Miller | MD390000U | Owner Manual | Miller INSIGHT CORE 14-PIN MODULE CE User manual

Miller INSIGHT CORE 14-PIN MODULE CE User manual
OM-260 430E
2015−05
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Submerged Arc (SAW) Welding
Description
Advanced/Automated Welding System
Insight Coret
14-Pin Module CE
Visit our website at
www.MillerWelds.com/ams
File: Advanced Manufacturing Systems
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − QUICK INSTALLATION GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. License Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Compatibility Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Connections and LED Designations On Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Mounting And Connecting The Insight Core Module To The Welding Power Source . . . . . . . . . . . . . . .
4-6. Mounting And Connecting The Insight Core Module To Sub Arc Digital Series
w/Low Voltage Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Mounting And Connecting An Insight Core Module To Sub Arc DC 650/800/1000/1250
Series Power Source Using 115V Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Mounting And Connecting An Insight Core Module To Sub Arc AC/DC 1000/1250 And
Summit Arc 1000 Series Power Sources Using 115V Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Downloading Connectivity Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Downloading And Installing Insight Core Setup Application To A PC . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Running Configuration App For Installation Of Firmware And Connection Criteria . . . . . . . . . . . . . . .
4-12. Prepare Firmware For Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Verification Of Accessability Before Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Configuring The Type Of Insight Coret Network Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Firmware Update Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Determining Device Serial Number And License Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Registering Initial Device And Creating An Account . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Registering Additional Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. Setting Up A Work Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Setting Up A Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
14­pin Insight Core Module
Stock Number
301072
Council Directives:
• 2004/108/EC Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain Hazardous Substances in electrical and electronic equipment
Standards:
• IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
December 01, 2014
_____________________________________
___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
269469A
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2013−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-260 430 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-260 430 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D
D Sparks can cause fires — keep flammables away.
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
MOVING PARTS can injure.
ARC WELDING can cause interference.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-260 430 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-260 430 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2013−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
D
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
D
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
D
D
D
D
D
D
D
D
D
D
D
D
D
D
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
OM-260 430 Page 5
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
D Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les
outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité
de fumées et de gaz auxquels est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
OM-260 430 Page 6
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent
de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES
(CEM) peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
LE BRUIT peut endommager l’ouïe.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que les
bouteilles de gaz font normalement partie du
procédé de soudage, les manipuler avec
précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application
spécifique; les maintenir ainsi que les éléments associés en bon
état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur
lors de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité suffisante pour lever
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
OM-260 430 Page 7
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D
D
D
D
D
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer
des véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
OM-260 430 Page 8
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D
D
D
D
D
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les CEM peuvent créer des interférences
avec certains implants médicaux comme des stimulateurs cardiaques.
Des mesures de protection pour les porteurs d’implants médicaux
doivent être prises: Limiter par exemple tout accès aux passants ou
procéder à une évaluation des risques individuels pour les soudeurs.
Tous les soudeurs doivent appliquer les procédures suivantes pour
minimiser l’exposition aux CEM provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-260 430 Page 9
OM-260 430 Page 10
SECTION 3 − QUICK INSTALLATION GUIDE
1.
Download and print Network Connectivity Survey from https://insight.millerwelds.com/download. Have form completed by IT department.
2.
Install Insight Core Configuration Utility from https://insight.millerwelds.com/download to a PC.(For more information, See Section 4-10.)
3.
Open Insight Core Configuration Utility using icon that was created on desktop. (See Figure 4-11.)
4.
Update firmware if newer revision is available. Skip to step 5 if firmware is current. (For more information, see Section 4-12.)
a. Click the hyperlink text “here” in Configuration Utility. Download newest firmware files from website.
b. Click Locate Files button in Configuration Utility and follow prompts.
5.
Using the completed Network Connectivity Survey, fill in the connection information. (For more information, see Section 4-14.)
. If using static addressing, the PC must be connected to the Insight Core with an ethernet cable at this point. Follow instructions in Section 4-14.
6.
Insert USB drive into PC.
7.
Click the Save button to save firmware and connection information to USB drive.
8.
Remove USB drive from PC and take it to Insight Core device to be updated and connected.
9.
Insert USB drive into Insight Core Device and turn on welding power source.
a. The Network LED (yellow) will flash multiple times. This means that data is being transferred to Insight Core device and files will be written
to USB drive for registration.
b. If the Network LED does not flash, try using a different USB drive. This means data was not transferred between the Insight Core device
and the USB drive.
10.
Once device is connected to the network (yellow LED is on) and to the internet (green LED is on), remove the USB drive.
. If connecting more than one Insight Core, repeat Steps 9 and 10 for each device with the same USB drive.
11.
Take the USB drive back to a computer that is connected to the internet.
12.
Open a web browser on the computer and browse to https://insight.millerwelds.com/.
13.
Click on First Time Set Up button.
14.
Enter data in every field. To find Core Device Serial Number and License Key, see Step 15.
15.
Insert USB drive into computer and open to view files and folders. (For more information, see Section 4-16.)
16.
Open the Device License Key folder.
. One .TXT file will be written for each device being installed.
17.
Open .TXT file associated with the serial number to be registered.
18.
Copy and Paste Serial Number and License Key from .TXT file to corresponding fields on registration webpage.
19.
Click the Save button.
OM-260 430 Page 11
SECTION 4 − SPECIFICATIONS AND INSTALLATION
7
4-1. License Agreement
You have acquired a device (Insight Core) which includes software licensed by Miller Electric Mfg. Co. Such software products, as well as associated
media, printed materials, and “online” or electronic documentation for such software are protected by international intellectual property laws and
treaties. The software is licensed, not sold. All rights reserved.
4-2. Compatibility Information
Compatible Power Sources
Deltaweld
Dimension
Goldstar
Invision
XMT
Alumapower
302
302
302
350 MPa
304 CC/CV
350 MPa
452
452
452
352 MPa
350 CC/CV
450 MPa
652
652
652
354 MP
350 MPa
1000
450MPa
450 CC/CV
NT w/Arc Reach
456MP
450 MPa
NT 450
456 P
456 CC/CV
650
Deposition is reported with 14 pin compliant welding power sources using MPa wire feeders.
Wirefeeders requiring 115 VAC are not compatible with this unit.
Units requiring High Frequency for TIG welding are not compatible with this unit. For information regarding Miller Power Sources not
included in the list, please call ISG Service at 920−954−3809.
Compatible SubArc Power Sources
SubArc Digital Series
SubArc Series
DC 650 Digital*
DC 650**
DC 800 Digital*
DC 800**
DC 1000 Digital*
DC 1000**
DC 1250 Digital*
DC 1250**
AC/DC 1000 Digital*
AC/DC 1000**
AC/DC 1250 Digital*
AC/DC 1250**
Summit Arc 1000**
Summit Arc 1250**
*SubArc Digital Series power sources using a low voltage SubArc Interface Digital/Analog require a SubArc Digital Series to Insight
Core Adapter 301 295.
**SubArc power sources using 115V Accessories, including the HDC 1500 Series controller, require a 115V to 14-Pin Adapter Cord 301 259.
. Please contact Miller for assistance in selecting the correct adapter for your needs.
OM-260 430 Page 12
NOTICE
Use ONLY with compatible
power sources or equipment
damage may occur.
• Do not use with Dynasty®, Maxstar®, or
Syncrowave® power sources.
• Read Owner’s Manual to check
compatibility.
AVIS
Utiliser des sources de courant
compatibles SEULEMENT,
sinon un bris d'équipement
pourrait survenir.
• Ne pas utiliser avec les sources de
courant DYNASTY, MAXSTAR ou
SYNCROWAVE.
• Lire le manuel d'opérateur pour vérifier
la compatibilité.
267353-A
Ref. 267 353-A
4-3. Environmental Specifications
A. IP Rating
IP Rating
IP21
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21 2014−06
B. Information On Electromagnetic Field (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
C. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
ce-emc 3 2014-07
OM-260 430 Page 13
4-4. Connections and LED Designations On Module
Ethernet
Port
Power
LED
Green
Internet
LED
Green
Network
LED
Yellow
USB
Port
Figure 4-1. Location Of USB Port, Ethernet Port, And LEDs On Insight Module
4-5. Mounting And Connecting The Insight Core Module To The Welding Power Source
2
1
2
3
Welding Power Source
14-Pin Insight Core Module
14-Pin Control Cable To
Power Source
4 14-Pin Control Cable From
Feeder
5 Positive (+) Weld Cable
6 Negative (−) Weld Cable
7 Gas Hose
8 Wire Feeder
9 Mig Gun
10 Work Piece
11 Gas Cylinder
1
2
11
1
. Module can
be mounted
on either side of welding
power source.
2
6
3
5
4
7
10
8
9
Ref. 803 502-A / 245 855-A
OM-260 430 Page 14
4-6. Mounting And Connecting The Insight Core Module To Sub Arc Digital Series
w/Low Voltage Accessories
1
2
3
1
2
4
Welding Power Source
14-Pin Insight Core Module
14-Pin Control Cable To
Power Source
Insight Core to SubArc
Digital Series Adapter
. SubArc Digital Series power
sources using a low voltage
SubArc Interface Digital/Analog require optional SubArc
Digital Series to Insight Core
Adaptor 301295. Contact
Miller Electric for assistance
in selecting the proper adaptor for your SubArc power
source.
5
2
6
SubArc Interface
Digital/Analog
SubArc Control Cable
. Module can
be mounted
on either side of welding
power source.
5
1
2
3
6
4
272 591-A / 272 594-A
OM-260 430 Page 15
4-7. Mounting And Connecting An Insight Core Module To Sub Arc DC 650/800/1000/1250
Series Power Source Using 115V Accessories
1
2
3
1
2
4
Welding Power Source
14-Pin Insight Core Module
14-Pin Control Cable To
Power Source
115VAC To 14-Pin Adapter
Cord
. SubArc power sources using
115V Accessories, including
the HDC 1500 Series controller, require 115V to 14-Pin
Adapter Cord 301 259. Contact Miller Electric for assistance in selecting the proper
adaptor for your SubArc power source.
2
5
6
HDC 1500 A/DX Controller
Control Cable
. Module can
be mounted
on either side of welding
power source.
1
5
6
3
2
4
272 592-A / 272 595-A
OM-260 430 Page 16
4-8. Mounting And Connecting An Insight Core Module To Sub Arc AC/DC 1000/1250 And
Summit Arc 1000 Series Power Sources Using 115V Accessories
1
2
3
1
2
4
Welding Power Source
14-Pin Insight Core Module
14-Pin Control Cable To
Power Source
115VAC To 14-Pin Adapter
Cord
. SubArc power sources using
115V Accessories, including
the HDC 1500 Series controller, require 115V to 14-Pin
Adapter Cord 301 259. Contact Miller Electric for assistance in selecting the proper
adaptor for your SubArc power source.
5
6
2
HDC 1500 A/DX Controller
Control Cable
. Module can
be mounted
on either side of welding
power source.
3
4
6
5
2
1
272 593-A / 272 589-A
OM-260 430 Page 17
4-9. Downloading Connectivity Survey
In order to ensure proper connectivity, visit the Insight Core Download page at https://insight.millerwelds.com/download.
Download and print the Network Connectivity Survey Form.
Ask your corporate IT department to complete the survey.
4-10. Downloading And Installing Insight Core Setup Application To A PC
1.
To download the Insight Core Setup Application, visit the webpage at https://insight.millerwelds.com/download.
2.
Click on the file name, and save it to your desktop (see Figure 4-2).
Figure 4-2. Download Web Page
3.
Once the application is downloaded, double click the desktop icon to install the application on your PC (see Figure 4-3).
Figure 4-3. Installation Application Icon
OM-260 430 Page 18
4.
Click Next on the Setup Wizard screen to begin installation to your computer (see Figure 4-4).
Figure 4-4. Setup Wizard Screen
5.
Read the End-User License Agreement, and check the box to accept. Click Next to continue (see Figure 4-5).
Figure 4-5. End-User License Agreement
OM-260 430 Page 19
6.
By default, the application will automatically select the local drive on your computer with sufficient space to install the program. Click Next to
accept this default location, or change the path before proceeding (see Figure 4-6).
Figure 4-6. Destination Folder Screen
7.
Click Install to complete the installation of the Configuration Utility (see Figure 4-7).
Figure 4-7. Utility Install Screen
OM-260 430 Page 20
8.
The installation process will display the status on screen until complete (see Figure 4-8).
Figure 4-8. Install Status Screen
9.
Click Finish when the application has completed the installation process (see Figure 4-9).
Figure 4-9. Install Completed Screen
OM-260 430 Page 21
10.
The application is now installed on your computer. The program can be found inside All Programs in a folder named Miller Insight Core Configuration (see Figure 4-10). A shortcut was also placed on your computer’s desktop during installation (see Figure 4-11).
Figure 4-10. Application Program Folder
OM-260 430 Page 22
4-11. Running Configuration App For Installation Of Firmware And Connection Criteria
. The application provides the ability to update the firmware on your Insight Core module, set the device for a wired Ethernet connection, or set it
for a wireless Wifi connection.
1.
To run the application, double-click on the shortcut that was automatically installed on your desktop, or on the program (.EXE) file inside the
application listed in All Programs (see Figure 4-11).
Figure 4-11. Setup Application Shortcut
2.
The application will automatically check to see if a newer version of the application exists. If so, you will be prompted to replace your version with
the most recent version (see Figure 4-12).
Figure 4-12. Checking For Newer Version Of Application
If you are running the application on a computer that is not connected to the internet, this automatic version check will fail, enabling you to continue using
the current version you have installed by clicking OK, or cancelling in order to re-establish an internet connection (see Figure Figure 4-13).
Figure 4-13. Internet Connection Message Screen
OM-260 430 Page 23
4-12. Prepare Firmware For Installation
. Before entering connectivity information you must first load the current revision of firmware from the download page. By clicking the blue text “here”
the download page will display if the computer is connected to the internet.
Figure 4-14. Checking For Latest Firmware
OM-260 430 Page 24
1.
Select the 14−pin Firmware. Save the firmware file to a location on the computer which can be easily found.
Figure 4-15. 14-Pin Firmware Selection
2.
Click the button labeled Locate Files inside the Firmware Updates box. A dialog box will open.
Figure 4-16. Locating Latest Firmware Update Files
OM-260 430 Page 25
3.
Click Browse and locate the firmware file names you downloaded previously to your computer.
Figure 4-17. Locating Latest Firmware Files
OM-260 430 Page 26
4.
Double-click on the files you plan to upgrade, placing the files inside the browse box and click OK.
Figure 4-18. Upgrade File(s) In The Browse Box
5.
Next, set the number of days you want these firmware files to be valid. (Options include 1 to 7 days. This setting will prevent an accidental
back-rev of old firmware files after this timeframe has expired.)
Figure 4-19. Locating Latest Firmware Update Files
. If only updating firmware, proceed to Section 4-15.
. For help configuring connection, proceed to Section 4-14.
OM-260 430 Page 27
4-13. Verification Of Accessability Before Connection
The Miller Insight Cloud must be accessible before the Insight Core unit will connect to a network.
Using a computer in the same location and connected to the same network as the Insight Core unit will be, navigate to http://collector.millerwelds.com.
If the connection is valid, a webpage validating the connection will appear (see Figure 4-20) and the connection process may be continued
If the webpage does not load correctly, contact your I.T. Department to resolve any potential firewall limitations before proceeding.
Figure 4-20. Insight Core Collector Webpage
OM-260 430 Page 28
4-14. Configuring The Type Of Insight Coret Network Connection
. If this is the initial installation of a unit, determine what type of installation will be required. Connection information is required for each new installation of the Insight Core product.
S
To configure a wired Ethernet connection using DHCP (dynamic IP addresses), go to Section D.
S
To configure a wireless WiFi connection, go to Section E.
S
To configure a wired Ethernet connection using static IP addressing, go to Section F*.
S
To configure a wireless WiFi connection using static WiFi addressing, go to Section G*.
* For static address connections, a computer must be connected directly to the module with an ethernet cable.
D. Connecting The Insight Core Module To Wired Ethernet Using Dynamic IP Assignment (DHCP)
. Before proceeding with installation, confirm that your wired Ethernet line has open access to the Internet by plugging your laptop into the network
jack using a CAT5 patch cord and browsing to a known external website. If successful, continue the process below. If not, contact your company’s
IT support staff.
1.
Click on Connect Module via Wired Ethernet.
2.
By default, the module will communicate to the Internet on port 80. If your network routes internet traffic over any other port, enter that port
number in the box immediately below the connect button.
Figure 4-21. Changing Port Number From Default Port 80
. To continue with firmware installation, proceed to Section 4-15.
OM-260 430 Page 29
E. Connecting The Insight Core Module To Wireless WiFi
. Once WiFi Settings is selected, use the information supplied by your IT department [from your Corporate Network Connectivity Survey of Requirements
(see Section 4-9 for information on obtaining survey)].
Connection Information required for initial installation of each unit purchased.
1.
Click the button Connect Module via Wireless / WiFi.
2.
Enter the name/SSID of your wireless network.
3.
Enter the security type of your wireless network. *Enterprise level security is not available at this time.
4.
Enter the security key (password) of your wireless network. (Note: this field will be disabled if your network is an “open” system.)
. These settings will work for all Axcess
Insight Core modules being installed and will only need to be done once during installation of additional
units.
Figure 4-22. Entering Security Key For Wireless Network
5.
By default, the Axcess Insight Core module will communicate to the Internet on port 80. If your wireless network routes internet traffic over any
other port, enter that port number in the box.
. To continue with firmware installation, proceed to Section 4-15.
OM-260 430 Page 30
F. Configuring A Wired Ethernet Connection Using A Static IP Address Per An Embedded Server Page
. Before proceeding with installation, confirm that your wired Ethernet line has open access to the Internet by plugging your laptop into the network
jack using a CAT5 patch cord and browsing to a known external website. If successful, continue the process below. If not, contact your company’s
IT support staff.
1.
Click on Connect Module via Wired Ethernet.
Figure 4-23. Selecting Wired Ethernet Configuration Settings
2.
Connect your PC directly to the Insight device network port (RJ45 jack) with an Ethernet cable (common CAT5 or CAT6).
3.
Turn on welding power source.
4.
Change your PC network adapter settings in order to interface with the Insight server page.
a.
For Windows computers, go to Control Panel / Hardware & Sound / Network & Internet / Network & Sharing Center / Change Adapter
Settings. These settings will vary by computer.
b.
Right click on your Local Area Connection, choose Properties.
c.
Click on Internet Protocol Version 4 (TCP/IPv4), and click the Properties button.
d.
Make note of your current network settings before proceeding.
e.
Select the “Use The Following IP Address” radio button.
f.
Set a static IP address to 169.254.0.1 or alternative (the last digit can be anything except 2).
g.
Set the Subnet Mask to 255.255.255.0
h.
Click OK when finished and close all network settings windows.
. The wireless feature on the PC may need to be turned off in order to connect to the Insight Module via Ethernet cable.
. All of these network adapter changes need to be reversed when you are finished with installations in order to reconnect to your corporate network.
5.
Close all open network setting dialog boxes and browsers. Open another browser window on your desktop. Wait approximately 30 seconds and
browse to the server page at 169.254.0.2 by typing this IP address directly into the browser’s URL text box (in place of a website name).
. If the Static Assigned IP address cannot be accessed, turn the power source off, insert the USB stick and power the unit on. This will write a text
file to the USB stick labeled IP_MAC_LIC_ADDR.txt. Open this file using Notepad to verify the Static Assigned IP address that you are attempting
to browse to is the same IP address of the Insight device as listed in the IP_MAC_LIC_ADDR.txt file.
OM-260 430 Page 31
6.
On the server page, select the radio button labeled Wired Ethernet and enter the desired parameters based on your company’s network environment as defined on the Insight Network Connectivity Requirements Checklist responses (see Section 4-9).
. This server page IP address (169.254.0.2) is the factory default for the Insight module. If you plan to set the Insight device connectivity to use
static IP address in your company, this server page IP address will change permanently once you assign the static IP in the process below.
. Using a static IP address connection enables you to view the server page of any Insight device installed on the shop floor from anywhere on your
network by browsing to its static IP address.
a.
In the Ethernet Settings section, select Static for Device IP Address and Primary DNS.
b.
Insert the device IP static address, subnet mask, gateway, DNS information, and port number provided by your IT Department (see
Figure 4-24).
MC10001Z
AC1000000X1X1X00XX00X0
Figure 4-24. Insight Server Page
c.
When finished, click Submit to save your settings for this device.
7.
Unplug the Ethernet (CAT5 or CAT6) patch cord from your PC, and connect the Insight module to your corporate Ethernet network jack using the
patch cord.
8.
Turn the welding power source off, and remove any USB stick if still inserted.
9.
Wait 10 seconds.
10.
Turn welding power source on. The yellow Network light should turn on first when it identifies your network. The green Internet light should turn on
when it sees open access to the Internet.
11.
When both LED lights are illuminated solid, the physical installation for Static IP Address is complete.
. If the LEDs are not illuminated and the network connection has been verified (See Section 4-13), please contact your Miller Sales representative.
. To continue with firmware installation, proceed to Section 4-15.
OM-260 430 Page 32
G. Configuring A WiFi Connection Using A Static IP Address Per An Embedded Server Page
. In order to setup a WiFi connection with a static IP
address, the unit must first be connected to a wired ethernet connection. Before proceeding
with installation, confirm that your wired Ethernet line has open access to the Internet by plugging your laptop into the network jack using a CAT5
patch cord and browsing to a known external website. If successful, continue the process below. If not, contact your company’s IT support staff.
1.
Click on Connect Module via Wired Ethernet.
Figure 4-25. Selecting Wired Ethernet Configuration Settings
2.
Connect your PC directly to the Insight device network port (RJ45 jack) with an Ethernet cable (common CAT5 or CAT6).
3.
Turn on welding power source.
4.
Change your PC network adapter settings in order to interface with the Insight server page.
a.
For Windows computers, go to Control Panel / Hardware & Sound / Network & Internet / Network & Sharing Center / Change Adapter
Settings. These settings will vary by computer.
b.
Right click on your Local Area Connection, choose Properties.
c.
Click on Internet Protocol Version 4 (TCP/IPv4), and click the Properties button.
d.
Make note of your current network settings before proceeding.
e.
Select Use the following IP address radio button.
f.
Set a static IP address to 169.254.0.1 or alternative (the last digit can be anything except 2).
g.
Set the Subnet Mask to 255.255.255.0
h.
Click OK when finished and close all network settings windows.
. All of these network adapter changes need to be reversed when you are finished with installations in order to reconnect to your corporate network.
5.
Close all open network setting dialog boxes and browsers. Open another browser window on your desktop and wait approximately 30 seconds.
Then, if firmware version being used is 1.19.10 or later, type the IP address 169.254.0.2 directly into the browser’s URL text box (in place of a
website name). If firmware version is prior to 1.19.10 use the IP address 169.254.0.2/wifi.shtm.
OM-260 430 Page 33
. If the Static Assigned IP address cannot be accessed, turn the power source off, insert the USB stick and power the unit on. This will write a text
file to the USB stick labeled IP_MAC_LIC_ADDR.txt. Open this file using Notepad to verify the Static Assigned IP address that you are attempting
to browse to is the same IP address of the Insight device as listed in the IP_MAC_LIC_ADDR.txt file.
6.
On the server page, locate the radio button labeled Wireless WiFi and enter the desired parameters based on your company’s network environment as defined on the Insight Network Connectivity Requirements Checklist responses (see Figure 4-26).
. This server page IP address (169.254.0.2) is the factory default for the Insight module. If you plan to set the Insight device connectivity to use
static IP address in your company, this server page IP address will change permanently once you assign the static IP in the process below.
. Using a static IP address connection enables you to view the server page of any Insight device installed on the shop floor from anywhere on your
network by browsing to its static IP address.
MC10001Z
AC1000000X1X1X00XX00X0
Figure 4-26. Insight Server Page
OM-260 430 Page 34
MC10001Z
AC1000000X1X1X00XX00X0
Figure 4-27. Insight Server Page
a.
In the WiFi Settings section, select Static for Device IP Address.
b.
Insert the device IP static address, subnet mask, gateway, DNS information, port number, security type, SSID, and security key provided
by your IT Department (see Figure Figure 4-27).
c.
When finished, click Submit to save your settings for this device.
7.
Unplug the Ethernet (CAT5 or CAT6) patch cord from your PC.
8.
Turn the welding power source off, and remove any USB stick if still inserted.
9.
Wait 10 seconds.
10.
Turn welding power source on. The yellow Network light should turn on first when it identifies your network. The green Internet light should turn on
when it sees open access to the Internet.
11.
When both LED lights are illuminated solid, the physical installation for Static WiFi IP Address is complete.
. To continue with firmware installation, proceed to Section 4-15.
OM-260 430 Page 35
4-15. Firmware Update Installation
. For help installing or running the Configuration Utility see Section 4-10 and Section 4-11. For help locating firmware files see Section 4-12.
Once firmware files are located and configuration settings are made (if necessary), click on the SAVE button in the Configuration window. You will be
prompted to insert a USB drive. After doing so, click Save. When finished, your USB drive will contain a file named Boot.cfg and a folder/directory
named Firmware which will contain the firmware file(s) you have selected. The Insight Core device requires these files/folder to be located on your USB
drive in order to upgrade the firmware.
Figure 4-28. Selecting USB Drive Letter
Figure 4-29. Approving Insight Configuration Settings
After clicking OK, the application will close, and you are ready to install the firmware upgrade on your Insight Core module.
. Make sure the module is either wired to an active Internet connection for wired connections, or that
the wireless network is available for wireless
connections.
1.
Connect 14−pin module to the welding power source.
2.
Turn the welding power source off.
3.
Insert the USB drive into 14−pin module.
4.
Turn the welding power source on.
. The LEDs on the front of the module will flash, indicating the transfer of your settings. When flashing stops, both the Internet and Network LED
lights will turn on solid to indicate successful connection to your network and Internet (see Section 4-4). Firmware update is complete.
. If only updating firmware, process is complete.
. The device is now reading for registration, to continue with registration, proceed to Section 4-16.
OM-260 430 Page 36
4-16. Determining Device Serial Number And License Key
. Obtaining device serial number and license key is necessary for product registration. The USB drive used in Section 4-15 now contains a .txt file
that is needed to obtain the license key.
1.
Remove USB drive from Insight Core unit and insert into computer. Allow time for computer to recognize the USB drive.
2.
Find and open the folder named Device License Keys on the USB drive.
Figure 4-30. Device License Keys Folder
3.
Open the .txt file called “IP_MAC_ADDR_LIC…” with a text editor (ie. Notepad), in order to find the module/device serial number and license key
needed to register the device.
Figure 4-31. Device License Key File
4.
Write down the serial number and license key for registration.
00 . XX . 000 .XXX
00 . XX . 00 . XX . 00 . XX
00 . XX . 00 . XX . 00 . XX
MC10001Z
AC1000000X1X1X00XX00X0XX
Figure 4-32. Device License Key Information
. This file also verifies the connections information. Exact information in the file will vary based on connection type and device.
. To continue device registration, proceed to Section 4-17.
OM-260 430 Page 37
4-17. Registering Initial Device And Creating An Account
1.
Open a web browser and navigate to https://insight.millerwelds.com/registration.
1.
Fill in all information shown in Figure 4-33. Use serial number and license key from Section 4-16.
. If this device is an additional module to be added to your existing fleet already registered, click Log In button and proceed to Section 4-18.
Insight Module
Serial Number
MC10001Z
AC1000000X1X1X00XX00X0XX
License Key
From Step #2
Figure 4-33. Registering A New Account
3.
After clicking on the Register button, the homepage for the company that was just created will appear (see Figure 4-34).
Figure 4-34. Insight Core Company Dashboard
. To register additional devices proceed to Section 4-18.
OM-260 430 Page 38
4-18. Registering Additional Devices
1.
Login to Inisght Core website at https://insight.millerwelds.com/.
2.
Click on the Configuration tab (See Figure 4-35).
3.
On the Configuration tab, click on the Register New Device button.
Figure 4-35. Configuration Screen
4.
A confirmation screen will appear. If the information is correct, click on the Save button (see Figure Figure 4-36).
MC10001Z
AC1000000X1X1X00XX00X0XX
Figure 4-36. Register Device Confirmation Screen
5.
Once registered, the device will appear inside the corporate asset tree and begin displaying activity as operators begin welding with this power
source.
OM-260 430 Page 39
4-19. Setting Up A Work Shift
. In order to make company settings, log in to Insight Core Website at https://insight.millerwelds.com/.
1.
To set up a work shift for an Insight Core module, click the Configuration tab, then click the Company tab, then click on the Add Shift button (see
Figure 4-37).
Figure 4-37. Setting Up A Work Shift
2.
Enter the data to set the work shift for the device, then click on the Save button (see Figure 4-38).
Figure 4-38. Adding A New Shift
OM-260 430 Page 40
3.
After clicking on the Save button, an Edit screen will appear to allow changes or corrections. Once the shift data is acceptable, click on the Save
button (see Figure 4-39).
Figure 4-39. Shift Data Edit Screen
4.
After clicking on the Save button, the shift data will appear under the company tab for the device work shift (see Figure 4-40).
Figure 4-40. Device Work Shift Data Screen
OM-260 430 Page 41
4-20. Setting Up A Group
1.
To set up a group to organize your Insight devices into logical groups, click on the Groups tab (see Figure 4-41).
Figure 4-41. Setting Up A Group Of Devices
2.
Enter a Group Name and click on the Save button (see Figure 4-42).
Figure 4-42. Entering A Group Name
3.
Once a group is established, return to the beginning of Section 4-18 to add more devices. Be sure to have all the serial numbers and access keys
for each additional device.
4.
To assign existing devices to a group, select the unit to be assigned, click Configuration, then click Groups. Select the appropriate group for the
unit.
OM-260 430 Page 42
SECTION 5 − TROUBLESHOOTING
If unit does not connect to the internet, try connecting to http://collector.millerwelds.com .
If the connection is valid, a webpage validating the connection will appear (see Figure 5-1).
Figure 5-1. Insight Core Collector Webpage
Notes
OM-260 430 Page 43
SECTION 6 − ELECTRICAL DIAGRAM
264 455-B
Figure 6-1. Circuit Diagram
OM-260 430 Page 44
SECTION 7 − PARTS LIST
Part
No.
Description
301 072
.........
.........
.........
.........
.........
.........
.........
.........
.........
.........
259 221
264 624
264 626
263 771
259 519
259 465
141 162
152 369
264 880
131 447
Quantity
Insight Coret 14-Pin Module Kit
. . Housing, Circuit Control 14 Pin Insight Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Assy, CCA Insight Core With Wifi 14 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Circuit Card Assy, 14 Pin Insight Core (W/Program) . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Circuit Card Assy, Radio Carrier Internal Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cable Assy, Interconnecting 14 Pin Insight Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Cable, Interconnecting Insight Core 14 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Housing Plug+Skts (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Panel, Mtg Components 14 Pin Insight Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..
Core, Toroidal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-260 430 Page 45
Notes
Ref. AWS/ANSI A2.4
Welding Symbols
Notes
Notes
Effective January 1, 2015
(Equipment with a serial number preface of MF or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
* Batteries
retail purchaser that new Miller equipment sold after the effective
* Bernard Guns (No Labor)
date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
* Accessory (Kits)
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
Within the warranty periods listed below, Miller will repair or replace
Non-Electronic Controls
any warranted parts or components that fail due to such defects in
* M-Guns
material or workmanship. Miller must be notified in writing within
* MIG Guns and Subarc (SAW) Torches
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
* Remote Controls and RFCS-RJ45
followed. If notification is submitted as an online warranty claim, the
* Replacement Parts (No labor)
claim must include a detailed description of the fault and the
* Roughneck Guns
troubleshooting steps taken to identify failed components and the
* Spoolmate Spoolguns
cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed twelve months
after the equipment is shipped to a North American distributor or
eighteen months after the equipment is shipped to an International
distributor.
1.
2.
3.
4.
5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs,
Diodes, and Discrete Rectifier Modules
3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic
Series) (No Labor)
* Engine Driven Welder/Generators
(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)
* Inverter Power Sources (Unless Otherwise Stated)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources
2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor)
* Fume Extractors − Capture 5, Filtair 400 and Industrial
Collector Series
1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* Desiccant Air Dryer System
* External Monitoring Equipment and Sensors
* Field Options
(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or
for a minimum of one year — whichever is greater.)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* HF Units
* ICE/XT Plasma Cutting Torches (No Labor)
* Induction Heating Power Sources, Coolers
(NOTE: Digital Recorders are Warranted Separately
by the Manufacturer.)
* LiveArc Welding Performance Management System
* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)
Miller’s True Blue® Limited Warranty shall not apply to:
1.
2.
3.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.
miller_warr 2015-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2015 Miller Electric Mfg. Co.
2015−01
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