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Smart Reader

OPERATING MANUAL

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Summary of Contents for Smart Reader

Page 1: ...Smart Reader OPERATING MANUAL ...

Page 2: ...rt Reader to other welding machines 15 3 3 Switch Smart Reader ON and OFF 19 3 4 Link Smart Reader to your company WeldEye account 20 3 5 Configure Smart Reader s network connection 20 3 6 Internet connectivity requirements 21 4 Collecting welding data 22 4 1 Welder s workflow with Smart Reader 22 4 2 Identifiers shown on Smart Reader 24 4 3 Alerts shown on Smart Reader 25 4 4 Reason codes 26 4 5 ...

Page 3: ...iii 6 1 Administrator section views 32 6 2 Updating Smart Reader firmware 34 6 3 Factory reset 35 7 Technical specifications 36 8 Contact information 37 9 Glossary 38 ...

Page 4: ...fter welding the welder gets feedback such as whether the welding parameters stayed within the WPS limits Smart Reader can be connected to any arc welding machine through an adapter and directly without an adapter to certain Kemppi welding machines In a typical use case every welding machine performing critical welding in the factory has a Smart Reader connected to it For factory wide productivity...

Page 5: ...ant welding standards Personnel and qualifications Includes the management and renewal processes of all personnel welders and inspectors qualification certificates Quality management Includes quality verification functionalities with digital WPS and qualification compliance control against automatically collected digital welding data Welding management Includes document register functionalities an...

Page 6: ...ly offline with reduced capability no new data sent to or received from the server until the connection becomes available again A security inspection was conducted for Smart Reader in May 2016 by a third party Quote from the final report As a summary the security status of the Smart Reader is good since no significant security issues were found The Smart Reader device was found quite secure in nor...

Page 7: ...o highlight items on the display Middle button press to select the highlighted item Left and right arrow buttons press to change the pass within a WPS 3 Barcode scanner Smart Reader is delivered with either 1d or 2d barcode scanner 4 Connection cable port Power DC in 50V 200mA 5 Back cover Removable OPERATING MANUAL EN 7 KEMPPI 2017 12 22 ...

Page 8: ...or For troubleshooting purposes 9 Ethernet connector 100 Mbit For troubleshooting purposes 10 Micro SD card slot By default a 4 Gb memory card is connected Smart Reader stores all welding and barcode data on the memory card The first time you power on Smart Reader the SD card is formatted Removing the back cover Use for example a coin to open the back cover lock Silicon cover Silicon cover is avai...

Page 9: ...WELDEYE 2 1 Parts 2 1 Figure 2 Attaching the silicon cover Hanging Smart Reader You can hang Smart Reader by the hook on the handle of the wire feeder OPERATING MANUAL EN 9 KEMPPI 2017 12 22 ...

Page 10: ...lder has no valid qualification certificate for the seelcted WPS 4 Identified feature The barcode for the feature has been scanned and the device has recognized the item 5 Unidentified feature The barcode for the feature has not been scanned In WeldEye cloud service you can select which features are always shown on the display See Identifiers shown on Smart Reader on page 24 6 Menu Select Menu to ...

Page 11: ...der s network connection To get the all the benefits of WeldEye also adjust other features such as cable compensation 3 1 Smart Reader operating principle Smart Reader is a handheld IoT device with multiple functionalities it connects to the welding machine or adapter for recording welding parameter data provides a user interface and reporting tool for the welder and communicates with the WeldEye ...

Page 12: ... fully automated robotic welding including MMA MIG TIG and SAW processes Smart Reader can handle welds of all lengths be it a small tack weld of under a second or long mechanized weld where the arc is it lit for many hours Smart Reader collects the welding parameters with a resolution of 1 10th of a second 10 samples per second Some averaging is performed in the WeldEye cloud service to reduce the...

Page 13: ...rements Welding machine power sources often conform to the standard IEC 60974 1 which states that 2 5 accuracy is required when displaying amps and volts It means that the displayed value must be within 2 5 of the actual value measured at the maximum power For example for a power source rated capable of producing 300A the error may be up to 7 5A Therefore the power source display may not always sh...

Page 14: ...en you are using Smart Reader together with An adapter for measuring voltage and current connect Smart Reader to the adapter with the connection cable Kemppi welding machine with Kemppi MSF wire feeder connect Smart Reader directly to the power source with the connection cable Kemppi welding machine with no Kemppi MSF wire feeder connect Smart Reader either to the power source or to the wire feede...

Page 15: ...ource Rated for maximum 500 A welding current ARC Euro Adapter CV Compatible with MIG MAG welding machines with Euro gun connector Connects to the wire feeder Rated for maximum 500 A welding current ARC Universal Adapter TIG Always use this adapter with TIG welding machines with High Frequency ignition Shielded against the high voltage ignition spark Rated for maximum 500 A welding current ARC SAW...

Page 16: ...onnector and the Dix branch connector to the opposite pole Figure 4 Connecting ARC Universal Adapter CV and Smart Reader to a welding machine 3 2 2 2 Connect Smart Reader with ARC Euro Adapter CV 1 Connect the connection cable from Smart Reader to the adapter 2 Connect the adapter to a separate power supply with ARC Control Cable required to power the Smart Reader 3 Connect the adapter to the wire...

Page 17: ...er with ARC Universal Adapter TIG 1 Connect the connection cable from Smart Reader to the adapter 2 Connect the adapter to a separate power supply with ARC Control Cable required to power the Smart Reader 3 Connect the adapter to the welding machine ground connector and the Dix branch connector to the opposite pole OPERATING MANUAL EN 17 KEMPPI 2017 12 22 ...

Page 18: ...o a welding machine 3 2 2 4 Connect Smart Reader with ARC SAW Adapter 1 Connect the connection cable from Smart Reader to the adapter 2 Connect the adapter to a separate power supply with ARC Control Cable required to power the Smart Reader 3 Bolt the adapter to the welding cable OPERATING MANUAL EN 18 KEMPPI 2017 12 22 ...

Page 19: ...arcode reader is automatically turned off after 2 minutes of inactivity to ensure the barcode scanner camera s long life To read barcodes again press the middle button in Smart Reader Smart Reader has a built in Li Ion battery which is used to gracefully switch off Smart Reader in the case of power loss The battery helps keep the device functional if the power is unstable Smart Reader stays powere...

Page 20: ...e downloading the configuration file The configuration file only applies to Smart Readers that are in the Devices list at the time of the download 6 Copy the downloaded file on a USB stick and disconnect it from the computer 7 Connect the USB stick to Smart Reader 8 Smart Reader asks whether to change the network settings Answer YES Smart Reader now automatically connects to the network WiFi icon ...

Page 21: ...s Open WPA Personal PSK TKIP and AES WPA2 Personal PSK TKIP and AES Note HTTP authentication cannot be used with Smart Reader HTTP authentication means that the user is authenticated via HTTP protocol using a web form or similar Bandwidth usage is mostly outbound Devices send welding parameter data after every weld causing up to 60 megabytes per day for 10 devices in one shift Network traffic is c...

Page 22: ... to the Smart Reader by scanning the welder barcode Welder barcodes are created in the Personnel view in WeldEye cloud service By default the Smart Reader user interface is in the language defined in the WiFi network configuration file However the language can be set for each person separately in the Personnel view in WeldEye 2 Scan barcodes to give meaning to the welding data If you do not have a...

Page 23: ...eld The following welding data is thus linked to that weld and correctly logged in WeldEye c Record the filler material batch number to provide traceability Scan the barcode from the filler material packaging or enter the number with the keyboard The first time a barcode is scanned Smart Reader reports that the barcode is unknown Select Define Wire batch The batch number becomes a known identifier...

Page 24: ... enabled in WeldEye and the welder has been identified with a barcode the welder is automatically logged out from the device after a period of inactivity non arc time Remember logged in welder with this setting the device remembers the identifiers that are read so that the welder WPS filler material and other identifiers are not lost when the device is rebooted 4 2 Identifiers shown on Smart Reade...

Page 25: ...qualification that matches or exceeds the WPS requirements the system raises an alert If the welder decides not to weld the alert is not recorded in the cloud service If the welder does weld despite the alert the alert is recorded in the cloud service WeldEye also compares the filler material information and shielding gas information that the welder enters with Smart Reader to the filler and shiel...

Page 26: ... pauses like machine breakdowns or waiting for a material delivery Use reason codes to identify bottlenecks in your production The welder selects the reason code with the Smart Reader WeldEye registers and stores the code To select a reason code in Smart Reader 1 Select Menu Set reason code 2 Browse the list of reason codes with up down arrow buttons and select the code you need OPERATING MANUAL E...

Page 27: ... Select a WPS c Scan a weld barcode All welding is now considered to be part of a pass and is taken into account when heat input is calculated 2 After welding select Menu Complete pass Note You can weld several runs select Complete pass at the end of the pass and enter the total length of the runs Smart Reader prompts you to complete the pass before changing the weld or WPS to ensure that all data...

Page 28: ...e based on this feedback If a WPS is currently identified the parameter limits are shown and deviating measured values are shown in red It is not necessary to acknowledge this screen after every weld If several welds have been made only the latest is shown The previous welds data cannot be shown in Smart Reader that information is available in WeldEye cloud service This feature is enabled in WeldE...

Page 29: ... source and the length and area of cables given by the welder To set up cable compensation 1 In Smart Reader select Menu Settings 2 Select Set cable area and enter the value x Π the diameter of the intermediate cables and earth cables multiplied by pi 3 Select Set cable compensation length and enter the total length of the cables accuracy of one meter Figure 8 Example of long intermediate cables t...

Page 30: ...ach Smart Reader welding machine separately Channel WPS enables mapping the welding machine s memory channels to welding procedures When the feature is enabled Smart Reader automatically associates WPS information with welds based on the selected memory channel By using the feature WPS reading is automated and the welder can work more effectively The feature fits best to simple welding where the n...

Page 31: ...Eye cloud service settings 5 6 Smart Reader usage and WPS limit enforcement Kemppi FastMig X welding machine supports enhanced integration with Smart Reader enabling Smart Reader usage enforcement and WPS limit enforcement For more information about this feature or how to enable it contact WeldEye support See Contact information on page 37 Smart Reader usage enforcement In some cases it is desirab...

Page 32: ...t Reader network configuration file and place it similarly to the root of the USB flash drive s file system i e D ArcQ_NetworkConfiguration cfg 6 1 Administrator section views Device information view Internal serial number of the device Currently installed software version Default language of the device Network settings view The mac addresses of the Smart Reader network interfaces current network ...

Page 33: ...ess networks those broadcast their SSID to the air Welding system view Information that Smart Reader reads from the bus either about the welding machine the Smart Reader is connected to or about the adapter the Smart Reader is connected to OPERATING MANUAL EN 33 KEMPPI 2017 12 22 ...

Page 34: ... up down with the arrow keys 6 2 Updating Smart Reader firmware You can update Smart Reader for new features and improvements There are two different ways to update Smart Reader update via USB stick or online update In each case WeldEye support provides the new version of Smart Reader firmware For information about administrator login see Administrator section views on page 32 OPERATING MANUAL EN ...

Page 35: ... of filler wire until text appears on screen Online update Smart Reader can be automatically updated through an online update In this case Smart Reader s update package is released in the WeldEye cloud service Smart Reader automatically downloads the new firmware version this happens in the background without disturbing the operation Once the download is complete there are two options to perform t...

Page 36: ...ature Description Supported WiFi standards 802 11b 802 11g 802 11n Type Non removeable Li Ion Battery Power 2200 mAh Size 4 3 Display Resolution 480 x 272 pixels Materials Cover Plastic Control cable port power DC 50V 200mA OPERATING MANUAL EN 36 KEMPPI 2017 12 22 ...

Page 37: ...WELDEYE 6 3 Factory reset 8 Contact information For support and more information on WeldEye visit www weldeye com OPERATING MANUAL EN 37 KEMPPI 2017 12 22 ...

Page 38: ...de WPS limits or if welder does not have qualifications a deviation alert is raised Filler batch number Batch number of the filler material can be recorded in WeldEye for detailed welding documentation Identifier A unique number or string usually in barcode format that identifies the welder WPS weld or other metadata Can be scanned with the Smart Reader s barcode scanner or entered manually Pass A...

Page 39: ...es connecting a welding machine to the WeldEye cloud service Smart Reader records welding parameters and sends the data to WeldEye using WiFi The welder can use Smart Reader to enter traceability information by selecting items on the display or by scanning barcodes and thus give meaning to the weld data Travel speed Welding speed Movement speed of the welding torch or gun along the weld Weld Weld ...

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