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Miller 14-Pin Insight Core CE, Owner'S Manual

The Miller 14-Pin Insight Core CE is a cutting-edge product designed to empower welders with its advanced features. Seamlessly control your welding processes with this state-of-the-art equipment. Ensure optimal performance by referring to the detailed Owner's Manual available for download – free of charge – at manualshive.com.

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OM-266 098 Page 41

SECTION 7 

−

 PARTS LIST

Description

Part

No.

301 072

Insight Core

t

 14-Pin Module Kit

Quantity

259 221

Housing, Circuit Control 14 Pin Insight Core

1

. . . . . . . . .

. .

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264 624

Assy, CCA Insight Core With Wifi 14 Pin

1

. . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

264 626

Circuit Card Assy, 14 Pin Insight Core (W/Program)

1

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. .

. . . . . . . . . . . . . . . . . . . . . . . . . .

263 771

Circuit Card Assy, Radio Carrier Internal Antenna

1

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. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

259 519

Cable Assy, Interconnecting 14 Pin Insight Core

1

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. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

259 465

Cable, Interconnecting Insight Core 14 Pin

1

. . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141 162

Housing Plug+Pins (Service Kit)

1

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152 369

Housing Plug+Skts (Service Kit)

1

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264 880

Panel, Mtg Components 14 Pin Insight Core

1

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131 447

Core, Toroidal

1

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

Summary of Contents for 14-Pin Insight Core CE

Page 1: ... 430C 2014 11 14 Pin Insight CoretCE File Advanced Manufacturing Systems Visit our website at www MillerWelds com ams Processes Description Advanced Automated Welding System MIG GMAW Welding Pulsed MIG GMAW P ...

Page 2: ...tinue 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...

Page 3: ...N 4 INSTALLING 14 PIN INSIGHT CORE 13 4 1 License Agreement 13 4 2 Compatibility Information 13 4 3 Connections and LED Designations On Module 14 4 4 Mounting And Connecting The Insight Core Module To The Welding Power Source 14 4 5 Downloading Connectivity Survey 15 4 6 Downloading And Installing Insight Core Setup Application To A PC 15 4 7 Running Configuration App For Installation Of Firmware ...

Page 4: ......

Page 5: ...ification Product Stock Number 14 pin Insight Core Module 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 60974 10 2007 Arc Welding Equipment Part 10 Electromagnetic compatibility EMC requirements Signatory _____________________________________ ________________...

Page 6: ......

Page 7: ...kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not wor...

Page 8: ...pared 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 D...

Page 9: ...ING 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 la...

Page 10: ... 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 Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 the...

Page 11: ...dé 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 condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ...

Page 12: ...louissements 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 p...

Page 13: ...s 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 lors que la bouteille est utilisée ou qu elle est reliée pour usage ulté rieur D Utiliser les équipements corrects les bonnes procédures et suf fisamment de p...

Page 14: ... 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 LE RAYONNEMENT HAUTE FRÉQUENCE H F risque de provoquer des interférences D Le rayonnement haute fréquence H F peut provoquer des interférences avec les équi pements de radio navigation et de com munication les services de sécurité et les...

Page 15: ... Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone...

Page 16: ...OM 260 430 Page 10 ...

Page 17: ...e 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 Insig...

Page 18: ...0MPa 450 CC CV NT w Arc Reach 456MP 450 MPa NT 450 456 P 456 CC CV 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...

Page 19: ...nd 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 The EMF assessment on this equipment was conducted at 0 5 meter S At a distance of 1 meter the EMF exposure values w...

Page 20: ...nting And Connecting The Insight Core Module To The Welding Power Source Ref 803 502 A 245 855 A Module can be mounted on either side of welding power source 1 1 2 2 2 1 Welding Power Source 2 14 Pin Insight Core Module 3 14 Pin Control Cable From Power Source 4 14 Pin Control Cable To Feeder 5 Positive Weld Cable 6 Negative Weld Cable 7 Gas Hose 8 Wire Feeder 9 Mig Gun 10 Work Piece 11 Gas Cylind...

Page 21: ... to complete the survey 4 7 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 you...

Page 22: ...p 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 ...

Page 23: ...er 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 ...

Page 24: ...on 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 ...

Page 25: ...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 Figure 4 10 Application Program Folder ...

Page 26: ...rams 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 aut...

Page 27: ...re 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 ...

Page 28: ...e 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 ...

Page 29: ...266 098 Page 23 3 Click Browse and locate the firmware file names you downloaded previously to your computer Figure 4 17 Locating Latest Firmware Files ...

Page 30: ...x 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 11 For help configuring connection proceed to Section 4 10 ...

Page 31: ...omputer 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 ...

Page 32: ...twork 3 Enter the security type of your wireless network 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 21 Entering Security Key For Wireless Network 5 By defau...

Page 33: ...e note of your current network settings before proceeding 8 Select the Use The Following IP Address radio button 9 Set a static IP address to 169 254 0 1 or alternative the last digit can be anything except 2 10 Set the Subnet Mask to 255 255 255 0 11 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 In...

Page 34: ...on select Static for Device IP Address and Primary DNS 16 Insert the device IP static address subnet mask gateway DNS information and port number provided by your IT Department see Figure 4 23 MC10001Z AC1000000X1X1X00XX00X0 Figure 4 23 Insight Server Page 17 When finished click Submit to save your settings for this device 18 Unplug the Ethernet CAT5 or CAT6 patch cord from your PC and connect the...

Page 35: ...t Protocol Version 4 TCP IPv4 and click the Properties button 7 Make note of your current network settings before proceeding 8 Select Use the following IP address radio button 9 Set a static IP address to 169 254 0 1 or alternative the last digit can be anything except 2 10 Set the Subnet Mask to 255 255 255 0 11 Click OK when finished and close all network settings windows All of these network ad...

Page 36: ...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 MC10001Z AC1000000X1X1X00XX00X0 Figure 4 25 Insight Server Page 14 Assigning a Static IP address enables you to view the server page of any Insight device ...

Page 37: ... save your settings for this device 18 Unplug the Ethernet CAT5 or CAT6 patch cord from your PC 19 Turn the welding power source off and remove any USB stick if still inserted 20 Wait 10 seconds 21 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 22 When both L...

Page 38: ... 4 28 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 ...

Page 39: ...igure 4 29 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 30 Device License Key File 4 Write down the serial number and license key for registration 00 XX 00 XX 00 XX 00 XX 00 XX 00 XX 00 XX 000 XXX MC10001Z AC1000000X1X1X00XX00X0XX Figure 4 3...

Page 40: ...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 License Key From Step 2 MC10001Z AC1000000X1X1X00XX00X0XX Figure 4 32 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 33 Figure 4 33 Insight Core Compa...

Page 41: ...Register New Device button Figure 4 34 Configuration Screen 4 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 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 powe...

Page 42: ...welds 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 36 Figure 4 36 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 37 Figure 4 37 Adding A New Shift ...

Page 43: ...s or corrections Once the shift data is acceptable click on the Save button see Figure 4 38 Figure 4 38 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 39 Figure 4 39 Device Work Shift Data Screen ...

Page 44: ...ick on the Save button see Figure 4 41 Figure 4 41 Entering A Group Name 3 Once a group is established return to the beginning of Section 4 14 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 click Configuration then Devices and use the Configure link to set the device properties including assign ing the d...

Page 45: ...HOOTING 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 ...

Page 46: ...OM 264 423 Page 40 SECTION 6 ELECTRICAL DIAGRAM 264 455 B Figure 6 1 Circuit Diagram ...

Page 47: ...sy Radio Carrier Internal Antenna 1 259 519 Cable Assy Interconnecting 14 Pin Insight Core 1 259 465 Cable Interconnecting Insight Core 14 Pin 1 141 162 Housing Plug Pins Service Kit 1 152 369 Housing Plug Skts Service Kit 1 264 880 Panel Mtg Components 14 Pin Insight Core 1 131 447 Core Toroidal 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Rep...

Page 48: ...Notes Welding Symbols Ref AWS ANSI A2 4 ...

Page 49: ...Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKNESS REFERENCE CHART ...

Page 50: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 51: ...ler s True Blue Limited Warranty shall not apply to 1 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 2 Items furnished by Miller but manufactured by others such as engines or trade accessories These items are...

Page 52: ...h your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to ...

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