Lincoln Vrtex 360, Operator'S Manual

Page 1: ...ct and be careful NOTICE The VRTEXTM 360 is a vir tual reality arc welding training machine only and NOT a real arc welder When welding with arc welding equip ment be aware of all standard safety practices associated with arc weld ing Some standard warnings are included in this manual For use with machines having Code Numbers AD1332 1 Software Version 1 0 7 7 AD1332 2 Sales and Service through Sub...

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Page 3: ...EARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available...

Page 4: ...r simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 ii SAFETY ii FUMES AND GASES can be dangerous 5 a Welding may produce fumes an...

Page 5: ...void welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode circuit is touching t...

Page 6: ...ables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloigner les matériaux...

Page 7: ...RTEX TM 360 System Handle the VR SMAW device and VR GMAW FCAW gun with care When not in use these items should be placed on the appropriate holders located on the sides of the VR machine These devices are customized and cannot be used on nor mal welding machines Handle the VR Coupons with care When not in use store them in the Coupon Drawer at the back of the VR Weld Machine During lightning storm...

Page 8: ...ether with normal waste In observance of European Directive 2002 96 EC on Waste Electrical and Electronic Equipment WEEE and its imple mentation in accordance with national law electrical equipment that has reached the end of its life must be collected sep arately and returned to an environmentally compatible recycling facility As the owner of the equipment you should get information on approved c...

Page 9: ...ortant when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincoln...

Page 10: ...ders View B 15 Instructors View B 15 LASER Live Action Student Evaluation Report B 15 Technique Parameters B 16 Position B 17 Work Travel Angle B 17 Pass Number Travel Direction Discontinuities B 18 Instructor Mode B 19 Updates B 19 WeldometerTM B 20 Tolerance Editor B 21 Choosing Tolerance Set up B 22 Choosing Tolerance To Load B 22 Tolerances Screen s B 22 B 25 Tolerances Whip Travel Speed B 26 ...

Page 11: ...ENT READ THIS OPERATORS MANUAL COMPLETELY INPUT VOLTAGE INPUT CURRENT PROTECTIVE GROUND WARNING or CAUTION Documentation must be con sulted in all cases where this symbol is displayed Explosion Dangerous Voltage Shock Hazard GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL U1 I1 1 Shock Hazard USB ...

Page 12: ...A LATER VERSION OF THE SAME STANDARD INCORPORATING THE SAME LEVEL OF TESTING REQUIREMENTS HEIGHT WIDTH DEPTH WEIGHT 78 0 in 39 0 in 47 0 in 102 lbs 1981 mm 990 mm 1194 mm 46 kg PHYSICAL DIMENSIONS STAND OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 410 950 F 50 350 C 320 1490 F 00 650 C TEMPERATURE RANGES 80 For Temperatures Up To 880 F 310 C 50 1040 F 400 C 6562 Feet 2000 Meters RELATIVE ...

Page 13: ...it breaker Route and protect power cable to minimize exposure to damage ENVIRONMENTAL AREA Keep the machine inside and dry at all times Do not place it on wet ground or in puddles Never place liq uids on top of the machine STACKING The VRTEXTM 360 cannot be stacked ELECTRIC SHOCK can kill Only qualified personnel should per form this installation Turn the input power OFF and unplug the machine fro...

Page 14: ...n the area can cause interference and result in increased jitter and or distortion in the motion tracking For best results do not install VRTEXTM 360 machine in the welding lab Electrical inter ference from power lines though generally small can be present Therefore all electri cal power or lighting wiring within 50 feet of the welding area shall be enclosed in grounded rigid metallic conduit In t...

Page 15: ...om the rear base securing the unit to the wooden crate 6 Remove the monitor from the back of the machine 4 Carefully slide the crate assembly from the VRTEXTM 360 towards the rear of the machine Be careful to avoid damaging the welding device hold ers located on each side of the machine 6 Carefully remove the post long rectangular shaped cardboard box from the crate 5 Carefully cut and remove plas...

Page 16: ...ening the screws 6 Insert one of the collar pins into the post at the 6 location 7 From the top slide the table onto the post letting it rest on the collar pin inserted in previous step 8 Insert the second collar pin into the post at the 13 position 9 Obtain the swing arm from the rear of the VRTEXTM 360 by removing the cable ties from the swing arm and cable Grey cable should remain connected to ...

Page 17: ...onitor or projector by using the SVGA output on the back of the machine The external display must support 1024x780 resolution 3 External speakers may be connected using the audio jack located on the back of the machine TRACKING SYSTEM FUNDAMENTALS The magnetic tracking system is composed of the following Control Unit Inside VR Machine o Contains the hardware and software neces sary to compute posi...

Page 18: ...a real arc welding machine Please be aware of all standard safety practices associated with welding Some standard warnings are included in this manual If the equipment is used in a manner not specified by the manufacturer the protection provided to the equipment and user may be impaired Access panels are not to be removed except by quali fied service personnel due to risk of electric shock from ac...

Page 19: ...ser to input wire feed speed or amperage depend ing on the VR welding process selected 5 The voltage dial allows the user to input the weld ing voltage This dial also allows input of trim val ues when pulse process is in use 6 The left and right white screen select arrows allow the operator to cycle through various screens 7 The process selector switch is used to selected the virtual welding proce...

Page 20: ...0 degree position Once the rod is at one of these angles release the handle The rod should now be fixed in that position Do not change the rod angle while the rod is extending or retracting VR SMAW DEVICE VR GMAW FCAW GUN CAUTION VR GMAW FCAW GUN Properly Stored CAUTION Store gun as shown below to avoid damage VR SMAW DEVICE Properly Stored CAUTION Store device as shown below to avoid damage VR SM...

Page 21: ...upons When not in use the coupons should be stored in the drawer To open the drawer press the top indent down and slide the drawer out Each coupon fits in its own area defined by the foam locator in the draw er Coupons The coupons represent the various workpieces on which the user can virtually weld During the virtual welding process they provide physical feedback to the student There are five VR ...

Page 22: ...d into the arm to accom modate flat horizontal vertical or overhead welding positions The knob on the front of the swing arm can be pulled out for coupons to be inserted or removed and pushed in for coupons to be secured The front of the swing arm can be rotated down at a 45 or 90 degree angle to allow 2G 5G and 6G pipe welding positions The arm can also be rotated around the post to comfortably a...

Page 23: ...ition and contact tip to work distance or arc length The software will step the user through the following setup screens Login Joint configuration selection Process selection Stand set up Environment Gas set up Weld machine settings Instructor s view Welder s view LASER Live Action Student Evaluation Report The key provided with the system allows the user to access the Instructor Mode with additio...

Page 24: ...the language menu The system stores the language selection and will automatically start up in the same language the next time 3 Measurement Units The blue unit menu button brings up the measurement system Use the joystick to highlight the desired unit of measurement Press the red select button to accept Press the blue again to exit the measurement unit menu Selecting Metric or Imperial converts th...

Page 25: ...hich to weld A rotating view of the highlight ed coupon shows in the upper area For some config urations the user will be given the choice of material thicknesses to choose from The user selects materi al thickness by using the joystick and red select but ton See Table B 2 for supported joint configurations JOINT CONFIGURATION SELECTION SCREEN TABLE B 2 Menu Selecting Logout takes the user to the ...

Page 26: ...r can reference what has previously been selected Menu Selecting Logout brings the user back to the login screen with the user s name removed Change Coupon Type Selecting Change Coupon Type goes back to the configuration selection screen Back Selecting Back takes the user to the previous screen Stand Set Up Screen Overview The correct VR stand information must be put into the software for the VRTE...

Page 27: ...in the desired position proceed with the following Use the joystick and red select button to enter the numbers that appear next to the pin positions for the table and arm height into the stand setup screen The image on the right side of the stand setup screen moves to match the selections entered on the left If the table is in the away posi tion enter a table height value of 0 Next enter the arm r...

Page 28: ...ss the red select button or green continue button to pro ceed VRTEXTM 360 ENVIRONMENT SCREEN GAS SET UP SCREEN Menu Selecting Logout takes the user back to the login screen with the user s name removed Back Selecting Back takes the user to the previous screen STAND SET UP SCREEN OVERLAY Back Selecting Back takes the user to the previous screen Indicate the coupon orientation used on the physical s...

Page 29: ...g Overview While a user is welding observers can see the Welder s view LASER screen or Instructor s view displayed on the monitor The Welder s view shows what the user with the helmet on is seeing through the FMD The LASER screen displays a real time graph of the weld being made and gives a score when the user selects end pass The Instructor s view allows another user to zoom in out and rotate the...

Page 30: ...CTWD arc length and travel work angle cues indicate whether the user is within the tolerances set in the tolerances editor Generally these cues are color coded as well as sym bolic When cues are red they indicate being out of tolerance Yellow cues indicate close to tolerance but not optimal Green cues indicate being within toler ance and close to optimal The Cheater Lens magnifies the image as see...

Page 31: ...s indicat ed that the weld is being made in the correct location or position TRAVEL WORK ANGLE AIM The Whip cue can be used with the E6010 VR SMAW process This cue helps the student use correct spac ing between whipping motions puddle time and whip time Correct whipping technique is indicated by a green outter ring spacing with a green center puddle and whip timing The Weave cue can be used with t...

Page 32: ... screen Overview This screen shows the coupon and virtual weld in real time An observer can rotate and or zoom in or out on the coupon This view also shows the VR GMAW FCAW gun or VR SMAW device being used Move the joystick to rotate the coupon Press the red select button to toggle the joystick from rotate to zoom mode Use the joystick to zoom in and out when in zoom mode NOTE Changing views on th...

Page 33: ... representing the top of the coupon The graph also shows how close the parame ter was to the ideal value The ideal value is indicated by the red line located in the center of the graph This value is determined by the tolerance editor settings The upper and lower white lines represent the acceptable maximum and minimum values that the parameter should be within These values are also determined by t...

Page 34: ... or VR SMAW device to a plane going through the ideal position location Travel Angle is the angle between the electrode and the workpiece in the direction of travel The upper right area of the screen displays if the user should be push ing or dragging If the user pushes when they should be dragging they will not receive maximum points For pipe welding this is the angle between the electrode and th...

Page 35: ...ass number For pipe the information is displayed in a similar manner on a 2D screen as though the pipe is unraveled and put on a flat surface The user can choose between viewing the whole pipe or one of the four quadrants of the pipe Use the joystick to highlight the pipe section desired Travel Direction The travel direction is located on the right side in the middle of the screen When the user fi...

Page 36: ... become familiar with the terms Instructor Mode Overview The Instructor Mode gives users the option of viewing the WeldometerTM using the tolerance editor and set ting other preferences In order to access instructor mode the user must first go back to the login screen This can be done on most screens by pressing menu logout and selecting yes Then the user must place the key into the turn key slot ...

Page 37: ...ds students have a virtual arc struck with each process Base Metal tracks how many virtual coupons have been used and their cumulative weight Note that plate 3 8 includes groove joints as well as tee joints while plate 1 4 includes both tee joints and practice plates Gas tracks how much virtual gas was used Consumables tracks the cumulative weight of each type of virtual consumable used It also di...

Page 38: ... modify the sys tem settings from the default to fit their curriculum The VRTEXTM 360 ships with Lincoln default welding parameters pre installed The parameters can be modified by the instructor to reflect a specific welding application or technique The welding parameters that can be modified include WFS range Voltage range Amperage range Gas mixture Gas flow rate The technique parameters ideal ra...

Page 39: ...ntified with the same name plus an incremented number after it Pressing Delete brings up an are you sure dialogue Selecting yes deletes the file currently shown The user can cancel out by pressing no or pressing the back button Pressing Rename brings the user to a keyboard screen where the name of the current file can be changed USB Edit This menu relates only to the files on the USB memo ry devic...

Page 40: ...e tolerances process selection screen Back Pressing Back goes back to the previous screen Continue Pressing Continue goes to the tolerance process selection screen Tolerances Process Selection Screen Overview The user selects which process to modify Menu Selecting Logout and then yes in the submenu brings the user back to the login screen in welding mode Selecting Change Coupon Type takes the user...

Page 41: ...rance indicated by the white lines on the LASER screen Any welding technique used within that range is acceptable but will be scored lower the further it is from the ideal value As an example a work angle with an ideal of 45 degrees and a of 10 degrees means that the user can use a work angle between 35 and 55 degrees and create an acceptable weld Settings that are non applicable to the process se...

Page 42: ...ermines how far off from the ideal position the stu dent can place the electrode before it results in a mis placed weld Tolerances Welding Technique Parameters Screen Overview This screen allows the modification of CTWD Arc Length Work Angle Travel Angl TOLERANCES WELDING TECHNIQUE PARAMETERS PATTERN AIM SCREEN Z Y X XX X Z TEE PIPE GROOVE Z Y X X X X Z TEE PIPE GROOVE Note The travel angle for dr...

Page 43: ...ue parameter relating to the whipping welding technique and travel speed including Dime Spacing Whip Time Puddle Time Travel Speed Tolerances Weave Screen Overview This screen allows for the modification of weaving welding technique including Width of Weave Weave Timing Weave Spacing WHIP TRAVEL SPEED SCREEN TOLERANCES WEAVE SCREEN ...

Page 44: ...NA FCAW S 5 64 E71T 8 NR 232 233 NA NA 1G 2G 375 130 21 DC FCAW S 5 64 E71T 8 NR 232 233 NA NA 3G up 375 125 19 5 DC SMAW 1 8 E6010 Fleetweld 5P NA NA Flat 25 90 5 NA DC SMAW 1 8 E6010 Fleetweld 5P NA NA 2F 3F up 4F 375 90 5 NA DC SMAW 1 8 E6010 Fleetweld 5P NA NA 1G 2G 3G up 4G 375 90 5 NA DC SMAW 1 8 E7018 Excalibur 7018 NA NA Flat 25 125 5 NA DC SMAW 1 8 E7018 Excalibur 7018 NA NA 2F 3F up 4F 3...

Page 45: ...ning alcohol to clean the lenses or plastic parts on the FMD You can also use a camera pressure canister to occasion ally blow out dirt You may want to clean the inside of the helmet occa sionally Be sure to do so without exposing the FMD to any unacceptable materials as explained above The FMD should be kept in a clean and dry location out of direct sunlight Avoid dirty or sandy environ ments as ...

Page 46: ...sible Cause If you do not understand or are unable to perform the Recommended Course of Action safely contact the Lincoln Electric Automation Division 22221 St Clair Ave Cleveland Ohio 44117 1199 U S A Phone 1 888 935 3878 Fax 216 383 8823 If the equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired HOW TO USE TROUBLESHOOTING GUIDE...

Page 47: ...be incorrect Press the menu button and select change process Make sure the images on the screen match the hardware being used The settings in the Instructor Mode are incorrect Holding the green button in does not shut down the VRTEXTM 360 This is normal USB not in front of machine Check for loose or faulty connections between the Helmet Monitor and the VRTEX 360 machine See the wiring diagram Make...

Page 48: ...ayed in the tolerance editor is the one being used The tolerance set can also be read from the student report The system may still be in the shut down mode The joint configuration may set up for one pass only The system may be located to large metal objects Only the buttons that are available for use light up Make sure the correct input power is being applied to the machine Use the joystick to go ...

Page 49: ...T R E D S W T R I R I G H T S W L E F T W H I T E L I G H T R E D L I G H T O R A N G E L I G H T Y E L L O W L I G H T N O O N O N N O N O N O N O N O N O N O N O N O N O L 1 L 1 L 2 C x C y C y 2 0 2 2 0 4 U S B 5 U S B P O R T L O C A T E D O N C A S E F R O N T V G A 6 V G A 6 A U D I O O U T L O C A T E D O N C A S E B A C K E M C F I L T E R 2 0 0 A 2 0 4 A 5 0 E 5 0 H 5 0 G 5 0 G 5 0 F I N ...

Page 50: ...NOTES VRTEXTM 360 ...

Page 51: ... electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Page 52: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não opere co...

Page 53: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...