Fronuis Xplorer Software

TYDELLIST HITSAUSTA
FRONIUS EXPLORER
/ Operating Instructions
v.01/2012 ENG
Dear reader,
EN
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.
1
2
Contents
EN
General 5
General ...................................................................................................................................................... 7
Principle ................................................................................................................................................ 7
Fronius Xplorer function packs ............................................................................................................. 7
Application areas .................................................................................................................................. 7
System requirements ................................................................................................................................. 8
PC system requirements....................................................................................................................... 8
Welding system requirements............................................................................................................... 8
Firmware versions................................................................................................................................. 8
System configuration example.............................................................................................................. 9
Configuring network ................................................................................................................................... 10
General ................................................................................................................................................. 10
Assigning an IP address ....................................................................................................................... 10
Assigning a firewall IP address ............................................................................................................. 10
Fronius Xplorer overview 11
Fronius Xplorer overview ........................................................................................................................... 13

General ................................................................................................................................................. 13
Fronius Xplorer ..................................................................................................................................... 13
Browser level overview ......................................................................................................................... 13
Work level overview .............................................................................................................................. 14
Buttons at the browser level.................................................................................................................. 15
Symbols for power source location ....................................................................................................... 15
System component symbols ................................................................................................................. 16
System status symbols ......................................................................................................................... 17
Symbols in the Jobs and Docu worksheets overview ........................................................................... 17
Menu - Tools 19
Options....................................................................................................................................................... 21
General ................................................................................................................................................. 21
LocalNet serial ports ............................................................................................................................. 21
Licences................................................................................................................................................ 21
Login ..................................................................................................................................................... 21
Creating a login via OPC ...................................................................................................................... 22
Creating a login via the UsbKey............................................................................................................ 22
User settings .............................................................................................................................................. 24
General ................................................................................................................................................. 24
Creating a new user with a new user profile ......................................................................................... 24
Managing the user profiles.................................................................................................................... 24
User management ................................................................................................................................ 25
Logging on and off automatically .......................................................................................................... 25
Changing the user................................................................................................................................. 25
Splitting the window ................................................................................................................................... 26
Splitting the window .............................................................................................................................. 26
Browser level 27
Browser level ............................................................................................................................................. 29

General ................................................................................................................................................. 29
Navigation in browser ........................................................................................................................... 29
Switching from browser view to status view.......................................................................................... 29
Copying a welding system to the selection bar..................................................................................... 30
Removing a welding system from the selection bar.............................................................................. 30
Worksheets 33
3
Worksheet overview................................................................................................................................... 35
Worksheet overview.............................................................................................................................. 35
Buttons and symbols in the Worksheet overview ................................................................................. 35
Backing up and restoring data .............................................................................................................. 36
Setting up automatic backup................................................................................................................. 36
Defining and cancelling the master backup .......................................................................................... 36
Displaying connection status ................................................................................................................ 37
Saving the device configuration ............................................................................................................ 38
Configuring the system name and location........................................................................................... 38
Control panel worksheet ............................................................................................................................ 39
Control panel worksheet ....................................................................................................................... 39
Operating the control panel using the keyboard ................................................................................... 39
Accessing a power source set-up menu ............................................................................................... 40
Jobs worksheet .......................................................................................................................................... 41
Jobs worksheet ..................................................................................................................................... 41
Buttons and symbols in the Jobs worksheet......................................................................................... 42
Displaying job data................................................................................................................................ 43
Copying and pasting jobs...................................................................................................................... 43
Exporting/importing jobs ....................................................................................................................... 43
Pasting job data into an external document.......................................................................................... 44
Attaching a file to a job/opening an attached file .................................................................................. 44
Deleting a job ........................................................................................................................................ 45
Changing a job...................................................................................................................................... 45
Job history............................................................................................................................................. 45
Docu worksheet ......................................................................................................................................... 46
Docu worksheet .................................................................................................................................... 46
Buttons and symbols in the Docu worksheet ........................................................................................ 46
Applying the default settings for consumption figures........................................................................... 47
Automatic Excel export ......................................................................................................................... 48
Switching welding data recording on and off ........................................................................................ 48
Time synchronisation ............................................................................................................................ 48
Displaying welds/consumption figures menu ........................................................................................ 49
Showing as a graph .............................................................................................................................. 49
Weld seam sections menu.................................................................................................................... 50
Parameter set values menu .................................................................................................................. 51
Actual welding parameter values menu ................................................................................................ 51
Errors menu .......................................................................................................................................... 52
Loading and displaying recorded welding data..................................................................................... 52
Saving welding data as an Excel file..................................................................................................... 53
Importing welding data.......................................................................................................................... 53
Documented welding data .................................................................................................................... 54
Log book worksheet................................................................................................................................... 57
Log book worksheet.............................................................................................................................. 57
Buttons and symbols in the Log book worksheet.................................................................................. 57
Loading and displaying log book data................................................................................................... 57
Saving log book data as an Excel file ................................................................................................... 58
Statistics worksheet ................................................................................................................................... 59
Statistics worksheet .............................................................................................................................. 59
Buttons and symbols in the Statistics worksheet .................................................................................. 59
Creating a new statistics bar................................................................................................................. 60
Graph worksheet........................................................................................................................................ 61
Graph worksheet................................................................................................................................... 61
Buttons and symbols in the Graph worksheet ...................................................................................... 61
Creating a new job graph...................................................................................................................... 62
Hiding/showing jobs .............................................................................................................................. 62
Zoom..................................................................................................................................................... 62
Importing data from systems not in the network ........................................................................................ 63
General ................................................................................................................................................ 63
Adding a welding system ...................................................................................................................... 63
4
General
General
EN
Principle The Fronius Xplorer software is a virtual control station for networked welding systems in
automated production areas. The graphical user interface, with its self-explanatory sym-
bols, facilitates the clear and simple management of any number of welding systems that
form part of a networked production line.
The location and status of each welding system can be seen at a glance. Tried and tested
settings can be copied easily from one system to another. The software also has touch-
screen capability for faster operation.
Fronius Xplorer Fronius Xplorer is available with different function packs and associated options:
function packs
(1) Power source + Fronius Xplorer (basic package)
(2) Power source + Fronius Xplorer + Docu
(3) Power source + Fronius Xplorer + JobExplorer + Docu (optional)
(4) Power source + Fronius Xplorer + RCU 5000i remote control
Function packs (1) (2) (3) (4)

All systems in the network can be seen X X X X
Monitoring the current operating status X X X X
Backup/restore functions X X X X
Remote control of the power source using PC X X X -
Documentation of set values - - X X
Documentation of changes to set values - - X X
Attaching documents or images as information - - X X
Copying jobs from one power source to another - - X X
Documentation of weld seam actual values (with part number - * * X
as option)
Limit monitoring of current and voltage - - - X
Motor current monitoring - - - X
Log book/graph/statistics - - - X
* Welds, sections
Application areas The application area encompasses all digital devices from the Fronius product family in au-
tomated and manual applications
- MIG/MAG welding and brazing (CMT)
- TIG welding
- DeltaSpot - spot welding
- Plasma welding
7
System requirements
PC system re- The system requirements of the computer depend on the number of connected welding
quirements systems for which data documentation is to be carried out. The following information re-
lates to a system with 16 welding systems whose data is to be documented on the compu-
ter:
- 3 GHz CPU
- 2 GB RAM
- WinXP, Win7 or WinServer2008 operating system + latest service packs
- Microsoft.NET Framework 2.0 (on "ToolsCD" CD-ROM or via internet)
- Screen resolution of at least 1024 x 768
- One free serial interface (for configuring the network)
- At least 100 Mbit network connection
- No hub in network
Welding system - Digital power source

requirements - Free LocalNet connection with "Ethernet" option on the power source
If no LocalNet connection is free:

- LocalNet passive distributor
For retrospective evaluation of welding data:

- RCU 5000i remote control
- or enabling of data documentation (Docu)
To use the log book, graph and statistics functions, an RCU 5000i remote control must be
connected to the respective power source.
Firmware ver- The device firmware must be kept up-to-date in order to be able to use all Fronius Xplorer
sions 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
8
System configu-
EN
ration example Welding cell
Production hall
Head office
Production hall
Welding cell
Production location
Example of network for management with Fronius Xplorer
9
Configuring network
General To configure the power source for network use, a connection must be established between
the power source and PC using a LocalNet/RS232 interface. The "Service module" soft-
ware is also required to make the settings.
More information about configuring the Ethernet interface can be found in the "Ethernet"
operating instructions.
(1) Wire-feed unit

(1) (2) RCU 5000i remote control option
(3) Power source
(2) (4) PC, laptop or touch screen with
Fronius Xplorer software
(5) LocalNet/RS232 interface
(3)
(4) (5)
Assigning an IP To identify a power source uniquely within a network, it must be assigned a numeric ad-
address dress (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 fire- By assigning a firewall IP address, access to the power source can be restricted to one
wall IP address 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".
10
Fronius Xplorer overview
Fronius Xplorer overview
EN
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 safe-
ty rules
NOTE! Due to software updates, you may find that your device has certain func-
tions that are not described in these operating instructions or vice versa. Individ-
ual illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.
IMPORTANT! To ensure system stability, make sure that Windows updates are installed
regularly (update.microsoft.com).
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 avail-
able on the network.
2. The work level
provides information about the welding system configuration
permits access to the operation of the power source, including background menu
displays a view of the saved jobs. If enabled, this can be changed and managed
(set value)
if enabled: contains welding data documentation (actual value documentation)
if an RCU 5000i remote control is connected

records parameter changes, change of user, firmware updates and any errors
that have occurred
performs a statistical analysis of the welding parameters
IMPORTANT! To record the current welding system data, Fronius Xplorer must be activat-
ed during welding and the RCU 5000i remote control connected (data documentation can
be enabled if required). Data that was recorded on the RCU 5000i remote control's Smart-
Media card can, however, be loaded into the program at a later date.
Browser level The browser level provides an overview of the status and location of the installed welding
overview systems.
13
(1)
(6)
TPS 5000 CMT

(10.4.146.244)
TPS 5000 TPS 5000 CMT TPS 4000 MW 4000 TIME 5000 Digital
(A) (10.4.2.120) (10.3.4.102) (10.2.2.220) (10.5.2.010) (10.4.2.122)
(B)
TIME 5000
(2)
(10.4.146.230)
(C) DeltaSpot 1 DeltaSpot 2 DeltaSpot 3 DeltaSpot 4 DeltaSpot 5
(5) (10.4.2.129) (10.3.4.145) (10.2.2.232) (10.5.2.246) (10.4.2.090)
! (D)
DeltaSpot 1
(10.2.130.201)
? (E)
DeltaSpot 4
(10.2.130.204) (3)
(4)
Browser level
(1) Fronius Xplorer bar

Overview showing progress of opened folders
(2) Scroll bar

For moving the screen view where there are more systems installed than can be
displayed on screen
(3) Subfolder overview

Overview of the systems in the open folder
(4) Status overview with buttons

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

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

Press the browser button to exit the work level and return to the browser level
Work level over- The work level allows access to all welding system settings. Any deviations from normal
view 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.
14
(1) *
EN
Place / .... (2)
F2 F3 F4 F5 F6 F7 F8
TPS 5000 CMT
(10.4.146.244) Overview Panel Jobs Doku LogBook Statistic Diagram
(5)
TIME 5000
(10.4.146.230)
TPS5000 (No:15440923)
FP25
TPS5000 (No:15440923) (3)
POWERMAG-OS 4.2.4
Weld Process Regulator 5.0.100
VR7000 -CMT
DB 0503 5.0.95
UST2BV1.4B 1.4.1
DeltaSpot 1 BPS53 V0.3A 0.3.0.
(10.2.130.201) Ethernet-Gate (No:15440923)

FP25
FP25_OS 1.21.14
RCU5000i (No:15050216) FP25 V1.6A 1.6.0
DeltaSpot 4
(10.2.130.204)
LN Router
(4)
Work level
* Available depending on option pack
(1) Location path of welding system

Shows name and location of the selected welding system
(2) Close welding system button

By pressing the "Close welding system" button, the welding system is removed
from the selection bar
(3) Licence manager

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

For navigating and working in the available worksheets
(5) Activated welding system in the selection bar

By activating a welding system, the user is taken to the work level of the welding
system
Buttons at the
Browser button
browser level
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 pow- Power source locations are defined using the following folder symbols:
er source location
15
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/Pro-
duction cell/
The type and status of the welding system are shown in the lowest folder level
System compo-
Power source symbol
nent symbols
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
16
System status
EN
(1) System activity status symbol:
symbols
Welding active
Arc is burning
(1) (2) System status symbol:
(2) Status OK
System working properly
(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 over-
Place / ....
view
F2 F3 F4 F5 F6 F7 F8
TPS 5000 CMT
(1) (2)
(1) 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 an-
other 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
17
18
Menu - Tools
Options
EN
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 cur-
rency 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 Interna-
tional\Fronius Xplorer". The user can select a preferred storage location in this menu. Se-
lect a network drive as the location so that the same data can be accessed from several
PCs.
LocalNet serial Serial interfaces

ports 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. Af-
ter the machine has been selected, Fronius Xplorer and the LocalNet server must be re-
started.
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 1 Open the menu "Tools - Options - Login"
via OPC Activate the "OPC" login interface
2
3 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.)
4 Add required user levels
5 Enter admin level
6 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 Fronius Xplorer can be assigned to a production area. A USB stick can be enabled for a
via the UsbKey number of production areas (Fronius Xplorer).
1 Open the menu "Tools - Options - Login"

2 Activate the "UsbKey" login interface
3 Enter the name of the production area under "Name"
4 Enter a password for the production area under "Password"
5 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:
1 Insert USB stick into the PC
2 Click the "UsbKey administration" menu item in the "Tools" menu
The "UsbKey administration" window opens
3 Select the desired USB stick under "Create or modify a UsbKey on the drive"
4 Select the desired production area under "For the production area"
5 Enter the password for the production area selected above under "Password"
Click "Edit" to enter other user information

1 Enter "User number"
2 Enter "Name"
3 Select "Profiles" (can be edited under "Tools - User profiles")
4 Enter "Pin"
5 Enter the "Master password" for the production area
6 Click "Save"
22
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.
EN
If the USB stick is disconnected, Fronius Xplorer immediately switches to observation
mode.
23
User settings
General In user management, various users can be assigned individual user profiles.
Permissions can be granted in the user profiles. User profiles can be created under "Tools
- User profiles".
The created profiles are assigned to the various users in the "Tools - User management"
menu.
The "User profiles" and "User management" menus can only be accessed by users with
the "Administrator" user profile.
Creating a new 1 Open the "User profiles" menu ("Tools - User profiles")
user with a new Click the "New" button to create a user profile
2
user profile
3 Enter the name and press "Enter"
4 Grant the required permissions to the newly created user profile by checking or un-
checking the box
In the next step, the user profile that you have just created will be assigned to a newly cre-
ated user:
1 Open the "User management" menu ("Tools - User management")
2 Press the "New user" button to create a user
3 Enter the user name (= login name) and assign the user profile
Managing the The user profile menu can only be accessed by users with the administrator user profile.
user profiles
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
Change password
Arc welding
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
User manage- The User management menu can only be accessed by users with the administrator user
EN
ment 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 Example of a user logging on and off automatically:

off automatically - The "Admin" user (user profile 1) logs on and carries out work on the system
- "Admin" forgets to log off
- Automatic log off is activated. "Admin" is automatically logged off the system after the
specified time.
- Automatic log on is specified for the user "User 1"

- "User 1" is logged on to the system without being prompted to enter a password
Changing the
1 Press the "Change user" button
user
2 Enter the user name and password
3 Press Enter
25
Splitting the window
Splitting the win- If split window is enabled under "Tools - Split window", then as many worksheets as re-
dow quired can be displayed side by side/below one other. To show/hide the welding systems,
click the relevant item in the selection list.
Place / .... Place / ....

F2 F3 F4 F2 F3 F4
TPS 5000 CMT
(10.4.146.244) Overview Panel Jobs D Overview Panel Jobs D
TIME 5000 TPS 5000 (No:15440923) TPS5000 (No:15440923) TIME 5000 (No:15440924) TPS5000 (No:15440924)
(10.4.146.230) FP25
POWERMAG-OS 4.2.4 POWERMAG-OS 4.2.4
Weld Process Regulator 5.0.100 Weld Process Regulator 5.0.100
VR7000 -CMT VR7000 -CMT
DB 0503 5.0.95 DB 0503 5.0.95
UST2BV1.4B 1.4.1 UST2BV1.4B 1.4.1
DeltaSpot 1 BPS53 V0.3A 0.3.0. BPS53 V0.3A 0.3.0.
(10.2.130.201) Ethernet-Gate (No:15440923) Ethernet-Gate (No:15440924)

FP25 FP25
FP25_OS 1.21.14 FP25_OS 1.21.14
RCU5000i (No:15050216) FP25 V1.6A 1.6.0 RCU5000i (No:15050217) FP25 V1.6A 1.6.0
DeltaSpot 4
(10.2.130.204)
LN Router
Windows displayed side by side
"Tools - Switch window split" allows you to switch between horizontal and vertical split.
26
Browser level
Browser level
EN
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 Folder structure:

browser
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 The browser view can be switched to a view that shows systems with the same status.
browser view to
status view 1 Press the relevant button for status view in the browser view
Ready 10
Errors 1
! Warnings 1
29
Systems with the same status are displayed in a table:
TPS 5000 CMT

(10.4.146.244)
DeltaSpot 3 (11.4.22.298)
Installed units 15
/Path/...
Ready 10
TPS 4000 (10.4.146.244)
TIME 5000
(10.4.146.230) /Path2/....
Errors 3
TPS 5000 CMT (10.4.141.221)
! Warnings 1
/Path3/...
DeltaSpot 1 ? Offline 2
(10.2.130.201)
2 Click the mouse to open the relevant system, provided that the firewall IP address is
configured for the PC trying to access it, or no firewall IP address is set and there are
fewer than 4 users logged in.
Copying a weld- To access the work level of a welding system, firstly copy the welding system to the selec-
ing system to the tion bar. It is possible to copy as many welding systems to the selection bar as desired.
selection bar 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:

1 Access the folder level of the desired production cell
2 Click the mouse to copy the welding system to the selection bar
TPS 5000 CMT

(10.4.146.244)
TPS 5000 TPS 5000 CMT TPS 4000 MW 4000
Installed units 15 (10.4.2.120) (10.4.146.244) (10.2.2.220) (10.5.2.010)
Ready 10
Errors 3
3 To copy more welding systems to the selection bar, repeat this process
Welding systems from various locations can be copied to the selection bar. Welding sys-
tems copied to the selection bar are retained, regardless of the current folder level.
Removing a weld-
ing system from
the selection bar Place / .... (2)
F2 F3 F4 F5 F6 F7 F8
TPS 5000 CMT
(1)
TIME 5000 TPS5000 (No:15440923) TPS5000 (No:15440923)

(10.4.146.230) FP25
POWERMAG-OS 4.2.4
VR7000 -CMT
DB 0503 5.0.95
UST2BV1.4B 1.4.1
Removing a welding system from the selection bar
1 Select the welding system that is to be removed from the selection bar (1)
2 Press the Close welding system button (2)
30
Alternatively, right-click on the welding system to be removed from the selection bar and
confirm by clicking Close.
EN
31
32
Worksheets
Worksheet overview
EN
Worksheet over- The Worksheet overview provides information about:
view - 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:
F2 F3 F4 F5 F6 F7 F8
Overview Panel Jobs Doku LogBook Statistic Diagram
TPS5000 (No:15440923) TPS5000 (No:15440923)

FP25
POWERMAG-OS 4.2.4
VR7000 -CMT
DB 0503 5.0.95
UST2BV1.4B 1.4.1
BPS53 V0.3A 0.3.0.
Ethernet-Gate (No:15440923)
FP25
FP25_OS 1.21.14
RCU5000i (No:15050216) FP25 V1.6A 1.6.0
LN Router
E.g.: system configuration with TPS 5000 power source
Buttons and sym-

Refresh button
bols in the Work-
Updates system information
sheet overview
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 The backup file contains all the welding system data. The backup path is specified and
restoring data saved under the serial number of the power source (Mt Documents/Fronius International/
arc/specific/serial no./backup). It is, however, possible to specify the backup path individ-
ually.
Creating the backup:

1 Press the "Backup" button
2 Select the storage location and confirm by pressing the "Save" button
The backup is created
Restoring the backup:

1 Press the "Restore" button
2 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 auto- The automatic backup backs up data at a defined interval.

matic backup
1 Press the "Options" button
2 Press "Automatic backup settings"

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

36
EN
2 Press "Master backup"
3 Select master backup and confirm by pressing "Open"
4 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.
2 Press "Deactivate master backup"
Displaying con- 1 Press the "Options" button

nection status
2 Press "Show connection settings"
Connection settings
IP address 10.4.146.245
Firewall IP 10.4.146.246 Active connections 10.4.120.7

0.0.0.0
0.0.0.0
0.0.0.0
Default gateway 10.4.146.245 Modbus UDP Fronius
Subnet mask 255.255.248.0 Modbus firewall 170.170.170.170
Port number 15001 Modbus port number 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. Set-
ting 0.0.0.0 means that no access restrictions have been set, and up to 4 computers can
access the power source.
Active connections XX.X.XX.XX
Displays the computers currently connected to the power source
37
Saving the device When documenting data, the current device configuration can be exported and saved on
configuration the data medium as a text file.
2 Press "Save device configuration"

3 Select the location and save the file
Configuring the 1 Press the "Options" button

system name and
location
2 Press "Machine configuration"
Machine configuration
New folder
Machine path:
Machine path: TPS 4000 (10.4.146.245)
3 Press the "New folder" button
4 Enter a name for the location and confirm or press the "New folder" button repeatedly
until the desired folder structure is created
5 Fill in the field for "Machine name" and confirm details
IMPORTANT! The "Machine" is always saved in the highlighted folder. If there are subfold-
ers with no machines under this highlighted folder, the subfolders are deleted automatical-
ly. The "Machine" can be moved to another folder at any time.
38
Control panel worksheet
EN
Control panel The control panel is modelled on the control panel of the connected power source. In ad-
worksheet dition, functions can be executed directly through shortcuts on the PC keyboard. The inte-
grated adjusting dial (2) makes the touchscreen easy to use.
Further information about the control panel function can be found in the power source op-
erating instructions.
NOTE! If the RCU 5000i remote control is connected to the power source, oper-
ation via the Control panel worksheet is no longer available. The current param-
eter settings are displayed on the screen. The buttons on the control panel cannot
be selected.
IMPORTANT! For safety reasons, the wire threading function is not available.
F3
Panel
(1)
(2)
Example: Comfort/TPS 5000 power source control panel
(1) Control panel options menu

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

For adjusting the currently selected welding parameter using the mouse or touch-
screen
Operating the All welding parameters can be adjusted using shortcuts on the PC keyboard. Press the
control panel us- space bar to display the shortcuts available.
ing the keyboard
39
+
A V -
S D O P N M E R
Example: displaying the shortcuts by pressing the space bar
Accessing a pow- To access a power source set-up menu:

er source set-up
menu
1 Select and hold down the Setup button
LOCK
CK
CK 2 Keep the left mouse button pressed down and move the cursor to Lock
3 Release left mouse button
4 The available set-up menus are displayed
5 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 Mai
Main
Menue Menue
Example: displaying available set-up menus
40
Jobs worksheet
EN
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 op-
tion must be enabled on the power source.
Connecting the RCU 5000i remote control increases the number of locations from 100 to
1000.
(2) (1)
(3)
(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
(2) Sizing bar

- Adjust window to desired size
- Double-click to change and adjust the view automatically
(3) Job/job groups scroll bar

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

For selecting available functions
(5) Job groups

- Select all jobs in the group by clicking the mouse
- Double-click to edit job group names
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
(7) Parameter display

- Shows current parameter settings and parameter changes
- Unconfirmed parameter changes are shown in yellow
(8) Welding parameter scroll bar

For scrolling in the parameter display
Buttons and sym-

Power source button
bols in the Jobs
The jobs are transferred from the machine to Fronius Xplorer
worksheet
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 con-
nection 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
IMPORTANT! Jobs that have not yet been synchronised with the power source are iden-
tified by a grey dot.
EN
Displaying job Click mouse to select a job. Show data in the parameter display (7).
data
Copying and Copying a job, jobs or job group

pasting jobs
1 Select a job, jobs or job group
2 Press the "Copy" button or Ctrl + C
3 Select location
4 Press the "Paste" button or Ctrl + V
Copying a job, jobs or job group from one power source to another

2 Press the "Copy" button or Ctrl + C
3 Select a power source for pasting the jobs

4 Select location
5 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 car-
ried out on the target power source, an error message appears.
Exporting/import- Exporting a job, jobs or job group to data medium

ing jobs
3 Press the "Export" option

4 Select storage location and save job(s)
Importing jobs from data medium
1 Select the desired paste location in the "Jobs" worksheet
43
1 Press "Import"
2 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 1 Select jobs

into an external Copy jobs to the clipboard by pressing the "Copy" button or Ctrl + C
2
document
3 Open a spreadsheet program, e.g. Excel, or a word processing program, e.g. Word,
and select "Paste" from the "Edit" menu, or press Ctrl + V
Attaching a file to 1 Select job

a job/opening an Press the "Attach file" button
2
attached file
3 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) (2)
Opening a file attachment
44
1 Select job with file attachment
2 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 1 Select a job, jobs or job groups

2 Press the "Delete" button
Changing a job 1 Select job

2 Press the "Change" button
3 Change welding parameters (see power source operating instructions)
Job history A detailed view of the selected job can be called up under Job history. Any changes made
to a job are recorded and shown here. Old versions of the job can be loaded onto the ma-
chine again.
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
Start Time Partnumber Seam Imin Arc Time Imean Imax Umin Umean Umax Gas wire E Q Limit
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
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:
1 Highlight welding data

2 Right-click and press "Load details"
Buttons and sym-

Welds symbol
bols in the Docu
Documents the welding data (actual data) for the entire weld seam
worksheet
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
Load welding data button
Displays and loads recorded welding data
EN
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 de- 1 Press the "Options" button

fault settings for
consumption fig-
ures
2 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 Welding data can be saved automatically in an Excel file after every weld. The file location
export can be specified in the "Export wizard".
2 Press "Excel export"
If "Excel export" is enabled, the data is saved in an Excel file after every weld.
Switching weld- "Data Receiver ON" must be enabled in the options menu to run the welding data docu-
ing data record- mentation.
ing on and off
2 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 synchroni- In order to obtain exact start and error times, synchronisation with the system time must
sation be carried out. Synchronisation may be carried out automatically or manually.
Automatic time synchronisation
2 Press "Automatic time synchronisation"
48
This setting is saved for each power source.
If a RCU 5000i remote control is connected, then automatic time synchronisation is
switched off as standard. If no RCU 5000i remote control is connected, then a prompt ap-
EN
pears for automatic time synchronisation when the system is first opened.
Manual time synchronisation
2 Press "Synchronise time now"
Displaying welds/ Completed welds are shown in the Welds menu. One weld seam consists of one or several
consumption fig- weld seam sections and lasts from welding start to welding stop. The completed welds are
ures menu 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.
1 Highlight one or more weld seams

2 Right-click and press "Consumption figures"
3 Consumption figures are shown
Welding parameter OK symbol

Relates to the number of highlighted weld seams
Exceeded limits symbol

Error symbol
Welding wire consumption symbol

Shielding gas consumption symbol

Weld time symbol

12
Energy consumption symbol

Total costs symbol

Showing as a Show weld seam as a graph:

graph
1 Select a weld seam
2 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
Weld seam sec- The Weld seam sections menu shows the individual sections of a weld or of individual jobs.
tions menu
e.g. starting current phase/main current phase/final current phase
I (A)
(1)
t (s)
(2) (3) (4) (5) (6)
(A1) (A2) (A3)
Sections/sections based on special 2-step mode
(1) Monitoring active

(2) Starting current phase
(3) Slope 1
(4) Main current phase
(5) Slope 2
(6) Final current phase
(A1) Section 1
(A2) Section 2
(A3) Section 3
The sequential weld seam sections are numbered and listed consecutively.
F4
Docu
Sections
(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
Weld seam sections display
(1) Part number

(2) Weld seam
(3) Section
(4) Job
(5) Weld time
(6) I mean (average current)
(7) U mean (average welding voltage)
(8) vD mean (average wire feed speed)
50
(9) vS mean (average welding speed)
(10) Limit (current and voltage limits exceeded)
EN
(*) Displayed values can be adjusted by right-clicking. By holding down the left mouse
button, the displayed values can also be moved to a desired position and in-
creased/decreased.
Parameter set val- Displays the parameter command values set on the RCU 5000i remote control
ues menu
F4
Docu
Command values
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (*)
displaying parameter set values according to the RCU 5000i
(1) Part number

(2) Weld seam
(3) Section
(4) Job
(5) Operating mode
(6) PrgNo (program number)
(7) Current
(8) Voltage
(9) Wire feed speed
(10) ALC (arc length correction)
(11) DYN (arc force dynamic correction)
(12) Options
(*) The values displayed depend on the welding process set, and can be adjusted in-
dividually by right-clicking on the header. By holding down the left mouse button,
the displayed values can also be moved to a desired position and increased/de-
creased.
Actual welding Displays the parameters that were actually used for a weld seam. The recording time in-
parameter values terval depends on the value set on the RCU 5000i remote control (0.1 - 9.9 s).
menu
F4
Docu
Actual values
(*)
displaying actual welding parameter values according to the RCU 5000i
(*) The values displayed depend on the welding process set, and can be adjusted in-
dividually by right-clicking on the header. By holding down the left mouse button,
51
the displayed values can also be moved to a desired position and increased/de-
creased.
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
errors occurred
(1) Time of error

(2) Weld seam
(3) Job
(4) Operating mode
(5) Error number
(6) Duration
(7) Description
(*) The values displayed depend on the welding process set, and can be individually
adjusted by right-clicking on the header. By holding down the left mouse button, the
displayed values can also be moved to a desired position and increased/de-
creased.
Loading and dis- The welding data is automatically saved on the data medium, and can be identified using
playing recorded the date, start and end time.
welding data
Opening welding data:
1 Press the "Open" button
2 Select welding data
RCU data symbol

Smart Media
Data imported from the SmartMedia card in the RCU 5000i remote control
1 Confirm
2 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
At the same time, the screen view is paused and the "Pause" button is enabled.
EN
3 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 1 Press the "Options" button

data as an Excel
file
2 Press "Export wizard"

The "Export wizard" window opens
3 Select storage location
4 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
5 Confirm
6 Press the "Export" button
The welding data can now be opened in Microsoft Excel.
Importing weld- Import saved welding data, e.g. from a SmartMedia card
ing data
2 Press "Import"
3 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
Weld time
welding data
Weld time from the beginning to the end of a weld seam (time during which the arc is ac-
tive)
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++ Exceeding a current/voltage limit
I--/U-- Falling below a current/voltage limit
Limits that have been exceeded/not reached are displayed in
M1++ combination Exceeding the motor current limit for the wire-feed
M2++ unit
vD++/vD-- Exceeding the motor current limit for the wire-feed unit
vS++/vS-- 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 SynchroPulse option active
Spatter-free ignition 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
Weld seam
Weld seam (from the start of welding until welding stops)
EN
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 enter-
ing 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 mo-
ment of droplet transfer.
HotStart (rod electrode)
Increases the set welding current in the starting current phase
Unit %
56
Log book worksheet
EN
Log book work- All errors/events that occurred during operation are recorded in the log book worksheet.
sheet
F6
Logbook
All events
Start time Key name

dd.mm.jjjj hr:min:sec user name
dd.mm.jjjj hr:min:sec
dd.mm.jjjj hr:min:sec user name
Log book worksheet
Buttons and sym-

Log book options menu
bols in the Log
For setting the storage location of the Excel file using the export wizard
book worksheet
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 con-
trol
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 da-
ta.
Save log book data as an Excel file button
Data is saved as an Excel file in the desired location
Loading and dis- The log book data is automatically saved on the data medium and can be identified using
playing log book the date, start and end time.
data
Open log book data
1 Press the "Open" button
57
2 Select log book data
3 Confirm
4 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 1 Press the "Options" button

data as an Excel
file
2 Press "Export wizard"

3 Select location and confirm
A subfolder with a serial number is generated automatically
4 Press the "Export" button
Log book data can now be opened in Microsoft Excel.
58
Statistics worksheet
EN
Statistics work- The Statistics worksheet analyses the documented welding data. The statistics are dis-
sheet played as a bar chart. Welding parameters shown in green are within the specified limits.
If the limit values are exceeded, the welding parameters are displayed in red.
IMPORTANT! In order to use the Statistics worksheet, limit values for the Q-Master func-
tion must be defined on the RCU 5000i remote control, and warning or shutdown must be
enabled in the Reaction menu item.
F7
Statistics
Welds Welds Welds Welds
Job
Job 79
79 80 81 82 83 84 85 86
I min [A] 99,9
6 10
I max [A] 99,9 13 20
U min [V] 30,03 8 40
20
25
U max [V] 30,03
20
7
10
I 2 10 21
2
I 1 2
U 2
U 5
vD 2
vD 1
M1 2
M2 5
Statistics worksheet
(1) Job number

(4) (2) Number of weld seams within the
specified limit values
Job 79 79 (1) (3) Number of weld seams outside the
I min [A] 96,8
specified limit values
I max [A] 99,9
U min [V] 26,07 8 (2) (4) Current and voltage extreme value
U max [V] 30,03
display. The display relates to the
total number of welded jobs. The
I 2
display saves the smallest and gre-
I 1 2 (3) atest value that occurred while the
U 2
5
selected job was being welded.
U
vD 2 (5) Detailed view of the number of ex-
vD 1 ceeds of the upper and lower limit
M1 2 values for
M2 5 - Voltage and current
- Wire feed speed
(5) - Motor currents
statistics: Job bar
Buttons and sym-

New statistics bar symbol
bols in the Statis-
Welds ld
Creates a new statistics bar for a job or a weld seam

tics worksheet
Welds
Delete statistics bar symbol
Deletes a statistics bar
59
Welds W ld
Empty statistics bar symbol
Edits the bar job number
Welds Job statistics bar symbol

Edits the bar job number
Ctrl button
Several bars can be selected by holding the button down (touchscreen).
Creating a new 1 Press the "New" button

statistics bar
Welds ld
2 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:

1 Select the statistics bar
2 Press the "Delete", "Reset" or "Change job" button
60
Graph worksheet
EN
Graph worksheet The graph worksheet provides a visual representation of the welding data. Different jobs
are shown in different colours.
F8
Diagram
A Current
Welds
300
Job 01
Welds
Job 02
Welds
250
Job 03
Welds
Job 04
200
150
100
50
0
0 4 8 12 16 20 24
Graph worksheet
Buttons and sym-

Add job button
bols in the Graph
Creates a new graph for the job number
worksheet
"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 us-
ing "Set graph entries"
The "Line" and "Spline" options can be found under "Graph type". If "Line" is set,
the data points in a curve are connected by a straight line. If "Spline" is set, a curve
is calculated between the individual data points and the graph no longer appears
angular.
61
Creating a new Create a new job graph
job graph
1 Press the "Add job" button
2 Enter job number in the input field and confirm
3 A colour is assigned to the job number entered, which is displayed on the screen in
the form of a button
4 Pressing the "Job XX" button displays the welding data on the screen
Hiding/showing Show/hide individual jobs using the relevant button:

jobs
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 col-
our several times by showing and hiding it.
Zoom In graphs, click the left mouse button and drag on either axis to zoom in. Press the "Single
view/general view of graph" button to show the original graph again.
62
Importing data from systems not in the network
EN
General For systems not connected to the network, there is an option to add these as virtual welding
systems in Fronius Xplorer by importing recorded welding data.
Adding a welding 1 Press the "Open file" button

system
2 Select FDO files from the SmartMedia card for the RCU 5000i remote control
3 Enter welding system serial number, if necessary
4 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

Fronuis Xplorer Software

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TYDELLIST HITSAUSTA

Fronius Xplorer overview 11

Fronius Xplorer overview ........................................................................................................................... 13

Browser level ............................................................................................................................................. 29

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

Welding system - Digital power source

If no LocalNet connection is free:

For retrospective evaluation of welding data:

Example of network for management with Fronius Xplorer

(1) Wire-feed unit

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

if an RCU 5000i remote control is connected

TPS 5000 CMT

(1) Fronius Xplorer bar

(2) Scroll bar

(3) Subfolder overview

(4) Status overview with buttons

(5) Selection bar

(6) Browser button

DeltaSpot 1 BPS53 V0.3A 0.3.0.

(10.2.130.201) Ethernet-Gate (No:15440923)

RCU5000i (No:15050216) FP25 V1.6A 1.6.0

* Available depending on option pack

(1) Location path of welding system

(2) Close welding system button

(3) Licence manager

(4) Work level

(5) Activated welding system in the selection bar

Production location symbol

Production hall symbol

Wire-feed unit symbol

Remote control symbol

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

Interface symbol (robot, Ethernet, etc.)

Gas sensor symbol

Part counter symbol

Serial interface symbol

DeltaSpot spot welding gun symbol

(3) System status symbol:

(1) Symbols in Jobs worksheet

Jobs licence, but currently no access rights

(2) Symbols in Docu worksheet

Data recording deactivated

LocalNet serial Serial interfaces

Login Automatic Windows login

Fronius Xplorer login

OPC login interface:

UsbKey login interface:

1 Open the menu "Tools - Options - Login"

Click "Edit" to enter other user information

Options Edit users

New Delete Rename

Logging on and Example of a user logging on and off automatically:

- Automatic log on is specified for the user "User 1"

Place / .... Place / ....

UST2BV1.4B 1.4.1 UST2BV1.4B 1.4.1

DeltaSpot 1 BPS53 V0.3A 0.3.0. BPS53 V0.3A 0.3.0.

(10.2.130.201) Ethernet-Gate (No:15440923) Ethernet-Gate (No:15440924)

FP25_OS 1.21.14 FP25_OS 1.21.14

Windows displayed side by side

Navigation in Folder structure:

Highest folder level: Home

Company or production location folder level

Production facility folder level