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Smart Reader
OPERATING MANUAL
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Contents
1 Introduction................................................................................................. 4
1.1 Introduction to Smart Reader................................................................................................................... 4
1.2 Introduction to WeldEye..............................................................................................................................4
1.3 Security................................................................................................................................................................6
2 Structure.......................................................................................................7
2.1 Parts......................................................................................................................................................................7
2.2 Main screen and navigation....................................................................................................................10
3 Getting started.......................................................................................... 11
3.1 Smart Reader operating principle......................................................................................................... 11
3.1.1 How welding data is recorded............................................................................................... 12
3.1.2 Identifier database....................................................................................................................... 12
3.1.3 Measurement of parameters................................................................................................... 12
3.1.4 Time-keeping................................................................................................................................. 13
3.2 Connect Smart Reader to the welding machine............................................................................. 13
3.2.1 Connect Smart Reader to Kemppi FastMig KMS/M/Pulse/X, KempArc KMS/
Pulse, Kemppi A7.............................................................................................................................. 14
3.2.2 Connect Smart 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
ii
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 Heat input tracking..................................................................................................................................... 27
4.6 Weld Data view after welding................................................................................................................ 28
5 Other Smart Reader features.................................................................. 29
5.1 Cable compensation................................................................................................................................... 29
5.2 Real-time WPS monitoring.......................................................................................................................29
5.3 Channel WPS..................................................................................................................................................30
5.4 WPS suggestion for weld identifiers....................................................................................................31
5.5 TIG drop-down filtering.............................................................................................................................31
5.6 Smart Reader usage and WPS limit enforcement.......................................................................... 31
6 Administration...........................................................................................32
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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
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WELDEYE 1.1 Introduction to Smart Reader
1 Introduction
1.1 Introduction to Smart Reader
Smart Reader is a device that enables automated monitoring of the quality and productivity of arc
welding.
Smart Reader records welding parameter data, and transmits the data to the WeldEye cloud
service through a wireless network.
Smart Reader is the welder's user interface to WeldEye for inputting identifying information, such
as welder identification, the WPS in use, the weld or welding piece, or filler material heat (batch)
number.
Smart Reader also displays useful information to the welder. For example, before welding,
the welder sees the current and voltage limits of the WPS, and after 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 use cases, all welding machines can be
equipped with one.
Smart Reader is available in the following user interface languages: Chinese, Danish, Dutch,
English, Finnish, French, German, Italian, Norwegian, Polish, Portuguese, Russian, Spanish,
Swedish.
1.2 Introduction to WeldEye
WeldEye is a comprehensive system for collecting and managing welding data, and your primary
tool and storage space for keeping your welding-related documents in order.
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WELDEYE 1.2 Introduction to WeldEye
Figure 1: 1. X8 MIG Welder 2. Kemppi FastMig, KempArc or A7 MIG Welder 3. Other welding
machines
WeldEye's modular structure is based on various useful functions that serve the needs of wideranging industries and welding-related tasks:
Welding procedures
Includes the digital library and management of pWPS, WPQR and WPS templates according to
the most important 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 and features for comprehensive welding project
documentation and management.
For more information on the full system and other modules, see www.weldeye.com.
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WELDEYE 1.3 Security
1.3 Security
Smart Reader is a handheld IoT device, and the related security issues have been taken into
account accordingly.
Smart Reader is a locked-down, embedded Linux-based device. It connects to a WiFi network,
communicates via encrypted HTTPS channel, and continuously uploads data as it is recorded.
Smart Reader is not dependent on an uninterrupted stable Internet connection; it works
seamlessly 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 normal mode thus not being a threat to the
underlying network infrastructure. Using the device as attack tool against the client infrastructure
was not found feasible during testing.
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WELDEYE 2.1 Parts
2 Structure
2.1 Parts
1. Display
Use the keyboard to scroll and select items.
2. Keyboard
• Up and down arrow buttons: press to 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
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WELDEYE 2.1 Parts
6. Buttons on the back under the sticker: BMS, RST, PWR
For resetting and troubleshooting purposes. Use a thin object, for example, a paper clip, to
press the buttons.
7. USB port
For maintenance purposes. Only USB flash storages (USB sticks) may be connected to the
port. Smart Reader configuration files and update packages are transferred to the Smart
Reader via USB port.
8. Micro USB connector
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 available as an accessory, ordered separately. It protects the device from metal
dust and provides additional protection if the device, for example, falls from heights.
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WELDEYE 2.1 Parts
1
2
Figure 2: Attaching the silicon cover
Hanging Smart Reader
You can hang Smart Reader by the hook on the handle of the wire feeder.
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WELDEYE 2.2 Main screen and navigation
2.2 Main screen and navigation
1. WPS pass number
To change the pass, press left/right arrow buttons.
2. Wifi icon
See Configure Smart Reader's network connection on page 20.
3. Qualification deviation alert
The alert is shown if the welder 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 go to other views and settings.
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WELDEYE 3.1 Smart Reader operating principle
3 Getting started
To take Smart Reader into use:
1. Connect Smart Reader to the welding machine.
2. Power on the Smart Reader. The first time you power on Smart Reader, the SD card is
formatted.
3. Link Smart Reader to your company WeldEye account.
4. Configure Smart Reader'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 servers to send and receive data to/from
the WeldEye cloud service.
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WELDEYE 3.1 Smart Reader operating principle
3.1.1 How welding data is recorded
Smart Reader collects welding parameter data automatically. Every weld is recorded, and the data
is stored.
Smart Reader communicates with the welding machine via a data link, reading information such
as current, voltage, and wire feed speed. This is possible natively with some Kemppi-branded
welding machines. For other arc welding machines, an additional adapter device is needed.
The adapter has a sensor that measures the current and voltage from the poles of the welding
machine's power source.
Smart Reader knows when the welding arc is ignited and stopped, and can thus distinguish
individual welding runs and tally arc time.
Smart Reader stores welding parameter data on an SD card. After every weld run, the data is
sent to the WeldEye cloud service for analysis and reporting. In a normal situation, the welding
data is visible in WeldEye within a few seconds after welding has ended. It is not possible to see
ongoing welding in the WeldEye cloud service; the information is transmitted only after welding
has ended.
If Smart Reader is not connected to WiFi or cannot connect to the Internet, the data is kept in
the buffer/queue until network becomes available again. The SD card has enough space to store
several months' welding data (in three shifts around the clock). When network connectivity is
restored, the data is sent to WeldEye.
Smart Reader is battle-tested in production use in numerous different environments, with all sorts
of arc welding: manual, mechanized and 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 natural
jitter in weld data. It is possible to filter away starts and stops of the weld, as hot start and crater
fill mechanisms of welding machines are not compliant with WPSes.
3.1.2 Identifier database
Smart Reader can provide 100 % traceability to every weld. To do this, various identifiers are
entered to the system before welding in order to give meaning to the welding data; for example,
the person welding, the WPS, and the weld number.
The identifying data is created and managed in the WeldEye cloud service. Smart Reader receives
this information from the cloud service and matches it with the identifiers that the welder enters
manually or with barcodes.
The identifier database is synchronized from WeldEye to the Smart Reader every 15 minutes when
the device is online. In Smart Reader, the database is stored in the SD card, so Smart Reader can
be used reliably in times when network connectivity is poor. If a new barcode (for example, a new
filler batch number) is entered to the system, it becomes available in the cloud service and for all
the Smart Readers connected to the service.
The 15 minute delay in updating the identifier database means that it will take up to 15 minutes
for Smart Reader to recognize any new identifiers that are added to the WeldEye database.
3.1.3 Measurement of parameters
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WELDEYE 3.2 Connect Smart Reader to the welding machine
Because of voltage drop and fluctuation in parameters, the measurement values are not
necessarily measured and displayed in WeldEye exactly as they are shown on the welding
machine, but they are still displayed in a meaningful manner and according to welding norms.
Fluctuation and averaging
Welding parameters always fluctuate during the welding. To show parameter data in a useful
format, WeldEye uses averaging to filter out extremes and to show the average graph of the
welding performance. You can adjust the averaging according to your needs in the Settings view.
Voltage drop
In MIG welding machines with long cables (from power source to wire feeder to gun), the voltage
drop can be significant due to electrical resistance. Therefore, welding machine power sources
generate a voltage ("pole voltage") that is higher than the voltage in the welding arc. Therefore,
voltage can be measured either at the poles of welding machine or at/near the arc. WeldEye
always tries to measure the effective arc voltage, but if this is not possible, WeldEye calculates it
based on cable lengths.
It is possible to define the cable length in Smart Reader to compensate for the voltage drop.
When you use WeldEye with Kemppi X8 MIG Welder and Kemppi FastMig X welding machines,
the compensation is done automatically.
Accuracy of measurements
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 show the true value.
Standard IEC 60974-1 and accuracy also applies to WeldEye's Universal Adapters. Thus, there can
be quite a large difference between what the welding machine displays and what the sensors
measure. However, in practice, the error is usually much smaller than what the standard allows.
Welding machines and measurement devices must be validated every two years to ensure they
are still accurate.
3.1.4 Time-keeping
To provide an accurate picture of welding activities, Smart Reader has a built-in real-time clock.
It is used to record the time of weld run starts, stops, parameter samples, and other events. It is
automatically kept synchronized through the cloud service.
Internally, Smart Reader uses global UTC time (Coordinated Universal Time), but adjusts it to the
time zone of the user. The time zone is controlled site-wide in the WeldEye cloud service.
The time is displayed as the user's local time in the Smart Reader's display and in the WeldEye
cloud service. In the cloud service, it is possible to search for weld runs according to the time the
welding took place.
3.2 Connect Smart Reader to the welding machine
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WELDEYE 3.2 Connect Smart Reader to the welding machine
Smart Reader needs to be connected to a welding machine to be able to record the measured
current and voltage parameters.The way to connect it depends on the type of welding machine. In
most cases,you need an additional adapter that measures the current and voltage.
With the following welding machines you do not need an adapter, as the machines have native
measurement functionality: Kemppi FastMig KMS/M/Pulse/X, KempArc KMS/Pulse, Kemppi A7
MIG Welder.
Figure 3: Welding machines and accessories for WeldEye usage. * Other brand welding machines can
be any welding machines.
When 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 feeder, depending on which is more convenient to you.
Note: Smart Reader cannot be connected to Kemppi FastMig KM machines. Smart
Reader is not required for Kemppi X8 MIG Welder, as it has built-in WeldEye functionality.
3.2.1 Connect Smart Reader to Kemppi FastMig KMS/M/Pulse/X,
KempArc KMS/Pulse, Kemppi A7
You do not need an adapter, when you connect Smart Reader to one of these welding machines.
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WELDEYE 3.2 Connect Smart Reader to the welding machine
Connect the 4-pin connector of the connection cable to the Smart Reader: align the pins,
1.
push, and turn.
Connect the 7-pin round connector of the connection cable either to the welding machine
2.
power source or to the wire feeder, whichever is more convenient for you.
3.2.2 Connect Smart Reader to other welding machines
Use an adapter for measuring voltage and current. Available adapters include:
ARC Universal Adapter - CV
Compatible with all MIG/MAG and MMA machines, and with TIG welding machines without
High frequency ignition. Connects to the power source. 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 Adapter
Always use this adapter with (high-voltage) submerged arc welding machines. Compatible
with heavy automatized welding machines used for SAW/121/125 welding processes. Rated
for maximum 1600 A welding current.
For detailed information, see the user manual of each device.
Warning: Universal Adapter -CV, TIG and SAW Adapter must be installed by a licensed
electrician.
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WELDEYE 3.2 Connect Smart Reader to the welding machine
3.2.2.1 Connect Smart Reader with ARC Universal Adapter - CV
Connect the connection cable from Smart Reader to the adapter.
1.
Connect the adapter to a separate power supply with ARC Control Cable (required to power
2.
the Smart Reader).
Connect the adapter to the welding machine ground connector, and the Dix branch
3.
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
Connect the connection cable from Smart Reader to the adapter.
1.
Connect the adapter to a separate power supply with ARC Control Cable (required to power
2.
the Smart Reader).
Connect the adapter to the wire feeder’s Euro gun connector, and the Dix branch connector
3.
between the power source and ground cable.
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WELDEYE 3.2 Connect Smart Reader to the welding machine
Figure 5: Connecting ARC Euro Adapter and Smart Reader to welding machine
3.2.2.3 Connect Smart Reader with ARC Universal Adapter - TIG
Connect the connection cable from Smart Reader to the adapter.
1.
Connect the adapter to a separate power supply with ARC Control Cable (required to power
2.
the Smart Reader).
Connect the adapter to the welding machine ground connector, and the Dix branch
3.
connector to the opposite pole.
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WELDEYE 3.2 Connect Smart Reader to the welding machine
Figure 6: Connecting ARC Universal Adapter TIG and Smart Reader to a welding machine
3.2.2.4 Connect Smart Reader with ARC SAW Adapter
Connect the connection cable from Smart Reader to the adapter.
1.
Connect the adapter to a separate power supply with ARC Control Cable (required to power
2.
the Smart Reader).
Bolt the adapter to the welding cable.
3.
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WELDEYE 3.3 Switch Smart Reader ON and OFF
Figure 7: Connecting ARC SAW Adapter and Smart Reader to a welding machine
3.3 Switch Smart Reader ON and OFF
If the Smart Reader is directly connected to the welding machine, Smart Reader is automatically
switched on or off when the welding machine is powered on or off.
If Smart Reader is connected to an adapter, it is powered on continuously. To switch Smart Reader
off, unplug the adapter power source.
When Smart Reader is powering on, the booting phase takes a couple of minutes. During
the booting, a logo is displayed. When Smart Reader has started, it asks the user to log in by
scanning a barcode.
Smart Reader's barcode 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 powered on for up to 2 minutes after the main is powered off. On the
backside of the device, under the plastic cover, there is a red LED light to indicate that the device
is still on.
If Smart Reader's battery has been discharged during a long period of shelving or other non-use
period, Smart Reader needs to be connected and powered on for up to 2 hours for the battery to
become charged and for the Smart Reader to start up.
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WELDEYE 3.4 Link Smart Reader to your company WeldEye account
3.4 Link Smart Reader to your company WeldEye account
Only WeldEye support personnel can link a Smart Reader to your WeldEye account. Contact the
support personnel and give them the serial number of the Smart Reader printed on the sticker on
the back of the device under the cover.
See Contact information on page 37.
3.5 Configure Smart Reader's network connection
Select the wireless network and enter the password in WeldEye cloud service, and transfer the
settings configuration file to Smart Reader.
Follow these steps:
In WeldEye, go to Administration view, and select Configurations.
1.
Click Add new.
2.
Fill in the information.
3.
Click Save. The settings are saved in the Configuration list.
4.
To download the settings file to your computer, check the box next to the configuration, and
5.
click Actions > Download.
Note: Link Smart Reader to WeldEye before downloading the configuration file. The
configuration file only applies to Smart Readers that are in the Devices list at the
time of the download.
Copy the downloaded file on a USB stick, and disconnect it from the computer.
6.
Connect the USB stick to Smart Reader.
7.
Smart Reader asks whether to change the network settings. Answer YES.
8.
Smart Reader now automatically connects to the network. WiFi icon on the top right corner of the
display shows the connection state:
• No icon - Smart Reader is not connected to WiFi.
• White icon - Smart Reader is connected to WiFi, but cannot communicate with the WeldEye
server.
• Green icon - Smart Reader is connected to WiFi, and WeldEye communication works.
If the icon is constantly toggling between no-icon and white-icon states, wifi reception may be
poor at that spot. Move the device closer to the WiFi access point, or install additional access
points.
If the icon is toggling between white-icon and green-icon states, wifi reception may be poor at
that spot, or there may be an error. Contact WeldEye support. See Contact information on page
37.
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WELDEYE 3.6 Internet connectivity requirements
3.6 Internet connectivity requirements
Smart Reader only supports WiFi connections. DHCP (automatic IP addressing) must be enabled
in the network. Only IPv4 protocol is supported.
Wireless network requirements
Wireless network should cover the entire area of the factory where devices are being used. Arc
welding has minimal effect on the quality of the WiFi signal, but, for example, steel structures
between the wireless router and the Smart Reader can block the signal.
Constantly poor wireless signal levels may affect the usage of WeldEye.
It is recommended that the wireless network is an isolated network that is not open to the
company internal network.
Smart Reader supports the following WLAN configurations:
• WLAN standards: 802.11b, 802.11g, 802.11n
WLAN encryption methods: 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 compressed.
For inbound traffic, devices fetch updated information every 15 minutes, causing up to
15 megabytes of traffic for 10 devices in a day.
Firewall configuration requirements
Devices connecting to WeldEye need unfiltered HTTPS access to the cloud service (address
https://weldeye.prod.api.kemppi.com) at port TCP 443.
If your firewall uses a MAC address-based filtering, each of the device’s MAC addresses must be
allowed to connect to the network.
If you have a transparent SSL proxy installed, it must be configured to bypass accesses to the
address: weldeye.prod.api.kemppi.com.
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WELDEYE 4.1 Welder's workflow with Smart Reader
4 Collecting welding data
Smart Reader always collects welding data when connected to the welding machine and powered
on, even if no bar codes have been scanned.
4.1 Welder's workflow with Smart Reader
Note: If your Smart Reader has a 1d scanner, make sure the light is bright enough and
the barcode lies on a flat surface so that the device is able to scan the barcode.
To associate the welder with the following welding data, log in to the Smart Reader by
1.
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.
Scan barcodes to give meaning to the welding data. If you do not have a barcode, enter the
2.
identifiers manually with the virtual keyboard by selecting Menu → Enter barcodes. The
following information types are supported:
• Welder
• WPS
• Filler material ("Wire")
• Filler material batch number ("Wire batch")
• Shielding gas ("Gas")
• Weld
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WELDEYE 4.1 Welder's workflow with Smart Reader
• Project
• Piece
• Work
Note:
• The identifier for which the barcode is scanned does not need to be highlighted
on the screen.
• It is possible to scan identifiers that are not listed on the display.
• Smart Reader's barcode reader turns itself off after 2 minutes of inactivity. To read
barcodes again, press the selection button.
a) Identify the WPS to be used by scanning the WPS barcode on a printed document. Select
pass number on the display. If there is only one pass, the pass selection is not shown.
If there is no barcode to scan, select the WPS using arrow buttons: In the main view, select
WPS. In the WPS list view, select Filter to narrow down the list. Then, browse the WPS list
to find the correct WPS.
b) Scan the weld barcode to identify the weld.
Smart Reader displays the weld number, project and other information about the weld.
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 and will
appear in Weldeye.
To enter filler batch number if there is no barcode, select Menu > Enter barcode, and
enter the barcode with the virtual keyboard. The first time the barcode is entered, Smart
Reader reports that it is an unknown barcode. Select Define > Wire batch.
To change pass within the WPS, press the left/right arrow button. Alternatively, you can scan
3.
the WPS barcode again, or use the menu to find the correct WPS and pass.
To mark that the weld is complete, select Menu > Weld Complete. Enter the length of the
4.
weld. This enables the calculation of heat input. For more information, see Heat input tracking
on page 27.
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WELDEYE 4.2 Identifiers shown on Smart Reader
Note: The Weld complete function requires that the Weld barcode has been
scanned. Availability of the Weld Complete function is controlled in WeldEye cloud
service settings.
When you finish using the welding machine, log out of Smart Reader so that the following
5.
welding data will not get registered under your name. To log out, select Menu > Log out.
Powering off the Smart Reader will also log out the welder, so that there is no need to
manually log out.
Note: WeldEye cloud service provides two settings that control logout behaviour:
• Automatic logout: when this setting is 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 Reader
In the WeldEye cloud service settings, it is possible to control which identifiers Smart Reader
suggests to the welder, that is, which identifiers are displayed on the Smart Reader even before
they are scanned (displayed as grey text). For example, you can select to display the identifiers
that are compulsory for the welder to scan. Other identifiers can still also be scanned.
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WELDEYE 4.3 Alerts shown on Smart Reader
4.3 Alerts shown on Smart Reader
Smart Reader shows alerts for insufficient welder qualifications, wrong filler material, and wrong
shielding gas.
WeldEye compares the range of qualifications on the welder's qualification certificates that are
stored in WeldEye to the qualifications required by the WPS. (The range of qualifications applies
to EN/ISO standards only). If the welder does not have a 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 shielding gas defined in the WPS. If these do not
match, the system raises an alert.
In the WeldEye Settings view, you can select whether the system raises alerts for non-conforming
qualifications or not.
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WELDEYE 4.4 Reason codes
4.4 Reason codes
Reason codes are a means of tracking non-welding time, that is, events that cause pauses in
the production. Reason codes can mark both expected pauses, like lunch breaks, or unexpected
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:
Select Menu > Set reason code.
1.
Browse the list of reason codes with up/down arrow buttons, and select the code you need.
2.
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WELDEYE 4.5 Heat input tracking
The reason code becomes visible in Smart Reader main screen. Reason code is active until Smart
Reader detects welding or until other reason code is selected.
Note: Logging out does not erase the reason code, even if Smart Reader does not show
that a reason code is active after a new login.
4.5 Heat input tracking
Smart Reader can track the heat input of each weld and give feedback to the welder about the
heat input values.
Heat input tracking is achieved with the Pass complete function. Pass complete function requires
the user to read the Weld barcode and weld at least one run after it. After welding, the Pass
complete selection appears in the menu.
The heat input is calculated based on travel speed, welding current, voltage, and the welding
process. Since there is no automated way to measure welding travel speed, WeldEye calculates it
based on the welding arc time and length of the weld entered by the welder.
To track heat input:
Before welding:
1.
a) Log in to Smart Reader.
b) 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.
After welding, select Menu > Complete pass.
2.
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 is recorded and documented. Pass complete can also be triggered if you try to
select Weld complete but the pass has not yet been completed.
Enter the welded length (mm). Use the virtual keyboard by moving the highlight with the
3.
arrow buttons and select the desired highlighted numbers or virtual buttons with the middle
button.
Note:
The length may be preset in WeldEye, but you can change it if needed.
4.
After the pass has been marked complete, Smart Reader shows the actual average heat input and
travel speed and whether they were within the WPS limits. The welder can adjust his parameters
or welding technique based on this feedback. The data is also sent to WeldEye cloud service for
documentation.
Heat input tracking feature is enabled in the WeldEye cloud service.
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WELDEYE 4.6 Weld Data view after welding
4.6 Weld Data view after welding
After welding, Smart Reader can display the Weld data view, which shows the minimum and
maximum current and voltage of the last welding. The welder can adjust his parameters or
welding technique 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 WeldEye cloud service settings.
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WELDEYE 5.1 Cable compensation
5 Other Smart Reader features
5.1 Cable compensation
Cable compensation enables the welder to adjust the welding voltage measurement in the case
that the welding machine has long intermediate cables, long earth cables, or long torch/gun
cables. The higher the welding current is and the longer and thinner the welding cables are, the
greater resistance occurs in the electrical circuit, leading to voltage loss. The cable compensation
function calculates the actual reduced voltage at the work piece based on the measured value at
the power source and the length and area of cables given by the welder.
To set up cable compensation:
In Smart Reader, select Menu > Settings.
1.
Select Set cable area, and enter the value ∅ x Π (the diameter of the intermediate cables and
2.
earth cables multiplied by pi).
Select Set cable compensation length, and enter the total length of the cables (accuracy of
3.
one meter).
Figure 8: Example of long intermediate cables, total length = 13m
5.2 Real-time WPS monitoring
Smart Reader displays the welding current and voltage while welding, and indicates whether
the values are within the limits of the currently identified WPS. This information is useful for
bystanders observing the welding, and in the case of mechanized welding, for the welding
operator.
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WELDEYE 5.3 Channel WPS
The measured welding current and voltage are displayed on the screen as large text (A), and the
WPS parameter limits as smaller text (B).
Color codes:
• Green: OK, measured value well within the WPS limits.
• Yellow: Warning, measured value near WPS limits.
• Red: Alert, measured value outside limits.
• White: WPS is not identified, only the measured values are shown with no indication of
whether they are correct.
There is a short grace period ("reaction time"), usually a few seconds, before the color changes.
This makes the display easier to read and enables the monitoring the overall welding quality.
For more information on Real-time WPS monitoring, see WeldEye help.
5.3 Channel WPS
Channel WPS is a feature that can be used with Kemppi welding machines only (FastMig family).
Channel WPS is enabled in the Smart Reader's settings for each 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 number of
WPSes is small. A typical use case for the feature is when the welding job requires welding over
corner so that the welding parameters and thus WPS needs to change on the fly without shutting
down the arc at any point.
Channel WPS also supports the MatchLog features. In FastMig pulse and FastMig X, the welder
is able to switch the memory channel on the fly using the MatchChannel feature. In FastMig KMS
and FastMig M, the welder is able to toggle the MiniLog feature during the welding. In both
cases, Smart Reader automatically divides the weld into sections based on the memory channel
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WELDEYE 5.4 WPS suggestion for weld identifiers
selection or MiniLog's state changes. The correct WPS is always applied during the welding based
on the predefined mappings.
5.4 WPS suggestion for weld identifiers
In the WeldEye cloud service, it is possible to assign one or more WPSes for a weld identifier.
When the weld barcode is scanned with Smart Reader, Smart Reader can automatically select the
correct WPS, or display a selection list of WPSes.
This feature is controlled in the WeldEye cloud service settings.
5.5 TIG drop-down filtering
To reduce the number of unnecessary warnings on the Smart Reader display, Smart Reader
applies TIG drop-down filtering.
When welding long runs with TIG, it is not ideal to stop the arc. However, the welder may need to
change the filler wire during welding while keeping the welding bead melting. During this time,
the welding current can be dropped to low levels to keep the arc on, but not burning through the
base material.
This feature is controlled in the WeldEye 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 desirable to enforce the use of Smart Reader to ensure that all welding
parameters are collected. For these occasions, it is possible to adjust FastMig X welding machine
so that it cannot be used for welding if Smart Reader is not connected and welder identification
scanned. Furthermore, it is possible to require the welder to give the WPS identification before
the welding machine is functional.
WPS limits enforcement
Smart Reader can adjust the welding machine automatically according to the parameter values
defined in the WPS, and enforce the WPS limits so that they cannot be exceeded by adjustments
through the welding machine panel. Smart Reader can automatically adjust the following welding
parameters: current, voltage, wire feed speed, and the welding program.
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WELDEYE 6.1 Administrator section views
6 Administration
Administrator section is used mainly for update and troubleshooting purposes. Administrator can
log in to Administrator section in two methods:
• Using a Smart Reader administrator's barcode (Note that the device must be attached to the
company before this is possible)
• Downloading a Smart 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, and connection
status, and possible proxy server and server connection status (working or not working).
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WELDEYE 6.1 Administrator section views
Visible networks view
List of all wireless 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.
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WELDEYE 6.2 Updating Smart Reader firmware
Diagnostics view
Diagnostics information of the Smart Reader state. This view is typically needed when
troubleshooting, for example, network connectivity. The page can be scrolled 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.
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WELDEYE 6.3 Factory reset
Update via USB flash drive (USB stick)
Smart Reader administrator receives the update file (a .xpk suffixed file) from WeldEye support.
The administrator saves the received file on a proper USB flash drive so that the update package
is in the root of the flash drive's file system ( D:\update_package.xpk.)
Administrator logs in to SmartReader's administration section.
Once the user is logged in as an administrator, Smart Reader automatically prompts for an
update. Select to install update. Smart Reader shuts down and starts the update process. Once
ready, Smart Reader informs about successful update.
Note: If Smart Reader reports an error when the USB stick is inserted, it is possible that
the device did not go to administrator mode. To start the administrator mode, press the
small BMS button on the back side of Smart Reader (for example, with a piece 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 the update:
• Smart Reader administrator logs into the Smart Reader's admin view. Once the user is logged
in as an administrator, Smart Reader prompts automatically to update the device software.
Select to install update, and update operation starts.
• Power off the welding machine for over two minutes, and then power it on. On start-up, Smart
Reader automatically updates the firmware.
6.3 Factory reset
Smart Reader can be reset to the software version that was installed in it in the factory. To reset
the device, press the BMS button under the back cover of the device for 20 seconds. When you
release the button, the reset process starts.
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WELDEYE 6.3 Factory reset
7 Technical specifications
Table 1:
Feature Description
Supported WiFi standards 802.11b, 802.11g, 802.11n
Type Non-removeable Li-IonBattery
Power 2200 mAh
Display
Materials Cover Plastic
Control cable port power DC+ / 50V /200mA
Size
Resolution 480 x 272 pixels
4.3"
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WELDEYE 6.3 Factory reset
8 Contact information
For support and more information on WeldEye, visit www.weldeye.com.
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WELDEYE 6.3 Factory reset
9 Glossary
Table 2:
Term Description
Adapter WeldEye adapter device that measures
current and voltage of a welding machine,
and enables the use of Smart Reader with
any welding machine.
Configuration file Smart Reader WiFi configuration file. Used
during the setup to configure Smart Reader
to connect to a wireless network. The
configuration file is created with WeldEye
cloud service. Contains the WiFi access point
name and password in encrypted format.
Deviation Alert or warning of non-conformance in
welding data. For example, if the welding
was done outside 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 single welding pass, such as the root layer.
May consist of multiple runs.
Pass complete Function that allows the welder to report
the completion of a single welding pass as
completed and enter the length of the weld.
WeldEye can calculate the heat input based
on this data. The function enables pass level
documentation and heat input tracking.
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WELDEYE 6.3 Factory reset
Term Description
Qualification Welder's or welding operator's qualification
to perform certain kinds of welding. Entering
welding certificates in WeldEye enables
the system to determine whether the
welder is qualified to weld certain types of
materials and weld joints according to the
relevant standards. Smart Reader displays
a qualification warning if the welder is not
qualified for a certain WPS.
Reason codes A list of non-welding activities that a welder
typically performs and can report. Use them
to track and categorize side times in various
reports.
Run A single welding run with start time, arc
time, current and voltage parameter data
and associated identifiers.
Smart Reader A device that enables 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 seam number, referring to a single
weld that also appears in technical drawings.
Each weld has a barcode in WeldEye to
allow welding data to be traced back to the
specific individual weld.
Weld complete Function that lets the welder report that
a weld is complete and no further work is
required. Weld completion is then visible in
the Weld Lists view of WeldEye.
WPS Welding Procedure Specification document
describing various aspects of welding
technique, including welding parameters to
use.
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