displays the current IP address

Firewall IP XX.X.XX.XX

Displays the IP addresses of the computers that have access to the power source. Set-ting 0.0.0.0 means that no access restrictions have been set, and up to 4 computers can access the power source.

Active connections XX.X.XX.XX

Displays the computers currently connected to the power source

Connection settings

IP address

Firewall IP Active connections 10.4.120.7

Default gateway

Subnet mask

Port number

10.4.146.246

0.0.0.0

0.0.0.0

0.0.0.0

10.4.146.245

255.255.248.0 Modbus firewall

Modbus UDP Fronius

170.170.170.170

Modbus port number 50215001

MAC address 00-03-AC-03-43-02

10.4.146.245

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Saving the device configuration

When documenting data, the current device configuration can be exported and saved on the data medium as a text file.


Press "Save device configuration"

Select the location and save the file

Configuring the system name and location


Press "Machine configuration"

Press the "New folder" button

Enter a name for the location and confirm or press the "New folder" button repeatedly until the desired folder structure is created

Fill in the field for "Machine name" and confirm details

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Machine configuration

Machine path:

Machine path:

New folder

TPS 4000 (10.4.146.245)

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IMPORTANT! The "Machine" is always saved in the highlighted folder. If there are subfold-ers with no machines under this highlighted folder, the subfolders are deleted automatical-ly. The "Machine" can be moved to another folder at any time.

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EN

Control panel worksheet

Control panel worksheet

The control panel is modelled on the control panel of the connected power source. In ad-dition, functions can be executed directly through shortcuts on the PC keyboard. The inte-grated adjusting dial (2) makes the touchscreen easy to use.Further information about the control panel function can be found in the power source op-erating instructions.

Example: Comfort/TPS 5000 power source control panel

(1) Control panel options menu

For selecting the control panel (e.g. TIG welding or US variant)

(2) Adjusting dial

For adjusting the currently selected welding parameter using the mouse or touch-screen

Operating the control panel us-ing the keyboard

All welding parameters can be adjusted using shortcuts on the PC keyboard. Press the space bar to display the shortcuts available.

NOTE! If the RCU 5000i remote control is connected to the power source, oper-ation via the Control panel worksheet is no longer available. The current param-eter settings are displayed on the screen. The buttons on the control panel cannot be selected.

IMPORTANT! For safety reasons, the wire threading function is not available.

F3

Panel

(1)

(2)

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Example: displaying the shortcuts by pressing the space bar

Accessing a pow-er source set-up menu

To access a power source set-up menu:

Example: displaying available set-up menus

A V+++---

WWWWWWWW

GGGG

SSSSS DDDDDDDDD OOO PPP NNN MMM EEE RRR

Select and hold down the Setup button

Keep the left mouse button pressed down and move the cursor to Lock

Release left mouse button

The available set-up menus are displayed

Open the desired set-up menu

Alternatively, access the set-up menu by right-clicking.

LOCKCCKCKK

12345

Jobcorr.

WFSWFWFSSMenueennu

GAS GAMenueMenuuuee

TriggeriggriggMenueMenueMenue

MainMaiMaiMenueMenueMenue

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EN

Jobs worksheet

Jobs worksheet The Jobs worksheet can be used to edit, copy and manage jobs. The locations are split into groups of 10 jobs.

Connecting the RCU 5000i remote control increases the number of locations from 100 to 1000.

Jobs worksheet

(1) Buttons for confirming job changes

Select according to parameter changes- Changes to power source or RC- Undo changes

(2) Sizing bar- Adjust window to desired size- Double-click to change and adjust the view automatically

(3) Job/job groups scroll bar

The following is displayed in the bar- White: free job spaces- Blue: occupied job spaces- Yellow: jobs with parameter changes- Red: jobs with incorrect parameter settings- Grey: jobs have not yet been synchronised with the power source

(4) Button bar

For selecting available functions

(5) Job groups- Select all jobs in the group by clicking the mouse- Double-click to edit job group names

IMPORTANT! In order to use all the functions of the Jobs worksheet, the JobExplorer op-tion must be enabled on the power source.

(3) (2) (1)

(8)

(7)(6)

(5)

(4)

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(6) Jobs display field- By selecting this, the parameter settings are shown in the parameter display (7)- Double-click on job names to edit them

(7) Parameter display- Shows current parameter settings and parameter changes- Unconfirmed parameter changes are shown in yellow

(8) Welding parameter scroll bar

For scrolling in the parameter display

Buttons and sym-bols in the Jobs worksheet

Power source buttonThe jobs are transferred from the machine to Fronius Xplorer

Save job buttonConfirm changes or newly created job

Undo buttonThe jobs on the machine are reset to their former status

Attach file buttonAttaches a file to the job (e.g. photo of weld seam, etc.)

Copy job buttonCopies selected jobs

"Delete job" buttonDeletes selected jobs

Change job buttonChanges selected jobs

History buttonProvides an overview of the history of the selected job

File attachment button and symbol- For opening an attached file- Shows that a file is attached to the job

Change to job warning symbolMeans that there has been a job change on the- power source- RCU 5000i remote control- Fronius Xplorer

E.g.: if the connection between an RCU 5000i remote control and Fronius Xplorer is interrupted, this is treated by the power source as a job change. Once the con-nection has been restored, the "Change to job warning symbol" appears next to the job that has been changed.

Job error buttonIncorrect parameter settings, job cannot be carried out

Important! If a job is transferred that contains an option that is not available on the machine (e.g. spatter-free ignition), its status will be displayed as "Limited".

Job change conflictDifferent job change on the RCU 5000i remote control and the power source during connection interruption.

Job options menuFor exporting and importing jobs

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Displaying job data

Click mouse to select a job. Show data in the parameter display (7).

Copying and pasting jobs

Copying a job, jobs or job group

Select a job, jobs or job group

Press the "Copy" button or Ctrl + C

Select location

Press the "Paste" button or Ctrl + V

Copying a job, jobs or job group from one power source to another


Press the "Copy" button or Ctrl + C

Select a power source for pasting the jobs

Select location

Press the "Paste" button or Ctrl + V

Exporting/import-ing jobs

Exporting a job, jobs or job group to data medium



Press the "Export" option

Select storage location and save job(s)

Importing jobs from data medium

Select the desired paste location in the "Jobs" worksheet

IMPORTANT! Jobs that have not yet been synchronised with the power source are iden-tified by a grey dot.

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IMPORTANT! Jobs can only be copied to another power source if the Job management option (JobExplorer) is enabled on the target power source. If the copied job cannot be car-ried out on the target power source, an error message appears.

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Press "Import"

Select job(s) and press "Open" to import

Pasting job data into an external document

Select jobs

Copy jobs to the clipboard by pressing the "Copy" button or Ctrl + C

Open a spreadsheet program, e.g. Excel, or a word processing program, e.g. Word, and select "Paste" from the "Edit" menu, or press Ctrl + V

Attaching a file to a job/opening an attached file

Select job

Press the "Attach file" button

Select file from data medium and confirm

The Attach file symbol appears next to the job

The user can attach as many files as required to one job.

Opening a file attachment

Opening a file attachment

2

IMPORTANT! The file that is imported always contains the same number of jobs that were selected during the export:- Single job- Several highlighted jobs- Job group- Several job groups

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IMPORTANT! When pasting, the original file is not pasted into the program, a link to the file is created instead. If the file is removed from its original location, the program will no longer be able to find the file.

(1) (2)

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EN

Select job with file attachment

Select "Attach file" button (1) and click to open

If desired, remove attached file by selecting the "Remove attached file" button (2).

Deleting a job Select a job, jobs or job groups

Press the "Delete" button

Changing a job Select job

Press the "Change" button

Change welding parameters (see power source operating instructions)

Job history A detailed view of the selected job can be called up under Job history. Any changes made to a job are recorded and shown here. Old versions of the job can be loaded onto the ma-chine again.

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Docu worksheet

Docu worksheet The documented welding data is shown in the Docu worksheet:- Welds- Weld seam sections- Set values of a weld seam (upslope, etc.)- Actual values (only when RCU 5000i remote control is connected)- Errors- Consumption figures

Docu worksheet

Welding data currently in the memory is shown using the red power source symbol

The welding data remains in the memory for approx. 10 min. weld time. Fronius Xplorer then deletes the welding data from the detailed views. The welding data that is no longer in the detailed views can be displayed by clicking the grey power source symbol.

Welding data that is no longer in the detailed views can only be viewed in the Weld seams menu. Double-clicking on the grey power source symbol causes Fronius Xplorer to reload the welding data in the detailed views, and all the welding data can be viewed again:

Highlight welding data

Right-click and press "Load details"

Buttons and sym-bols in the Docu worksheet

dd.mm.yyy hh:mm:ss.x KXX-XXXX XX XX XXX,X XXX XXX XX,X XX,X XX,X

dd.mm.yyy hh:mm:ss.x KXX-XXXX XX XX XXX,X XXX XXX XX,X XX,X XX,Xdd.mm.yyy hh:mm:ss.x KXX-XXXX XX XX XXX,X XXX XXX XX,X XX,X XX,X

dd.mm.yyy hh:mm:ss.x KXX-XXXX XX XX XXX,X XXX XXX XX,X XX,X XX,Xdd.mm.yyy hh:mm:ss.x KXX-XXXX XX XX XXX,X XXX XXX XX,X XX,X XX,X

dd.mm.yyy hh:mm:ss.x KXX-XXXX XX XX XXX,X XXX XXX XX,X XX,X XX,X

XX,X

XX,XXX,X

XX,XXX,X

XX,X

XX,X

XX,XXX,X

XX,XXX,X

XX,X

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XX,XXX,X

XX,XXX,X

XX,X

XX,X

XX,XXX,X

XX,XXX,X

XX,X

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XX,XXX,X

XX,X

F4

IminStart Time SeamPartnumber Arc Time Imean Imax Umin Umean Umax LimitwireGas QE

Welds

Docu

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Welds symbolDocuments the welding data (actual data) for the entire weld seam

Sections symbolDocuments the welding data (actual data) for individual sections of the weld seam

Set values symbolDocuments the specified set values

Actual values symbolDocuments the actual welded values. Records voltage (U), current (I) and weld time (arc time) every 100 ms.

Error symbolDocuments any errors that occur with a time stamp and in plain text.

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EN

Applying the de-fault settings for consumption fig-ures


Select "Consumption figures default settings"

Load welding data buttonDisplays and loads recorded welding data

Display current welding data buttonDisplays current welding data recording on the screen

Pause current screen view buttonThe current screen view stays on screen. Data continues to be recorded in the background. Activation takes place automatically when recorded welding data is opened.

Save welding data as Excel file buttonThe user can either export the highlighted welds to Fronius Xplorer (selected welds) or automatically save the selected FDO files (Fronius data format) in the background.

Online welding data symbolWelding data that is currently in the memory is shown by the red power source symbol

Offline welding data symbolDisplays welding data that is no longer in the memory. Displayed using the grey power source symbol.

Docu data options menuFor selecting- default settings for welding wire and shielding gas consumption figures- data import- country-specific settings- Excel export- switch data recording on/off (data receiver)- time synchronisation- diagram type

Limit exceed symbolLimit exceed of upper/lower current or voltage limit

Error symbolAn error has occurred during welding

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Wire diameter in mmFor setting the wire diameter being used

Gas consumption in l/minFor setting the gas consumption. When using the GAS 30 I-kit, this option cannot be selected (preset by the sensor).

Welding speed in cm/min symbolFor setting the degree of efficiency

Degree of efficiency in % symbolFor setting the degree of efficiency

New wire buttonFor creating new wire material with a specific weight

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Automatic Excel export

Welding data can be saved automatically in an Excel file after every weld. The file location can be specified in the "Export wizard".


Press "Excel export"

If "Excel export" is enabled, the data is saved in an Excel file after every weld.

Switching weld-ing data record-ing on and off

"Data Receiver ON" must be enabled in the options menu to run the welding data docu-mentation.


Press "Data Receiver ON"

Time synchroni-sation

In order to obtain exact start and error times, synchronisation with the system time must be carried out. Synchronisation may be carried out automatically or manually.

Automatic time synchronisation


Press "Automatic time synchronisation"

Update wire material buttonFor updating existing wire material

Delete wire material buttonFor deleting wire material from the database

IMPORTANT! The currency can be set under "Tools - Options".

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IMPORTANT! If the welding data documentation is disabled, no data is recorded in the worksheets, log book, statistics and graph.

A symbol in the Worksheet overview indicates whether the data receiver is enabled:

Data receiver enabled

Data receiver disabled

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EN

This setting is saved for each power source.If a RCU 5000i remote control is connected, then automatic time synchronisation is switched off as standard. If no RCU 5000i remote control is connected, then a prompt ap-pears for automatic time synchronisation when the system is first opened.

Manual time synchronisation


Press "Synchronise time now"

Displaying welds/consumption fig-ures menu

Completed welds are shown in the Welds menu. One weld seam consists of one or several weld seam sections and lasts from welding start to welding stop. The completed welds are numbered and listed consecutively (they may also be assigned to a part number).

Displaying consumption figures:the calculation is made using the default settings for the consumption figures.

Highlight one or more weld seams

Right-click and press "Consumption figures"

Consumption figures are shown

Showing as a graph

Show weld seam as a graph:

Select a weld seam

Right-click and press "Show as a graph" (use "Load details" to show the weld seam in a worksheet graph)

The weld seam is shown as a graph

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Welding parameter OK symbolRelates to the number of highlighted weld seams

Exceeded limits symbolRelates to the number of highlighted weld seams

Error symbolRelates to the number of highlighted weld seams

Welding wire consumption symbolRelates to the number of highlighted weld seams

Shielding gas consumption symbolRelates to the number of highlighted weld seams

Weld time symbolRelates to the number of highlighted weld seams

Energy consumption symbolRelates to the number of highlighted weld seams

Total costs symbolRelates to the number of highlighted weld seams

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Weld seam sec-tions menu

The Weld seam sections menu shows the individual sections of a weld or of individual jobs.

e.g. starting current phase/main current phase/final current phase

Sections/sections based on special 2-step mode

(1) Monitoring active

(2) Starting current phase

(3) Slope 1

(4) Main current phase

(5) Slope 2

(6) Final current phase

(A1) Section 1

(A2) Section 2

(A3) Section 3

The sequential weld seam sections are numbered and listed consecutively.

Weld seam sections display

(1) Part number

(2) Weld seam

(3) Section

(4) Job

(5) Weld time

(6) I mean (average current)

(7) U mean (average welding voltage)

(8) vD mean (average wire feed speed)

I (A)

(2) (3) (4) (5) (6)

(1)

(A1) (A2) (A3)

t (s)

KXX-XXXX XX XX XXX,X Std XXX XXX XX,X XX,X

KXX-XXXX XX XX XXX,X Std XXX XXX XX,X XX,XKXX-XXXX XX XX XXX,X Std XXX XXX XX,X XX,X



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XX,XXX,X

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F4

Sections

Docu

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (*)

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EN

(9) vS mean (average welding speed)

(10) Limit (current and voltage limits exceeded)

(*) Displayed values can be adjusted by right-clicking. By holding down the left mouse button, the displayed values can also be moved to a desired position and in-creased/decreased.

Parameter set val-ues menu

Displays the parameter command values set on the RCU 5000i remote control

displaying parameter set values according to the RCU 5000i

(1) Part number

(2) Weld seam

(3) Section

(4) Job

(5) Operating mode

(6) PrgNo (program number)

(7) Current

(8) Voltage

(9) Wire feed speed

(10) ALC (arc length correction)

(11) DYN (arc force dynamic correction)

(12) Options

(*) The values displayed depend on the welding process set, and can be adjusted in-dividually by right-clicking on the header. By holding down the left mouse button, the displayed values can also be moved to a desired position and increased/de-creased.

Actual welding parameter values menu

Displays the parameters that were actually used for a weld seam. The recording time in-terval depends on the value set on the RCU 5000i remote control (0.1 - 9.9 s).

displaying actual welding parameter values according to the RCU 5000i

(*) The values displayed depend on the welding process set, and can be adjusted in-dividually by right-clicking on the header. By holding down the left mouse button,





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Command values

Docu

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (*)





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Actual values

Docu

(*)

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the displayed values can also be moved to a desired position and increased/de-creased.

Errors menu Displays errors that occurred during a weld.

errors occurred

(1) Time of error

(2) Weld seam

(3) Job

(4) Operating mode

(5) Error number

(6) Duration

(7) Description

(*) The values displayed depend on the welding process set, and can be individually adjusted by right-clicking on the header. By holding down the left mouse button, the displayed values can also be moved to a desired position and increased/de-creased.

Loading and dis-playing recorded welding data

The welding data is automatically saved on the data medium, and can be identified using the date, start and end time.

Opening welding data:

Press the "Open" button

Select welding data

Confirm

The selected welding data is first displayed with the offline welding data symbol

Offline welding data can only be seen in the "Weld seams" menu and provides an overview of the data created on the selected date.

dd.mm.jjjj hh:mm:ss

dd.mm.jjjj hh:mm:ss

XX

XXXX

XXXX

XXX

XXXXXX

XXXXXX

XXX

XXXXXX

XXXXXX

ABCD

ABCDABCD

ABCDABCD

dd.mm.jjjj hh:mm:ss

dd.mm.jjjj hh:mm:ss

dd.mm.jjjj hh:mm:ss

F4

Docu

Errors

(*)(1) (2) (3) (4) (5) (6) (7)

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RCU data symbolData imported from the SmartMedia card in the RCU 5000i remote control

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Smart Media

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EN

At the same time, the screen view is paused and the "Pause" button is enabled.

By double-clicking on the weld seam, all the data created for the selected weld seam is loaded and saved in the memory.

By pressing the "On" button, the display reverts to the current recording of welding data

Saving welding data as an Excel file


Press "Export wizard"

The "Export wizard" window opens

Select storage location

In the wizard, tick the boxes to select the data that is to be exported- Welds (already set)- Sections- Actual values (during a weld)- Errors

Confirm

Press the "Export" button

The welding data can now be opened in Microsoft Excel.

Importing weld-ing data

Import saved welding data, e.g. from a SmartMedia card


Press "Import"

Select path and confirm

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IMPORTANT! To prevent data from different welding systems being mixed, data can only be imported from the welding system that is currently open (same serial number)

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Documented welding data

Weld timeWeld time from the beginning to the end of a weld seam (time during which the arc is ac-tive)

ALCThe currently set arc length correction or the arc length correction for an active job

DescriptionDescription of an error that has occurred

DurationThe length of time for which an error has occurred

DYNThe currently set arc force dynamic correction or the arc force dynamic correction for an active job

Error numberError code displayed when an error occurs

Time of errorThe exact time at which an error occurred

CurrentWelding current set value according to the RCU 5000i remote control (created by entering the wire feed speed parameter in the MIG/MAG synergic welding screen)

ImaxMaximum welding current within a weld seam section

ImeanAverage welding current within a weld seam section

IminMinimum welding current within a weld seam section

JobNumber of the job in which e.g. a weld seam section was welded

LimitShows whether the user has exceeded or fallen below a Q-Master value specified on the RCU 5000i remote control within a weld seam section

I++/U++I--/U--

M1++M2++vD++/vD--vS++/vS--

Exceeding a current/voltage limitFalling below a current/voltage limitLimits that have been exceeded/not reached are displayed in combination Exceeding the motor current limit for the wire-feed unitExceeding the motor current limit for the wire-feed unitExceeding/falling below the wire feed speed limitExceeding/falling below the welding speed

Operating modeWelding process: pulse or standard

OptionsShows whether power source options are active during a weld seam section

Synchro activeSpatter-free ignition

SynchroPulse option activeSpatter-free ignition option active

Part numberDisplays the number of the welded part. Using the part counter, consecutive numbers can be assigned to any desired parts or workpieces. Each part can be precisely identified through the assigned number, e.g. when an error occurs.

PrgNrReference number of the welding characteristic used

SectionWeld seam section, individual sections of weld seams

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Weld seamWeld seam (from the start of welding until welding stops)

Start timeStart time of the weld seam according to the RCU 5000i remote control

VoltageWelding voltage set value according to the RCU 5000i remote control (created by enter-ing the "welding voltage" parameter in the manual MIG/MAG welding screen)

UmaxMaximum welding voltage within a weld seam section

UmeanAverage welding voltage within a weld seam section

UminMinimum welding voltage within a weld seam section

Wire feed speedWire feed speed set value according to the RCU 5000i remote control (corresponds to the value of the "wirefeed speed" parameter in the "MIG/MAG synergic welding and MIG/ MAG manual welding screens)

vDmaxMaximum welding wire feed speed within a weld seam section

vDmeanAverage welding wire feed speed within a weld seam section

vDminMinimum welding wire feed speed within a weld seam section

WireWire consumption according to set consumption figures in the Docu data options menu

GasGas flow rate according to set consumption figures in the Docu data options menu

EEnergy input

QHeat energy

vSmaxMaximum welding speed within a weld seam section

vSmeanAverage welding speed within a weld seam section

vSminMinimum welding speed within a weld seam section

Fdi (TIG)Cold wire option, wire threading speed

Balance (TIG)Relationship between fusing power and cleaning actionUnit 1Setting range -5 to +5Factory setting 0-5 highest fusing power, lowest cleaning action+5 highest cleaning action, lowest fusing power

ACF (TIG)AC frequencyUnit Hz

Iground (TIG)Ground currentUnit %Shown as a percentage of the selected main current

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Duty cycle (TIG)Ratio of pulse duration to ground current duration where a pulse frequency has been setUnit %

Pulse frequency (TIG)Unit Hz / kHzSetting range OFF/0.20 Hz - 2.00 kHz

Fd2 (TIG)Feeder 2 - wire feed speed 2 (for optional cold wire-feed unit)Wire feed speed during pulse welding in the ground current phase

Stick (rod electrode)

Current (rod electrode)Unit A

Dyn (rod electrode)The arc-force dynamic parameter is used to influence the short circuit current at the mo-ment of droplet transfer.

HotStart (rod electrode)Increases the set welding current in the starting current phase Unit %

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Log book worksheet

Log book work-sheet

All errors/events that occurred during operation are recorded in the log book worksheet.

Log book worksheet

Buttons and sym-bols in the Log book worksheet

Loading and dis-playing log book data

The log book data is automatically saved on the data medium and can be identified using the date, start and end time.

Open log book data

Press the "Open" button

Start time Key name

dd.mm.jjjj hr:min:sec user name

dd.mm.jjjj hr:min:sec

dd.mm.jjjj hr:min:sec user name

F6

All events

Logbook

Log book options menuFor setting the storage location of the Excel file using the export wizard

Log book symbolDisplays all recorded events

Job change log book symbolDisplays all recorded parameter changes within a job

Change of log book user symbolDisplays all recorded changes of user

Firmware update log book symbol (RCU 5000i)Displays all recorded updates of firmware versions on the RCU 5000i remote con-trol

Error symbolDisplays all recorded errors on the welding system

Load log book data buttonDisplays and loads recorded log book data

Show current log book data buttonShows current recorded log book data on the screen

Pause current screen view buttonThe current screen view stays on the screen. Data continues to be recorded in the background. This function is automatically enabled when opening the log book da-ta.

Save log book data as an Excel file buttonData is saved as an Excel file in the desired location

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Select log book data

Confirm

The "Pause" button is enabled, loaded log book data appears on screen

To display current log book data again, press the "On" button

Saving log book data as an Excel file


Press "Export wizard"

Select location and confirm

A subfolder with a serial number is generated automatically

Press the "Export" button

Log book data can now be opened in Microsoft Excel.

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EN

Statistics worksheet

Statistics work-sheet

The Statistics worksheet analyses the documented welding data. The statistics are dis-played as a bar chart. Welding parameters shown in green are within the specified limits. If the limit values are exceeded, the welding parameters are displayed in red.

Statistics worksheet

statistics: Job bar

(1) Job number

(2) Number of weld seams within the specified limit values

(3) Number of weld seams outside the specified limit values

(4) Current and voltage extreme value display. The display relates to the total number of welded jobs. The display saves the smallest and gre-atest value that occurred while the selected job was being welded.

(5) Detailed view of the number of ex-ceeds of the upper and lower limit values for

- Voltage and current- Wire feed speed- Motor currents

Buttons and sym-bols in the Statis-tics worksheet

IMPORTANT! In order to use the Statistics worksheet, limit values for the Q-Master func-tion must be defined on the RCU 5000i remote control, and warning or shutdown must be enabled in the Reaction menu item.

F7

WeldsWeldsWeldsWelds WeldsWeldsWeldsWelds

79 8180 82 83 84 85 86

8

2

6

7

20

10

20

2

10

20

4025

21

13

10

Job 79

I min [A]

I max [A]

U min [V]

U max [V]

99,999,9

30,0330,03

2

2

5

1I I U U vD vD M1 M2

2

25

1

Job

Statistics

79

8

2

Job 79I min [A]

I max [A]U min [V]U max [V]

I I U U

96,899,9

30,0326,07

2

25

1

vD vD M1 M2

2

25

1

(1)

(2)

(3)

(4)

(5)

New statistics bar symbolCreates a new statistics bar for a job or a weld seam

Delete statistics bar symbolDeletes a statistics bar

ldWeldsWelds

WeldsWelds

59

Creating a new statistics bar

Press the "New" button

Enter job or weld seam number in the input field and confirm

The statistics bar appears in the display and begins recording as soon as the weld job/seam is welded.

To edit a statistics bar:

Select the statistics bar

Press the "Delete", "Reset" or "Change job" button

Empty statistics bar symbolEdits the bar job number

Job statistics bar symbolEdits the bar job number

Ctrl buttonSeveral bars can be selected by holding the button down (touchscreen).

W ldWeldsWelds

WeldsWelds

1

ldWeldsWelds

2

12

60

EN

Graph worksheet

Graph worksheet The graph worksheet provides a visual representation of the welding data. Different jobs are shown in different colours.

Graph worksheet

Buttons and sym-bols in the Graph worksheet

00

50

100

150

200

250

300

4 8 12 16 20 24

AAA

Job 04

Job 03

Job 02

Job 01WeldsWelds

WeldsWelds

WeldsWelds

WeldsWelds

F8

Current

Diagram

Add job buttonCreates a new graph for the job number

"Delete Job" buttonDeletes the selected job from the screen view

Reset graph buttonResets the recorded graph for a selected job

Print buttonPrints the current graph

Copy buttonPress this button to copy the current graph to the clipboard

Pause screen viewThe graph can be saved in a variety of formats.

Graph options menuThe maximum number of curves shown in parallel in a single graph can be set us-ing "Set graph entries"

The "Line" and "Spline" options can be found under "Graph type". If "Line" is set, the data points in a curve are connected by a straight line. If "Spline" is set, a curve is calculated between the individual data points and the graph no longer appears angular.

61

Creating a new job graph

Create a new job graph

Press the "Add job" button

Enter job number in the input field and confirm

A colour is assigned to the job number entered, which is displayed on the screen in the form of a button

Pressing the "Job XX" button displays the welding data on the screen

Hiding/showing jobs

Show/hide individual jobs using the relevant button:

Zoom In graphs, click the left mouse button and drag on either axis to zoom in. Press the "Single view/general view of graph" button to show the original graph again.

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2

3

4

Show job

Hide job

IMPORTANT! The colour assigned to the saved jobs always depends on the sequence in which each job is shown. Note that a job that is currently being processed can change col-our several times by showing and hiding it.

Job 02

62

EN

Importing data from systems not in the network

General For systems not connected to the network, there is an option to add these as virtual welding systems in Fronius Xplorer by importing recorded welding data.

Adding a welding system

Press the "Open file" button

Select FDO files from the SmartMedia card for the RCU 5000i remote control

Enter welding system serial number, if necessary

Welding system is added to the browser in the Snapshots subfolder and opened

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Maahantuonti ja myynti:

Pronius Oy

Keisarinviitta 20 B33960 Pirkkala

+358 (0)44 200 [email protected]