Miller 14-Pin Insight Core CE Owner's Manual
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Miller 14-Pin Insight Core CE Owner's Manual

Miller 14-Pin Insight Core CE Owner's Manual

Advanced/automated welding system
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www.MillerWelds.com/ams
14-Pin Insight CoretCE
OM-260 430C
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Description
Advanced/Automated Welding System
File: Advanced Manufacturing Systems
2014−11

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Summary of Contents for Miller 14-Pin Insight Core CE

  • Page 1 OM-260 430C 2014−11 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Description Advanced/Automated Welding System 14-Pin Insight CoretCE Visit our website at File: Advanced Manufacturing Systems www.MillerWelds.com/ams...
  • Page 2 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.
  • Page 3 TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 5: Declaration Of Conformity

    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).

  • Page 7: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 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 Indicates special instructions.
  • Page 8 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 10: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2013−09 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.
  • Page 12 D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements câble pour le procédé...

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    LES BOUTEILLES peuvent exploser DES PIECES DE METAL ou DES si elles sont endommagées. SALETES peuvent provoquer des blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser.
  • Page 14 LES CHARGES ÉLECTROSTATI- RAYONNEMENT HAUTE QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque cuits imprimés. provoquer des interférences. D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi- pements de radio−navigation et de com- D Utiliser des pochettes et des boîtes antista-...

  • Page 15: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres formations congénitales et, dans certains cas, des cancers.
  • Page 16 OM-260 430 Page 10...

  • Page 17: Section 3 − Quick Installation Guide

    SECTION 3 − QUICK INSTALLATION GUIDE Download and print Network Connectivity Survey from https://insight.millerwelds.com/download . Have form completed by IT department. Install Insight Core Configuration Utility from https://insight.millerwelds.com/download to a PC.(For more information, See Section 4-7.) Open Insight Core Configuration Utility using icon that was created on desktop. (See Figure 4-11.) Update firmware if newer revision is available.

  • Page 18: License Agreement

    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.

  • Page 19: Environmental Specifications

    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.

  • Page 20: Connections And Led Designations On Module

    4-4. Connections and LED Designations On Module Network Ethernet Power Internet Port Port Yellow Green Green 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 Welding Power Source 14-Pin Insight Core Module 14-Pin Control Cable From...

  • Page 21: Downloading Connectivity Survey

    4-6. 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. 4-7. Downloading And Installing Insight Core Setup Application To A PC To download the Insight Core Setup Application, visit the webpage at https://insight.millerwelds.com/download Click on the file name, and save it to your desktop (see Figure 4-2).
  • Page 22 Click Next on the Setup Wizard screen to begin installation to your computer (see Figure 4-4). Figure 4-4. Setup Wizard Screen 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 266 098 Page 16...
  • Page 23 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 Click Install to complete the installation of the Configuration Utility (see Figure 4-7).
  • Page 24 The installation process will display the status on screen until complete (see Figure 4-8). Figure 4-8. Install Status Screen Click Finish when the application has completed the installation process (see Figure 4-9). Figure 4-9. Install Completed Screen 266 098 Page 18...
  • Page 25 The application is now installed on your computer. The program can be found inside All Programs in a folder named Miller Insight Core Configura- tion (see Figure 4-10). A shortcut was also placed on your computer’s desktop during installation (see Figure 4-11).

  • Page 26: Running Configuration App For Installation Of Firmware And Connection Criteria

    4-8. 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. 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).

  • Page 27: Prepare Firmware For Installation

    4-9. 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.
  • Page 28 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 Click the button labeled Locate Files inside the Firmware Updates box. A dialog box will open. Figure 4-16.
  • Page 29 Click Browse and locate the firmware file names you downloaded previously to your computer. Figure 4-17. Locating Latest Firmware Files 266 098 Page 23...
  • Page 30 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 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.

  • Page 31: Configuring The Type Of Insight Coret Network Connection

    4-10. 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 installa- tion of the Insight Core product. To configure a wired Ethernet connection using DHCP (dynamic IP addresses), go to Section D.
  • Page 32 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 4-6 for information on obtaining survey)]. Connection Information required for initial installation of each unit purchased. Click the button Connect Module via Wireless / WiFi.
  • Page 33 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.
  • Page 34 On the server page, select the radio button labeled Wired Ethernet and enter the desired parameters based on your company’s network environ- ment as defined on the Insight Network Connectivity Requirements Checklist responses (see Section 4-6). 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.
  • Page 35 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.
  • Page 36 On the server page, locate the radio button labeled Wireless WiFi and enter the desired parameters based on your company’s network environ- ment as defined on the Insight Network Connectivity Requirements Checklist responses (see Figure 4-25). 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.
  • Page 37 MC10001Z AC1000000X1X1X00XX00X0 Figure 4-26. Insight Server Page In the WiFi Settings section, select Static for Device IP Address. 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 4-26).

  • Page 38: Firmware Update Installation

    4-11. Firmware Update Installation For help installing or running the Configuration Utility see Section 4-7 and Section 4-8. For help locating firmware files see Section 4-9. 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.

  • Page 39: Determining Device Serial Number And License Key

    4-12. 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 4-11 now contains a .txt file that is needed to obtain the license key. Insert USB drive into computer and allow time for computer to recognize the USB drive.

  • Page 40: Registering Initial Device And Creating An Account

    4-13. Registering Initial Device And Creating An Account Open a web browser and navigate to https://insight.millerwelds.com/registration Fill in all information shown in Figure 4-32. Use serial number and license key from Section 4-12. If this device is an additional module to be added to your existing fleet already registered, click Log In button and proceed to Section 4-14. Insight Module Serial Number MC10001Z...

  • Page 41: Registering Additional Devices

    4-14. Registering Additional Devices Login to Inisght Core website at https://insight.millerwelds.com/. Click on the Configuration tab (See Figure 4-34). On the Configuration tab, click on the Register New Device button. Figure 4-34. Configuration Screen A confirmation screen will appear. If the information is correct, click on the Save button (see Figure Figure 4-35). MC10001Z AC1000000X1X1X00XX00X0XX Figure 4-35.

  • Page 42: Setting Up A Work Shift

    4-15. Setting Up A Work Shift In order to make company settings, log in to Insight Core Website at https://insight.millerwelds.com/. 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 4-36).
  • Page 43 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 4-38). Figure 4-38. Shift Data Edit Screen After clicking on the Save button, the shift data will appear under the company tab for the device work shift (see Figure 4-39). Figure 4-39.

  • Page 44: Setting Up A Group

    4-16. Setting Up A Group To set up a group to organize your Insight devices into logical groups, click on the Groups tab (see Figure 4-40). Figure 4-40. Setting Up A Group Of Devices Enter a Group Name and click on the Save button (see Figure 4-41). Figure 4-41.

  • Page 45: Section 5 − Troubleshooting

    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 266 098 Page 39...

  • Page 46: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 264 455-B Figure 6-1. Circuit Diagram OM-264 423 Page 40...

  • Page 47: Section 7 − Parts List

    SECTION 7 − PARTS LIST Part Description Quantity 301 072 Insight Coret 14-Pin Module Kit ..259 221 Housing, Circuit Control 14 Pin Insight Core ........
  • Page 48 Notes Ref. AWS/ANSI A2.4 Welding Symbols...
  • Page 49 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in.
  • Page 50 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
  • Page 51 Effective January 1, 2014 (Equipment with a serial number preface of ME or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 52 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 2014 Miller Electric Mfg. Co. 2014−01...

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