TYDELLIST 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.

EN

Contents
General
General ......................................................................................................................................................
Principle ................................................................................................................................................
Fronius Xplorer function packs .............................................................................................................
Application areas ..................................................................................................................................
System requirements .................................................................................................................................
PC system requirements.......................................................................................................................
Welding system requirements...............................................................................................................
Firmware versions.................................................................................................................................
System configuration example..............................................................................................................
Configuring network ...................................................................................................................................
General .................................................................................................................................................
Assigning an IP address .......................................................................................................................
Assigning a firewall IP address .............................................................................................................
Fronius Xplorer overview
Fronius Xplorer overview ...........................................................................................................................
General .................................................................................................................................................
Fronius Xplorer .....................................................................................................................................
Browser level overview .........................................................................................................................
Work level overview ..............................................................................................................................
Buttons at the browser level..................................................................................................................
Symbols for power source location .......................................................................................................
System component symbols .................................................................................................................
System status symbols .........................................................................................................................
Symbols in the Jobs and Docu worksheets overview ...........................................................................
Menu - Tools
Options.......................................................................................................................................................
General .................................................................................................................................................
LocalNet serial ports .............................................................................................................................
Licences................................................................................................................................................
Login .....................................................................................................................................................
Creating a login via OPC ......................................................................................................................
Creating a login via the UsbKey............................................................................................................
User settings ..............................................................................................................................................
General .................................................................................................................................................
Creating a new user with a new user profile .........................................................................................
Managing the user profiles....................................................................................................................
User management ................................................................................................................................
Logging on and off automatically ..........................................................................................................
Changing the user.................................................................................................................................
Splitting the window ...................................................................................................................................
Splitting the window ..............................................................................................................................
Browser level
Browser level .............................................................................................................................................
General .................................................................................................................................................
Navigation in browser ...........................................................................................................................
Switching from browser view to status view..........................................................................................
Copying a welding system to the selection bar.....................................................................................
Removing a welding system from the selection bar..............................................................................
Worksheets

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Worksheet overview...................................................................................................................................
Worksheet overview..............................................................................................................................
Buttons and symbols in the Worksheet overview .................................................................................
Backing up and restoring data ..............................................................................................................
Setting up automatic backup.................................................................................................................
Defining and cancelling the master backup ..........................................................................................
Displaying connection status ................................................................................................................
Saving the device configuration ............................................................................................................
Configuring the system name and location...........................................................................................
Control panel worksheet ............................................................................................................................
Control panel worksheet .......................................................................................................................
Operating the control panel using the keyboard ...................................................................................
Accessing a power source set-up menu ...............................................................................................
Jobs worksheet ..........................................................................................................................................
Jobs worksheet .....................................................................................................................................
Buttons and symbols in the Jobs worksheet.........................................................................................
Displaying job data................................................................................................................................
Copying and pasting jobs......................................................................................................................
Exporting/importing jobs .......................................................................................................................
Pasting job data into an external document..........................................................................................
Attaching a file to a job/opening an attached file ..................................................................................
Deleting a job ........................................................................................................................................
Changing a job......................................................................................................................................
Job history.............................................................................................................................................
Docu worksheet .........................................................................................................................................
Docu worksheet ....................................................................................................................................
Buttons and symbols in the Docu worksheet ........................................................................................
Applying the default settings for consumption figures...........................................................................
Automatic Excel export .........................................................................................................................
Switching welding data recording on and off ........................................................................................
Time synchronisation ............................................................................................................................
Displaying welds/consumption figures menu ........................................................................................
Showing as a graph ..............................................................................................................................
Weld seam sections menu....................................................................................................................
Parameter set values menu ..................................................................................................................
Actual welding parameter values menu ................................................................................................
Errors menu ..........................................................................................................................................
Loading and displaying recorded welding data.....................................................................................
Saving welding data as an Excel file.....................................................................................................
Importing welding data..........................................................................................................................
Documented welding data ....................................................................................................................
Log book worksheet...................................................................................................................................
Log book worksheet..............................................................................................................................
Buttons and symbols in the Log book worksheet..................................................................................
Loading and displaying log book data...................................................................................................
Saving log book data as an Excel file ...................................................................................................
Statistics worksheet ...................................................................................................................................
Statistics worksheet ..............................................................................................................................
Buttons and symbols in the Statistics worksheet ..................................................................................
Creating a new statistics bar.................................................................................................................
Graph worksheet........................................................................................................................................
Graph worksheet...................................................................................................................................
Buttons and symbols in the Graph worksheet ......................................................................................
Creating a new job graph......................................................................................................................
Hiding/showing jobs ..............................................................................................................................
Zoom.....................................................................................................................................................
Importing data from systems not in the network ........................................................................................
General ................................................................................................................................................
Adding a welding system ......................................................................................................................

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General

EN

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 symbols, 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 touchscreen capability for faster operation.

Fronius Xplorer
function packs

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

Monitoring the current operating status

Backup/restore functions

Remote control of the power source using PC

Documentation of set values

Documentation of changes to set values

Attaching documents or images as information

Copying jobs from one power source to another

Documentation of weld seam actual values (with part number

as option)

Limit monitoring of current and voltage

Motor current monitoring

Log book/graph/statistics

* Welds, sections

Application areas

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

System requirements
PC system requirements

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 relates to a system with 16 welding systems whose data is to be documented on the computer:
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 versions

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

EN

System configuration example

Welding cell

Production hall

Head office

Production hall
Welding cell
Production location
Example of network for management with Fronius Xplorer

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" software is also required to make the settings.
More information about configuring the Ethernet interface can be found in the "Ethernet"
operating instructions.
(1)
(2)
(3)
(4)

(1)
(2)

(5)

Wire-feed unit
RCU 5000i remote control option
Power source
PC, laptop or touch screen with
Fronius Xplorer software
LocalNet/RS232 interface

(3)

(4)

Assigning an IP
address

(5)

To identify a power source uniquely within a network, it must be assigned a numeric address (IP address).
IMPORTANT! The IP address must be different for each power source.
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 firewall IP address

10

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".

Fronius Xplorer overview

EN

Fronius Xplorer overview

General

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 safety rules
NOTE! Due to software updates, you may find that your device has certain functions that are not described in these operating instructions or vice versa. Individual 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).
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.
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.

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 available 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

IMPORTANT! To record the current welding system data, Fronius Xplorer must be activated 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 SmartMedia card can, however, be loaded into the program at a later date.

Browser level
overview

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

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(1)
(6)
TPS 5000 CMT
(10.4.146.244)

(A)
TIME 5000
(10.4.146.230)

(5)

!
DeltaSpot 1
(10.2.130.201)

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

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)

(2)

DeltaSpot 4
(10.2.130.204)

(3)

(4)
Browser level

Work level overview

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(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

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)

EN

(2)

Place / ....

(5)

TPS 5000 CMT

(10.4.146.244)

TIME 5000
(10.4.146.230)

F3

F2

Panel

Overview

F5

F4

TPS5000 (No:15440923)

LogBook

Doku

Jobs

VR7000 -CMT

Statistic

F8

Diagram

(3)

TPS5000 (No:15440923)

Weld Process Regulator

DB 0503

4.2.4
5.0.100
5.0.95

UST2BV1.4B

1.4.1

BPS53 V0.3A

0.3.0.

Ethernet-Gate (No:15440923)
FP25

1.21.14

FP25_OS

RCU5000i (No:15050216)

DeltaSpot 4
(10.2.130.204)

F7

FP25
POWERMAG-OS

DeltaSpot 1
(10.2.130.201)

F6

1.6.0

FP25 V1.6A

LN Router

(4)
Work level

* Available depending on option pack

Buttons at the
browser level

(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 options 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

Browser button
For switching from the work level to the browser level
"Create new file" button
For creating a new file
"Open file" button
For opening Fronius Xplorer files (e.g. data from non-networked systems)

Symbols for power source location

Power source locations are defined using the following folder symbols:

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Home symbol
The highest folder level: Home/
Production location symbol
The second folder level: Home/Production location/
Factory symbol
The third folder level: Home/Production location/Factory/
Production hall symbol
The fourth folder level: Home/Production location/Factory/Production hall/
Production cell symbol
The fifth folder level: Home/Production location/Factory/Production hall/Production cell/
The type and status of the welding system are shown in the lowest folder level

System component symbols

Power source symbol

Applies to all Fronius power sources from the digital series
Wire-feed unit symbol
Applies to all available Fronius wire-feed units
Remote control symbol
Applies 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 symbol
When using a gas sensor
Part counter symbol
When 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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(1)

EN

System status
symbols

System activity status symbol:

Welding active
Arc is burning

(1)

(2)

System status symbol:

Status OK
System working properly

(2)
(3)

Warning
System displays a warning

Unknown status
System is currently unavailable (switched off or disconnected from mains)
System stop
System displays an error on the control panel and is not working properly

(3)

System status symbol:

Welding system online
Connection to system established, data being retrieved
System available
System ready to establish a connection
No connection
The connection to the system is interrupted (e.g. system is switched off)

Symbols in the
Jobs and Docu
worksheets overview

Place / ....
TPS 5000 CMT
(10.4.146.244)

F3

F2

Overview

Panel

F6

LogBook

Doku

(1)
(1)

F5

F4

Jobs

F7

Statistic

F8

Diagram

(2)

Symbols in Jobs worksheet

Jobs licence and access rights
The Jobs worksheet is available, jobs are available for editing
Jobs licence, but currently no access rights
The Jobs worksheet is available, but the job is currently locked for editing by another user
Jobs licence not available
The Jobs worksheet is not available

(2)

Symbols in Docu worksheet

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

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18

Menu - Tools

EN

Options
General

Browser settings
Searches 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.
Language
The language for Fronius Xplorer can be set here.
Currency
The "Documentation" worksheet has an option for entering consumption figures. The currency to be displayed can be set in this menu.
Data directory
The document data and user data is saved by default in "My Documents\Fronius International\Fronius Xplorer". The user can select a preferred storage location in this menu. Select a network drive as the location so that the same data can be accessed from several
PCs.

LocalNet serial
ports

Serial interfaces
Fronius 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. After the machine has been selected, Fronius Xplorer and the LocalNet server must be restarted.

Login

Automatic Windows login

Only 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.

21

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

22

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"

23

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.

User settings
General

Creating a new
user with a new
user profile

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.

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 unchecking the box

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

Managing the
user profiles

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

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

User profiles
Administrator

Userprofile 1

Options

Edit users

New file

Enable Automatic logoff

Open file

Automatic logoff in minutes:

Open/close machines
Delete machines from browser
Arc welding

Change password
Split

DeltaSpot

New

Delete

Rename

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.

24

The 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.
-

Changing the
user

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

Press the "Change user" button

Enter the user name and password

Press Enter

25

EN

User management

Splitting the window

Splitting the window

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

Place / ....
TPS 5000 CMT
(10.4.146.244)

TIME 5000
(10.4.146.230)

Place / ....
F3

F2

Panel

Overview

TPS 5000 (No:15440923)

Jobs

VR7000 -CMT

Panel

TIME 5000 (No:15440924)

TPS5000 (No:15440923)

Weld Process Regulator

DB 0503

4.2.4
5.0.100
5.0.95

UST2BV1.4B

1.4.1

BPS53 V0.3A

0.3.0.

Ethernet-Gate (No:15440923)

F4

Jobs

TPS5000 (No:15440924)
POWERMAG-OS

VR7000 -CMT

Weld Process Regulator

DB 0503

4.2.4
5.0.100
5.0.95

UST2BV1.4B

1.4.1

BPS53 V0.3A

0.3.0.

Ethernet-Gate (No:15440924)
FP25

FP25_OS

RCU5000i (No:15050216)

DeltaSpot 4
(10.2.130.204)

Overview

FP25
POWERMAG-OS

DeltaSpot 1
(10.2.130.201)

F3

F2

F4

FP25 V1.6A

FP25

1.21.14
1.6.0

FP25_OS

RCU5000i (No:15050217)

FP25 V1.6A

1.21.14
1.6.0

LN Router

Windows displayed side by side

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

26

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:

Highest folder level: Home

Provides an overview of the production locations on the network.
Company or production location folder level
Provides an overview of the production facilities at the production location.
Production facility folder level
Provides an overview of the production halls at the production facility.
Production hall folder level
Provides an overview of the welding cells in the production hall.
Welding cell folder level
Provides an overview of the welding systems in the cell.
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

Ready

10

Errors

Warnings

29

Systems with the same status are displayed in a table:

TPS 5000 CMT

(10.4.146.244)

Installed units

15

Ready

10

Errors

Warnings

Offline

DeltaSpot 3 (11.4.22.298)
/Path/...

TIME 5000
(10.4.146.230)

DeltaSpot 1
(10.2.130.201)

Copying a welding system to the

selection bar

TPS 4000 (10.4.146.244)

/Path2/....

TPS 5000 CMT (10.4.141.221)

/Path3/...

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.

To access the work level of a welding system, firstly copy the welding system to the selection 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

TPS 5000 CMT

(10.4.146.244)

Installed units

15

Ready

10

Errors

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)

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 systems copied to the selection bar are retained, regardless of the current folder level.

Removing a welding system from

the selection bar

(2)

Place / ....

(1)

TPS 5000 CMT

(10.4.146.244)

TIME 5000
(10.4.146.230)

F3

F2

Panel

Overview

F5

F4

Jobs

TPS5000 (No:15440923)

Doku

F6

LogBook

F7

Statistic

F8

Diagram

TPS5000 (No:15440923)

FP25
POWERMAG-OS

VR7000 -CMT

Weld Process Regulator

DB 0503
UST2BV1.4B

4.2.4
5.0.100
5.0.95

1.4.1

Removing a welding system from the selection bar

30

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

Press the Close welding system button (2)

EN

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

31

32

Worksheets

EN

Worksheet overview
Worksheet overview

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:
F3

F2

Panel

Overview

F5

F4

Doku

Jobs

TPS5000 (No:15440923)

F6

LogBook

F7

Statistic

F8

Diagram

TPS5000 (No:15440923)

FP25
POWERMAG-OS

VR7000 -CMT

Weld Process Regulator

DB 0503

4.2.4
5.0.100
5.0.95

UST2BV1.4B

1.4.1

BPS53 V0.3A

0.3.0.

Ethernet-Gate (No:15440923)
FP25

FP25_OS

RCU5000i (No:15050216)

FP25 V1.6A

1.21.14
1.6.0

LN Router

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

Buttons and symbols in the Worksheet overview

Refresh button
Updates system information
Undo button
The jobs on the machine are reset to their former status
Attach file button
Attaches a file to the job (e.g. photo of weld seam, etc.)
Maintenance panel button
Allows 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 button
for 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

35

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 individually.
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

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

Setting up automatic 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
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

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

Defining and cancelling the master

backup

It is possible to define a backup that will be restored automatically when the "Restore backup" 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

1
36

Press the "Options" button

EN

Press "Master backup"

Select master backup and confirm by pressing "Open"

Import master backup by pressing the "Restore backup" button

Cancelling the master backup

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

Displaying connection status

Press the "Options" button

Press "Deactivate master backup"

Press the "Options" button

Press "Show connection settings"

Connection settings
IP address
Firewall IP

10.4.146.245
10.4.146.246

Active connections

10.4.120.7

0.0.0.0
0.0.0.0
0.0.0.0
Default gateway
Subnet mask

10.4.146.245

Modbus UDP Fronius

Modbus firewall

255.255.248.0

Port number 15001

Modbus port number

170.170.170.170
502

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

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. Setting 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

37

Saving the device

configuration

Configuring the
system name and
location

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

Press the "Options" button

Press "Save device configuration"

Select the location and save the file

Press the "Options" button

Press "Machine configuration"

Machine configuration
New folder

Machine path:

Machine path:

TPS 4000 (10.4.146.245)

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

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

38

EN

Control panel worksheet

Control panel
worksheet

The control panel is modelled on the control panel of the connected power source. In addition, functions can be executed directly through shortcuts on the PC keyboard. The integrated adjusting dial (2) makes the touchscreen easy to use.
Further information about the control panel function can be found in the power source operating instructions.
NOTE! If the RCU 5000i remote control is connected to the power source, operation via the Control panel worksheet is no longer available. The current parameter 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)

Example: Comfort/TPS 5000 power source control panel

Operating the
control panel using the keyboard

(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 touchscreen

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

39

+
A

W
G
D

O P

N M

E R

Example: displaying the shortcuts by pressing the space bar

Accessing a power source set-up

menu

To access a power source set-up menu:

LOCK
CK
CK

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.

Jobcorr.

WFS
WFS
Menue
en
nu

GA
GAS
Menue
Menu
ue

Trigger
rigg
igg
Menue

Example: displaying available set-up menus

40

Mai
Main
Menue

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.
IMPORTANT! In order to use all the functions of the Jobs worksheet, the JobExplorer option must be enabled on the power source.
Connecting the RCU 5000i remote control increases the number of locations from 100 to
1000.

(3)

(2)

(1)

(4)

(8)
(5)

(6)

(7)

Jobs worksheet

(1)
-

Buttons for confirming job changes

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

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

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

(2)

(3)

(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

41

(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

Parameter display
Shows current parameter settings and parameter changes
Unconfirmed parameter changes are shown in yellow

(7)

(8)

Buttons and symbols in the Jobs

worksheet

Welding parameter scroll bar

For scrolling in the parameter display

Power source button

The jobs are transferred from the machine to Fronius Xplorer
Save job button
Confirm changes or newly created job
Undo button
The jobs on the machine are reset to their former status
Attach file button
Attaches a file to the job (e.g. photo of weld seam, etc.)
Copy job button
Copies selected jobs
"Delete job" button
Deletes selected jobs
Change job button
Changes selected jobs
History button
Provides 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 symbol

Means 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 connection has been restored, the "Change to job warning symbol" appears next to the
job that has been changed.
Job error button
Incorrect 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 conflict
Different job change on the RCU 5000i remote control and the power source during
connection interruption.
Job options menu
For exporting and importing jobs

42

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

Select a job, jobs or job group

Press the "Copy" button or Ctrl + C

Select a power source for pasting the jobs

Select location

Press the "Paste" button or Ctrl + V

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 carried out on the target power source, an error message appears.

Exporting/importing jobs

Exporting a job, jobs or job group to data medium

Select a job, jobs or job group

Press the "Options" button

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

43

EN

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

Press the "Options" button

Press "Import"

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

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

Pasting job data

into an external
document

Attaching a file to
a job/opening an
attached file

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

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.

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.
Opening a file attachment

(1)

Opening a file attachment

44

(2)

Select job with file attachment

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

EN

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

Deleting a job

Changing a job

Job history

Select a job, jobs or job groups

Press the "Delete" button

Select job

Press the "Change" button

Change welding parameters (see power source operating instructions)

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 machine again.

45

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

F4

Docu
Welds
wire

XXX,X

Imean
XXX

Imax
XXX

XX,X

Umean
XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

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,X

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,X

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,X

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,X

XX,X

XX,X

XX,X

Start Time

Partnumber

Umin

Gas

Imin
XX

Umax

KXX-XXXX

Seam
XX

Arc Time

dd.mm.yyy hh:mm:ss.x
dd.mm.yyy hh:mm:ss.x

Limit

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:

Buttons and symbols in the Docu

worksheet

Highlight welding data

Right-click and press "Load details"

Welds symbol
Documents the welding data (actual data) for the entire weld seam
Sections symbol
Documents the welding data (actual data) for individual sections of the weld seam
Set values symbol
Documents the specified set values
Actual values symbol
Documents the actual welded values. Records voltage (U), current (I) and weld
time (arc time) every 100 ms.
Error symbol
Documents any errors that occur with a time stamp and in plain text.

46

EN

Load welding data button

Displays and loads recorded welding data
Display current welding data button
Displays current welding data recording on the screen
Pause current screen view button
The 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 button
The 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 symbol
Welding data that is currently in the memory is shown by the red power source
symbol
Offline welding data symbol
Displays welding data that is no longer in the memory. Displayed using the grey
power source symbol.
Docu data options menu
For 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 symbol
Limit exceed of upper/lower current or voltage limit
Error symbol
An error has occurred during welding

Applying the default settings for

consumption figures

Press the "Options" button

Select "Consumption figures default settings"

Wire diameter in mm
For setting the wire diameter being used
Gas consumption in l/min
For 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 symbol
For setting the degree of efficiency
Degree of efficiency in % symbol
For setting the degree of efficiency
New wire button
For creating new wire material with a specific weight

47

Update wire material button

For updating existing wire material
Delete wire material button
For deleting wire material from the database
IMPORTANT! The currency can be set under "Tools - Options".

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 the "Options" button

Press "Excel export"

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

Switching welding data recording on and off

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

Press the "Options" button

Press "Data Receiver ON"

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

Time synchronisation

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

48

Press the "Options" button

Press "Automatic time synchronisation"

Manual time synchronisation

Displaying welds/
consumption figures menu

Press the "Options" button

Press "Synchronise time now"

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

Welding parameter OK symbol
Relates to the number of highlighted weld seams
Exceeded limits symbol
Relates to the number of highlighted weld seams
Error symbol
Relates to the number of highlighted weld seams
Welding wire consumption symbol
Relates to the number of highlighted weld seams
Shielding gas consumption symbol
Relates to the number of highlighted weld seams

12

Weld time symbol

Relates to the number of highlighted weld seams
Energy consumption symbol
Relates to the number of highlighted weld seams
Total costs symbol
Relates to the number of highlighted weld seams

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

49

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 appears for automatic time synchronisation when the system is first opened.

Weld seam sections 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
I (A)

(1)

t (s)
(2)

(3)

(4)

(A1)

(5)

(A2)

(6)
(A3)

Sections/sections based on special 2-step mode

(1)
(2)
(3)
(4)
(5)
(6)
(A1)
(A2)
(A3)

Monitoring active
Starting current phase
Slope 1
Main current phase
Slope 2
Final current phase
Section 1
Section 2
Section 3

The sequential weld seam sections are numbered and listed consecutively.

F4

Docu
Sections

(1)

(2) (3)

(4)

(5) (6) (7) (8)

(9)

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

Weld seam sections display

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

50

(10) (11) (12)

KXX-XXXX
KXX-XXXX

Part number
Weld seam
Section
Job
Weld time
I mean (average current)
U mean (average welding voltage)
vD mean (average wire feed speed)

(*)

vS mean (average welding speed)

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 increased/decreased.

EN

(9)
(10)

Parameter set values menu

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

F4

Docu
Command values

(1)

(2) (3)

(4)

(5) (6) (7) (8)

(9)

(10) (11) (12)

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XX,X

XXX

(*)

displaying parameter set values according to the RCU 5000i

Actual welding
parameter values
menu

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

Part number
Weld seam
Section
Job
Operating mode
PrgNo (program number)
Current
Voltage
Wire feed speed
ALC (arc length correction)
DYN (arc force dynamic correction)
Options

(*)

The values displayed depend on the welding process set, and can be adjusted individually 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/decreased.

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

F4

Docu
Actual values

(*)
KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

XX,X

XX,X

XX,X

XX,X

KXX-XXXX

XX

XX

XXX,X

Std

XXX

XXX

XX,X

displaying actual welding parameter values according to the RCU 5000i

(*)

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

51

the displayed values can also be moved to a desired position and increased/decreased.

Errors menu

Displays errors that occurred during a weld.

F4

Docu
Errors
(1)

(2)

(3) (4)

(5)

(6)

(7)

dd.mm.jjjj

hh:mm:ss

XX

XXX

XXX

ABCD

dd.mm.jjjj

hh:mm:ss

XX

XXX

XXX

ABCD

hh:mm:ss

XX

XXX

XXX

ABCD

dd.mm.jjjj

hh:mm:ss

XX

XXX

XXX

ABCD

dd.mm.jjjj

dd.mm.jjjj

hh:mm:ss

XX

XXX

XXX

ABCD

(*)

errors occurred

Loading and displaying recorded

welding data

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

Time of error
Weld seam
Job
Operating mode
Error number
Duration
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/decreased.

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

RCU data symbol
Data imported from the SmartMedia card in the RCU 5000i remote control
Smart Media

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.

52

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 the "Options" button

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 welding data

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

Press the "Options" button

Press "Import"

Select path and confirm

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)

53

Documented
welding data

Weld time
Weld time from the beginning to the end of a weld seam (time during which the arc is active)
ALC
The currently set arc length correction or the arc length correction for an active job
Description
Description of an error that has occurred
Duration
The length of time for which an error has occurred
DYN
The currently set arc force dynamic correction or the arc force dynamic correction for an
active job
Error number
Error code displayed when an error occurs
Time of error
The exact time at which an error occurred
Current
Welding 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)
Imax
Maximum welding current within a weld seam section
Imean
Average welding current within a weld seam section
Imin
Minimum welding current within a weld seam section
Job
Number of the job in which e.g. a weld seam section was welded
Limit
Shows 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 limit

Falling below a current/voltage limit
Limits that have been exceeded/not reached are displayed in
combination Exceeding the motor current limit for the wire-feed
unit
Exceeding the motor current limit for the wire-feed unit
Exceeding/falling below the wire feed speed limit
Exceeding/falling below the welding speed

Operating mode
Welding process: pulse or standard
Options
Shows whether power source options are active during a weld seam section
Synchro active
Spatter-free ignition

SynchroPulse option active

Spatter-free ignition option active

Part number
Displays 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.
PrgNr
Reference number of the welding characteristic used
Section
Weld seam section, individual sections of weld seams

54

EN

Weld seam
Weld seam (from the start of welding until welding stops)
Start time
Start time of the weld seam according to the RCU 5000i remote control
Voltage
Welding voltage set value according to the RCU 5000i remote control (created by entering the "welding voltage" parameter in the manual MIG/MAG welding screen)
Umax
Maximum welding voltage within a weld seam section
Umean
Average welding voltage within a weld seam section
Umin
Minimum welding voltage within a weld seam section
Wire feed speed
Wire 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)
vDmax
Maximum welding wire feed speed within a weld seam section
vDmean
Average welding wire feed speed within a weld seam section
vDmin
Minimum welding wire feed speed within a weld seam section
Wire
Wire consumption according to set consumption figures in the Docu data options menu
Gas
Gas flow rate according to set consumption figures in the Docu data options menu
E
Energy input
Q
Heat energy
vSmax
Maximum welding speed within a weld seam section
vSmean
Average welding speed within a weld seam section
vSmin
Minimum welding speed within a weld seam section
Fdi (TIG)
Cold wire option, wire threading speed
Balance (TIG)
Relationship between fusing power and cleaning action
Unit 1
Setting range -5 to +5
Factory setting 0
-5 highest fusing power, lowest cleaning action
+5 highest cleaning action, lowest fusing power
ACF (TIG)
AC frequency
Unit Hz
Iground (TIG)
Ground current
Unit %
Shown as a percentage of the selected main current

55

Duty cycle (TIG)

Ratio of pulse duration to ground current duration where a pulse frequency has been set
Unit %
Pulse frequency (TIG)
Unit Hz / kHz
Setting 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 moment of droplet transfer.
HotStart (rod electrode)
Increases the set welding current in the starting current phase
Unit %

56

EN

Log book worksheet

Log book worksheet

All errors/events that occurred during operation are recorded in the log book worksheet.
F6

Logbook
All events
Start time
dd.mm.jjjj hr:min:sec

Key name
user name

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

user name

Log book worksheet

Buttons and symbols in the Log

book worksheet

Log book options menu

For setting the storage location of the Excel file using the export wizard
Log book symbol
Displays all recorded events
Job change log book symbol
Displays all recorded parameter changes within a job
Change of log book user symbol
Displays all recorded changes of user
Firmware update log book symbol (RCU 5000i)
Displays all recorded updates of firmware versions on the RCU 5000i remote control
Error symbol
Displays all recorded errors on the welding system
Load log book data button
Displays and loads recorded log book data
Show current log book data button
Shows current recorded log book data on the screen
Pause current screen view button
The 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 data.
Save log book data as an Excel file button
Data is saved as an Excel file in the desired location

Loading and displaying 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

57

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 the "Options" button

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.

58

EN

Statistics worksheet
Statistics worksheet

The Statistics worksheet analyses the documented welding data. The statistics are displayed 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.
IMPORTANT! In order to use the Statistics worksheet, limit values for the Q-Master function must be defined on the RCU 5000i remote control, and warning or shutdown must be
enabled in the Reaction menu item.
F7

Statistics
Welds

Welds

Welds

Welds

Job
Job 79
79
I min [A]

80

81

82

83

99,9

I max [A]

99,9

U min [V]

30,03

U max [V]

30,03

2
1

U
vD
vD

5
2
1

M1

M2

13

85

20

86

40

20

25
20

10

84

10

21

10
2

Statistics worksheet

(1)
(2)

(4)
Job 79
I min [A]

79

(1)

(3)

(2)

(4)

(3)

96,8

I max [A]

99,9

U min [V]

26,07

U max [V]

30,03

I
I

2
1

U
vD
vD

5
2
1

M1

M2

(5)

(5)
-

Job number
Number of weld seams within the
specified limit values
Number of weld seams outside the
specified limit values
Current and voltage extreme value
display. The display relates to the
total number of welded jobs. The
display saves the smallest and greatest value that occurred while the
selected job was being welded.
Detailed view of the number of exceeds of the upper and lower limit
values for
Voltage and current
Wire feed speed
Motor currents

statistics: Job bar

Buttons and symbols in the Statistics worksheet

Welds

Welds

ld

New statistics bar symbol

Creates a new statistics bar for a job or a weld seam
Delete statistics bar symbol
Deletes a statistics bar

59

Welds

Empty statistics bar symbol

Edits the bar job number

W ld

Job statistics bar symbol

Edits the bar job number

Welds

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

Creating a new
statistics bar

Press the "New" button

Welds

ld

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:

60

Select the statistics bar

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

EN

Graph worksheet
Graph worksheet

The graph worksheet provides a visual representation of the welding data. Different jobs
are shown in different colours.
F8

Diagram

A
Welds

Job 01

Current

300

Welds

Job 02
Welds

Job 03

250

Welds

Job 04

200

150

100

50

0
0

12

16

20

24

Graph worksheet

Buttons and symbols in the Graph

worksheet

Add job button

Creates a new graph for the job number
"Delete Job" button
Deletes the selected job from the screen view
Reset graph button
Resets the recorded graph for a selected job
Print button
Prints the current graph
Copy button
Press this button to copy the current graph to the clipboard
Pause screen view
The graph can be saved in a variety of formats.
Graph options menu
The maximum number of curves shown in parallel in a single graph can be set using "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

Hiding/showing
jobs

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

Show/hide individual jobs using the relevant button:

Show job
Job 02

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 colour several times by showing and hiding it.

Zoom

62

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.

EN

Importing data from systems not in the network

General

Adding a welding
system

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.

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

63

Maahantuonti ja myynti:

Pronius Oy
Keisarinviitta 20 B
33960 Pirkkala
+358 (0)44 200 9060
info@pronius.fi
www.pronius.fi