Miller COBOT INTERFACE 14-PIN INSIGHT CORE MODULE Owners manual

OM-286673C

Processes

MIG (GMAW) Welding
Pulsed MIG (GMAW-P) Welding

Description

Advanced/Automated Welding System

Cobot Interface

14–Pin Insight Core

2022-08

™

Module CE

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

OWNER’S MANUAL

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be
the best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and
service that meets the high standards of quality and value established
in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They
will help you protect yourself against potential hazards on the
worksite. We’ve made installation and operation quick and easy. With
Miller, you can count on years of reliable service with proper
maintenance. And if for some reason the unit needs repair, there’s a
Troubleshooting section that will help you figure out what the problem
is, and our extensive service network is there to help fix the problem.

Working as hard as you do −
every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Warranty and maintenance information for your particular model are
also provided.

Miller Electric manufactures a full line of
welders and welding-related equipment. For
information on other quality Miller products,
contact your local Miller distributor to receive
the latest full line catalog or individual
specification sheets. To locate your nearest

distributor or service agency call
1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Miller is the first welding
equipment manufacturer in the
U.S.A. to be registered to the
ISO 9001 Quality System
Standard.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2 Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-3 Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-4 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-5 Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-6 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-2 Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-3 Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . 7

2-4 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-5 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-6 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-1 Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-2 Information About Default Weld Parameters And Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-3 Compatibility Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-4 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-5 Connections And LED Designations On Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-6 Equipment Connection Diagram With Cobot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3-7 Recommended Cobot Interface Connection Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 4 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-1 Insight Core Quick Installation Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-2 Downloading Connectivity Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4-3 Downloading And Installing Insight Core Setup Application To A PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4-4 Running Configuration App For Installation Of Firmware And Connection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-5 Preparing Firmware For Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-6 Verifying Accessibility Before Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4-7 Configuring The Type Of Insight Core Network Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4-8 Firmware Update Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4-9 Determining Device Serial Number And License Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4-10 Registering Initial Device And Creating An Account . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4-11 Registering Additional Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4-12 Setting Up A Work Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4-13 Setting Up A Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

SECTION 5 – TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SECTION 6 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

DECLARATION OF CONFORMITY

For European Community (CE marked) products.

MILLER Electric Mfg. LLC, 1635 West 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 Directives(s), Commission Regulation(s) and Standard(s).

Product/Apparatus Identification:

Product

Stock Number

COBOT 14-PIN INSIGHT CORE MODULE

301072002

Council Directives and Commission Regulations:

• 2014/53/EU Radio equipment

• 2011/65/EU and amendment 2015/863 Restriction of the use of certain hazardous substances in electrical

and electronic equipment

Standards for conformity with essential requirements of 2014/53/EU:

Standard Reference

Article of 2014/53/EU

EN 62368-1: 2014/AC: 2015
EN 62311:2008

3.1 (a): Health and Safety

ETSI EN 301 489-1 V2.2.3
ETSI EN 301 489-17 V3.2.4
EN 60974-10:2014/A1:2015

3.1 (b): Electromagnetic Compatibility
ETSI EN 300 328 V2.2.2

3.2: Efficient use of Radio Spectrum

Standards for conformity with other essential and relevant requirements:

• EN IEC 63000:2018 Technical documentation for the assessment of electrical and electronic products
with respect to the restriction of hazardous substances

Signatory:

_____________________________________ ___________________________________________

David A. Werba Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

August 10, 2022

292378A

Add Sig

DECLARATION OF CONFORMITY

For United Kingdom (UKCA marked) products.

MILLER Electric Mfg. LLC, 1635 West 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 Regulation(s) and Standard(s).

Product/Apparatus Identification:

Product

Stock Number

COBOT 14-PIN INSIGHT CORE MODULE

301072002

Regulations:

• S.I. 2017/1206 The Radio Equipment Regulations 2017

• S.I. 2012/3032 Restriction of the Use of Certain Hazardous Substances in Electrical and Electronic

Equipment Regulations

Standards for conformity with essential requirements of S.I. 2017/1206:

Standard Reference

Regulation of S.I. 2017/1206

EN 62368-1: 2014/AC: 2015
EN 62311:2008

6.1 (a): Health and Safety

ETSI EN 301 489-1 V2.2.3
ETSI EN 301 489-17 V3.2.4
EN 60974-10:2014/A1:2015

6.1 (b): Electromagnetic Compatibility
ETSI EN 300 328 V2.2.2

6.2: Efficient use of Radio Spectrum

Standards for conformity with other essential and relevant requirements:

• EN IEC 63000:2018 Technical documentation for the assessment of electrical and electronic products
with respect to the restriction of hazardous substances

Signatory:

_____________________________________ ___________________________________________

David A. Werba Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

August 10, 2022

292379A

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! – Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained
in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible haz­ards are shown in the adjoining symbols or explained in
the text.

NOTICE – Indicates statements not related to personal injury.

Indicates special instructions.

F

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instruc­tions to avoid the hazard. The safety information given be­low is only a summary of the more complete safety
information found in the Principal Safety Standards. Read
and follow all Safety Standards.

Only qualified persons should install, operate, maintain,
and repair this equipment. A qualified person is defined as
one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge,
training and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety
training to recognize and avoid the hazards involved.

During operation, keep everybody, especially children,
away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.

cuits are also live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, and all metal parts
touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.

l Do not touch live electrical parts.
l Wear dry, hole-free insulating gloves and body protection.
l Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

l Do not use AC weld output in damp, wet, or confined spaces, or if

there is a danger of falling.

l Use AC output ONLY if required for the welding process.
l If AC output is required, use remote output control if present on

unit.

l Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp loca­tions or while wearing wet clothing; on metal structures such as
floors, gratings, or scaffolds; when in cramped positions such as
sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual

The input power circuit and machine internal cir-

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult
symbols and related instructions below for necessary actions to
avoid these hazards.

(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

l Disconnect input power or stop engine before installing or servic-

ing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

l Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

l Always verify the supply ground —check and be sure that input

power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

l When making input connections, attach proper grounding conduc-

tor first—double-check connections.

l Keep cords dry, free of oil and grease, and protected from hot met-

al and sparks.

l Frequently inspect input power cord and ground conductor for

damage or bare wiring — replace immediately if damaged — bare
wiring can kill.

l Turn off all equipment when not in use.
l Do not use worn, damaged, undersized, or repaired cables.
l Do not drape cables over your body.
l If earth grounding of the workpiece is required, ground it directly

with a separate cable.

l Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

l Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

l Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

l Wear a safety harness if working above floor level.
l Keep all panels and covers securely in place.
l Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

l Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

l Do not connect more than one electrode or work cable to any sin-

gle weld output terminal. Disconnect cable for process not in use.

l Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

OM-286673 Page 1

HOT PARTS can burn.

l Do not touch hot parts bare handed.
l Allow cooling period before working on equipment.
l To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to

prevent burns.

FLYING METAL OR DIRT can injure

eyes.

l Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they
can throw off slag.

l Wear approved safety glasses with side shields even under your

welding helmet.

FUMES AND GASES can be

hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

l Keep your head out of the fumes. Do not breathe the fumes.
l Ventilate the work area and/or use local forced ventilation at the

arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

l If ventilation is poor, wear an approved air-supplied respirator.
l Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, con­sumables, coolants, degreasers, fluxes, and metals.

l Work in a confined space only if it is well ventilated, or while wear-

ing an air-supplied respirator. Always have a trained watchperson
nearby. Welding fumes and gases can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.

l Do not weld in locations near degreasing, cleaning, or spraying

operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.

l Do not weld on coated metals, such as galvanized, lead, or cadmi-

um plated steel, unless the coating is removed from the weld area,
the area is well ventilated, and while wearing an air-supplied respi­rator. The coatings and any metals containing these elements can
give off toxic fumes if welded.

BUILDUP OF GAS can injure or kill.

l Shut off compressed gas supply when not in use.
l Always ventilate confined spaces or use approved

air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

l Wear an approved welding helmet fitted with a proper shade of fil-

ter lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).

l Wear approved safety glasses with side shields under your

helmet.

l Use protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

l Wear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leath­er gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

OM-286673 Page 2

WELDING can cause fire or

explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up.

Sparks can fly off from the welding arc. The flying
sparks, hot workpiece, and hot equipment can cause fires and burns.
Accidental contact of electrode to metal objects can cause sparks, ex­plosion, overheating, or fire. Check and be sure the area is safe be­fore doing any welding.

l Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

l Do not weld where flying sparks can strike flammable material.
l Protect yourself and others from flying sparks and hot metal.
l Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

l Watch for fire, and keep a fire extinguisher nearby.
l Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

l Do not cut or weld on tire rims or wheels. Tires can explode if

heated. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

l Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 (see Safety Standards).

l Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

l 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.

l Do not use welder to thaw frozen pipes.
l Remove stick electrode from holder or cut off welding wire at con-

tact tip when not in use.

l Wear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leath­er gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

l Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

l After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

l Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

l Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

l Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, con­sumables, coolants, degreasers, fluxes, and metals.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

l Wear approved ear protection if noise level is high.

ELECTRIC AND MAGNETIC FIELDS
(EMF) can affect Implanted Medical
Devices.

l Wearers of Pacemakers and other Implanted Med-

ical Devices should keep away.

l Implanted Medical Device wearers should consult their doctor and

the device manufacturer before going near arc welding, spot weld­ing, gouging, plasma arc cutting, or induction heating operations.

CYLINDERS can explode if

damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the weld-

ing process, be sure to treat them carefully.

l Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

l Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

l Keep cylinders away from any welding or other electrical circuits.
l Never drape a welding torch over a gas cylinder.
l Never allow a welding electrode to touch any cylinder.

l Never weld on a pressurized cylinder—explosion will result.
l Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

l Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the
valve.

l Keep protective cap in place over valve except when cylinder is in

use or connected for use.

l Use the proper equipment, correct procedures, and sufficient

number of persons to lift, move, and transport cylinders.

l Read and follow instructions on compressed gas cylinders, asso-

ciated equipment, and Compressed Gas Association (CGA) publi­cation P-1 listed in Safety Standards.

1-3. Additional Hazards For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

l Do not install or place unit on, over, or near com-

bustible surfaces.

l Do not install unit near flammables.
l Do not overload building wiring — be sure power

supply system is properly sized, rated, and protected to handle
this unit.

FALLING EQUIPMENT can injure.

l Use lifting eye to lift unit only, NOT running gear,

gas cylinders, or any other accessories.

l Use correct procedures and equipment of ad-

equate capacity to lift and support unit.

l If using lift forks to move unit, be sure forks are long enough to ex-

tend beyond opposite side of unit.

l Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

l Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94-110) when manually
lifting heavy parts or equipment.

OVERUSE can cause

OVERHEATING.

l Allow cooling period; follow rated duty cycle.
l Reduce current or reduce duty cycle before start-

ing to weld again.

l Do not block or filter airflow to unit.

FLYING SPARKS can injure.

l Wear a face shield to protect eyes and face.
l Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

l Sparks can cause fires—keep flammables away.

STATIC (ESD) can damage PC

boards.

l Put on grounded wrist strap BEFORE handling

boards or parts.

l Use proper static-proof bags and boxes to store,

move, or ship PC boards.

MOVING PARTS can injure.

l Keep away from moving parts.

l Keep away from pinch points such as drive rolls.

WELDING WIRE can injure.

l Do not press gun trigger until instructed to do so.

l Do not point gun toward any part of the body, other

people, or any metal when threading welding wire.

BATTERY EXPLOSION can injure.

l Do not use welder to charge batteries or jump start

vehicles unless it has a battery charging feature
designed for this purpose.

MOVING PARTS can injure.

l Keep away from moving parts such as fans.
l Keep all doors, panels, covers, and guards closed

and securely in place.

l Have only qualified persons remove doors, panels,
covers, or guards for maintenance and troubleshooting as
necessary.

l Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

l Read and follow all labels and the Owner’s Manual

carefully before installing, operating, or servicing
unit. Read the safety information at the beginning
of the manual and in each section.

l Use only genuine replacement parts from the manufacturer.
l Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and lo­cal codes.

H.F. RADIATION can cause

interference.

l High-frequency (H.F.) can interfere with radio navi-

gation, safety services, computers, and communi­cations equipment.

l Have only qualified persons familiar with electronic equipment per-

form this installation.

l The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

l If notified by the FCC about interference, stop using the equipment

at once.

l Have the installation regularly checked and maintained.
l Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

OM-286673 Page 3

ARC WELDING can cause

interference.

l Electromagnetic energy can interfere with sensitive

electronic equipment such as microprocessors,
computers, and computer-driven equipment such

as robots.

l Be sure all equipment in the welding area is electromagnetically

compatible.

1-4. California Proposition 65 Warnings

WARNING – This product can expose you to chemicals in­cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Pro­tection, ANSI Standard Z87.1, from American National Standards In-

stitute. Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Weld­ing and Cutting, American Welding Society Standard AWS F4.1.

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Pro­tection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P­1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.

csagroup.org.

l To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

l Locate welding operation 100 meters from any sensitive electronic

equipment.

l Be sure this welding machine is installed and grounded according

to this manual.

l If interference still occurs, the user must take extra measures such

as moving the welding machine, using shielded cables, using line
filters, or shielding the work area.

For more information, go to www.P65Warnings.ca.gov.

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Sub­part N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH). Web­site: www.cdc.gov/NIOSH.

SOM 2022–01

1-6. EMF Information

Electric current flowing through any conductor causes localized elec­tric and magnetic fields (EMF). The current from arc welding (and al­lied processes including spot welding, gouging, plasma arc cutting,
and induction heating operations) creates an EMF field around the
welding circuit. EMF fields can interfere with some medical implants,
e.g. pacemakers. Protective measures for persons wearing medical
implants have to be taken. For example, restrict access for passers

−by or conduct individual risk assessment for welders. All welders
should use the following procedures in order to minimize exposure to
EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the weld­ing circuit as possible.

5. Connect work clamp to workpiece as close to the weld as
possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire
feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding,
spot welding, gouging, plasma arc cutting, or induction heating opera­tions. If cleared by your doctor, then following the above procedures
is recommended.

OM-286673 Page 4

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT

UTILISATION

Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

DANGER! – Indique une situation dangereuse qui si on l’é­vite pas peut donner la mort ou des blessures graves. Les
dangers possibles sont montrés par les symboles joints
ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut
donner la mort ou des blessures graves. Les dangers pos­sibles sont montrés par les symboles joints ou sont expli­qués dans le texte.

AVIS – Indique des déclarations pas en relation avec des blessures
personnelles.

Indique des instructions spécifiques.

F

2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce
manuel pour attirer l’attention et identifier les dangers pos­sibles. En présence de ce symbole, prendre garde et suivre
les instructions afférentes pour éviter tout risque. Les
consignes de sécurité présentées ci-après ne font que résu­mer l’information contenue dans les Normes de sécurité
principales. Lire et suivre toutes les Normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une per­sonne qualifiée est définie comme celle qui, par la posses­sion d’un diplôme reconnu, d’un certificat ou d’un statut
professionnel, ou qui, par une connaissance, une formation
et une expérience approfondies, a démontré avec succès sa
capacité à résoudre les problèmes liés à la tâche, le travail
ou le projet et a reçu une formation en sécurité afin de re­connaître et d’éviter les risques inhérents.

Au cours de l’utilisation, tenir toute personne à l’écart et
plus particulièrement les enfants.

UNE DÉCHARGE ÉLECTRIQUE peut

entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures

sous tension lorsque le courant est délivré à la sortie. Le circuit d’ali­mentation et les circuits internes de la machine sont également sous
tension lorsque l’alimentation est sur Marche. Dans le mode de sou­dage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau
et toutes les parties métalliques en contact avec le fil sont sous ten­sion électrique. Un équipement installé ou mis à la terre de manière
incorrecte ou impropre constitue un danger.

l Ne pas toucher aux pièces électriques sous tension.
l Porter des gants isolants et des vêtements de protection secs et

sans trous.

l S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.

l Ne pas utiliser de sortie de soudage CA dans des zones humides

ou confinées ou s’il y a un risque de chute.

l Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

l 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.

l D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement hu­mide ou si l’on porte des vêtements mouillés ; sur des structures

graves. Le circuit de l’électrode et de la pièce est

Ce groupe de symboles veut dire Avertissement! Attention! DAN­GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE­CES CHAUDES. Reportez-vous aux symboles et aux directives ci­dessous afin de connaître les mesures à prendre pour éviter tout
danger.

métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder
ou le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste
à souder AC à tension à vide réduite. Dans la plupart des situ­ations, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !

l Couper l’alimentation ou arrêter le moteur avant de procéder

à l’installation, à la réparation ou à l’entretien de l’appareil. Déver­rouiller l’alimentation selon la norme OSHA 29 CFR 1910.147
(voir normes de sécurité).

l Brancher correctement la mise à la terre et utiliser cet appareil

conformément à son manuel d’utilisateur et aux codes nationaux,
provinciaux et municipaux.

l Toujours vérifier la mise à la terre — vérifier et assurez-vous que

le conducteur de mise à la terre du cordon d’alimentation est bien
raccordé à la borne de mise à la terre dans le boîtier de déconne­xion ou que la fiche du cordon est raccordée à une prise correcte­ment mise à la terre.

l En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

l Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez-les contre les étincelles et les pièces métalliques
chaudes.

l Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé -,
le remplacer immédiatement s’il l’est -. Un fil dénudé peut entraî­ner la mort.

l L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
l Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

l Ne pas enrouler les câbles autour du corps.
l Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

l Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

l Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide
doublée.

l N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformé­ment à ce manuel.

l Porter un harnais de sécurité si l’on doit travailler au-dessus du

sol.

OM-286673 Page 5

l S’assurer que tous les panneaux et couvercles sont correctement

en place.

l Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.

l Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

l Ne pas raccorder plus d’une électrode ou plus d’un câble de

masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.

l Utiliser une protection différentielle lors de l’utilisation d’un équipe-

ment auxiliaire dans des endroits humides ou mouillés.

LES PIÈCES CHAUDES peuvent

provoquer des brûlures.

l Ne pas toucher des parties chaudes à mains nues.
l Prévoir une période de refroidissement avant de

travailler à l’équipement.

l Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

l Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

des étincelles et des particules métalliques volantes. Pendant la
période de refroidissement des soudures, elles risquent de proje­ter du laitier.

l Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

l Eloigner votre tête des fumées. Ne pas respirer les fumées.
l À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de sou­dage. Pour déterminer la bonne ventilation, il est recommandé de
procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.

l Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

l Lire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidisse­ment, les dégraisseurs, les flux et les métaux.

l Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours
à un surveillant dûment formé de se tenir à proximité. Des fumées
et des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

l Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

l Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

OM-286673 Page 6

LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.

l Fermer l’alimentation du gaz comprimé en cas de

non utilisation.

l Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses

(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.

l Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

l Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

l Avoir recours à des écrans protecteurs ou à des rideaux pour pro-

téger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas re­garder l’arc.

l Porter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des panta­lons sans revers, des chaussures hautes et une casquette.

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés
tels que des réservoirs, tambours ou des conduites
peut provoquer leur éclatement. Des étincelles

peuvent être projetées de l’arc de soudure. La projection d’étincelles,
des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.

l Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.

l Ne pas souder dans un endroit là où des étincelles peuvent tom-

ber sur des substances inflammables.

l Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

l Des étincelles et des matériaux chauds du soudage peuvent faci-

lement passer dans d’autres zones en traversant de petites fissu­res et des ouvertures.

l Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

l Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

l Ne pas couper ou souder des jantes ou des roues. Les pneus peu-

vent exploser s’ils sont chauffés. Les jantes et les roues réparées
peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les
normes de sécurité.

l Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les Nor­mes de Sécurité).

l Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par
exemple).

l Brancher le câble de masse sur la pièce le plus près possible de

la zone de soudage pour éviter le transport du courant sur une lon­gue distance par des chemins inconnus éventuels en provoquant
des risques d’électrocution, d’étincelles et d’incendie.

l Ne pas utiliser le poste de soudage pour dégeler des conduites

gelées.

l En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

l Porter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des panta­lons sans revers, des chaussures hautes et une casquette.

l Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

l Une fois le travail achevé, assurez-vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

l Utiliser exclusivement des fusibles ou coupe-circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

l Suivre les recommandations dans OSHA 1910.252 (a) (2) (iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et
un extincteur à proximité.

l Lire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidisse­ment, les dégraisseurs, les flux et les métaux.

Le BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut
affecter l’ouïe.

l Porter des protections approuvées pour les oreilles

si le niveau sonore est trop élevé.

Les CHAMPS
ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants
médicaux.

l Les porteurs de stimulateurs cardiaques et autres

implants médicaux doivent rester à distance.

l Les porteurs d’implants médicaux doivent consulter leur médecin

et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.

Si des BOUTEILLES sont
endommagées, elles pourront
exploser.

Des bouteilles de gaz comprimé protecteur
contiennent du gaz sous haute pression. Si une

bouteille est endommagée, elle peut exploser. Du fait que les bouteil­les de gaz font normalement partie du procédé de soudage, les mani­puler avec précaution.

l Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

l Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

l Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

l Ne jamais placer une torche de soudage sur une bouteille à gaz.
l Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

l Ne jamais souder une bouteille pressurisée - risque d’explosion.
l Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

l 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 lerégulateur lors
de l’ouverture de la vanne.

l Maintenir le chapeau de protection sur la soupape, sauf en cas

d’utilisation ou de branchement de la bouteille.

l Utilisez les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever, déplacer et transporter les
bouteilles.

l Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de
sécurité.

2-3. Symboles de dangers supplémentaires en relation avec l’installation, le

fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

l Ne pas placer l’appareil sur, au-dessus ou à proxi-

mité de surfaces inflammables.

l Ne pas installer l’appareil à proximité de produits

inflammables

l Ne pas surcharger l’installation électrique – s’assurer que l’alimen-

tation est correctement dimensionné et protégé avant de mettre
l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut

provoquer des blessures.

l Utiliser l’anneau de levage uniquement pour soule-

ver l’appareil, NON PAS les organes de roulement,
les bouteilles de gaz ou tout autre accessoire.

l Utilisez les procédures correctes et des équipements d’une capa-

cité appropriée pour soulever et supporter l’appareil.

l En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.

l Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

l Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

l Laisser l’équipement refroidir ; respecter le facteur

de marche nominal.

l Réduire le courant ou le cycle opératoire avant de

recommancer le soudage.

l Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

l Porter un écran facial pour protéger le visage et

les yeux.

OM-286673 Page 7

l Affûter l'électrode au tungstène uniquement à la meuleuse dotée

de protecteurs. Cette manœuvre est à exécuter dans un endroit
sûr lorsque l'on porte l'équipement homologué de protection du vi­sage, des mains et du corps.

l Les étincelles risquent de causer un incendie - éloigner toute sub-

stance inflammable.

LES CHARGES
ÉLECTROSTATIQUES peuvent
endommager les circuits imprimés.

l Établir la connexion avec la barrette de terre

AVANT de manipuler des cartes ou des pièces.

l Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent
causer des blessures.

l Ne pas s’approcher des organes mobiles.
l Ne pas s’approcher des points de coincement tels

que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

l Ne pas appuyer sur la gachette avant d’en avoir

reçu l’instruction.

l Ne pas diriger le pistolet vers soi, d’autres person-

nes ou toute pièce mécanique en engageant le fil de soudage.

L’EXPLOSION DE LA BATTERIE peut
provoquer des blessures.

l Ne pas utiliser l’appareil de soudage pour charger

des batteries ou faire démarrer des véhicules à
l’aide de câbles de démarrage, sauf si l’appareil

dispose d’une fonctionnalité de charge de batterie destinée à cet
usage.

Les PIÈCES MOBILES peuvent
causer des blessures.

l S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

l Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protection.

l Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou dis­positifs de protection uniquement par du personnel qualifié.

l Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher l’a­limentation électrique.

LIRE LES INSTRUCTIONS.

l Lire et appliquer les instructions sur les étiquettes

et le Mode d’emploi avant l’installation, l’utilisation
ou l’entretien de l’appareil. Lire les informations de
sécurité au début du manuel et dans chaque

section.

l N’utiliser que des pièces de remplacement provenant du fabricant.
l Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.

l Le rayonnement haute fréquence (H. F.) peut pro-

voquer des interférences avec les équipements de

radio-navigation et de communication, les services de sécurité et
les ordinateurs.

l Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner
l’installation.

l L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

l Si le FCC signale des interférences, arrêter immédiatement

l’appareil.

l Effectuer régulièrement le contrôle et l’entretien de l’installation.
l Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une dis­tance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.

LE SOUDAGE À L’ARC risque de
provoquer des interférences.

l L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement

commandé par ordinateur tel que les robots.

l Veiller à ce que tout l’équipement de la zone de soudage soit

compatible électromagnétiquement.

l Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).

l Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

l Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

l En cas d’interférences après avoir pris les mesures précédentes,

il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la
zone de travail.

2-4. Proposition californienne 65 Avertissements

AVERTISSEMENT – Ce produit peut vous exposer à des pro­duits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malforma­tions ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65Warnings.ca.gov.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Pro­tection, ANSI Standard Z87.1, from American National Standards Ins-

titute. Website: www.ansi.org.

OM-286673 Page 8

Safe Practices for the Preparation of Containers and Piping for Weld­ing and Cutting, American Welding Society Standard AWS F4.1.

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Pro­tection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P­1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www. csa-

group.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.

Website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910.177

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des
champs électromagnétiques (CEM) à certains endroits. Le courant is­su d’un soudage à l’arc (et de procédés connexes, y compris le sou­dage par points, le gougeage, le découpage plasma et les opérations
de chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques pro­duits peuvent causer interférence à certains implants médicaux,
p. ex. les stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple,
des restrictions d’accès pour les passants ou une évaluation indivi­duelle des risques pour les soudeurs. Tous les soudeurs doivent ap­pliquer les procédures suivantes pour minimiser l’exposition aux CEM
provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câ­bles d’un côté et à distance de l’opérateur.

Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH). Web­site: www.cdc.gov/NIOSH.

SOM_fre 2022–01

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.

5. Connecter la pince sur la pièce aussi près que possible de la
soudure.

6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir
ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les procé­dures précédentes.

OM-286673 Page 9

SECTION 3 – SPECIFICATIONS

1 5432

3-1. Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at

https://www.millerwelds.com/eula and are incorporated by reference herein.

3-2. Information About Default Weld Parameters And Settings

NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical
welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are
for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriate­ness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific require­ments. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld
parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warran­ties including any implied warranty of fitness for a particular purpose.

3-3. Compatibility Information

Unit requires an Invision 352 MPa welding power source and S-74 MPa Plus Cobot wire feeder or S-74 MPa Control Cobot with wire feed drive.

3-4. 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.

B. Information On Electromagnetic Compatibility (EMC)

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radiated disturbances.

3-5. Connections And LED Designations On Module

OM-286673 Page 10

1 Ethernet Port

2 Power LED —Green

3 Internet LED —Green

4 Network LED —Yellow

5 USB Port

3-6. Equipment Connection Diagram With Cobot

286792-B

The integrator shall conduct a risk
assessment for the collaborative op­eration as described in ISO 10218–
2:2011: Robots and robotic devices
— Safety requirements for industrial
robots — Part 2: Robot systems and
integration.

The user should participate in the risk

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assessment and design of the work­space. See RIA TR15.606–2016: Col­laborative Robots.

1 Welding Power Source
2 Positive (+) Weld Cable
3 Negative (-) Weld Cable
4 Cobot 14– Pin Insight Core Power

Source Cord
5 Cobot 14–Pin Insight Core Module
6 Wire Feeder Control Cord
7 Cobot 14–Pin Insight Core Wire Feeder

Cord
8 10–Pin Interconnecting Cable (10 Foot)

9 4–Pin Interconnecting Cable (15 Foot)
10 Workpiece
11 Welding Gun
12 Wire Feeder
13 Gas Hose
14 Gas Cylinder And Regulator (Customer

Supplied)

Shielding gas pressure not to exceed

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100 psi (689 kPa).

OM-286673 Page 11

3-7. Recommended Cobot Interface Connection Information

4–Pin Receptacle

Contains wire feeder signals for control of
Jog and Purge functions.

1 Jog Relay

Open = Jog Off

Closed = Jog On

2 Purge Relay

Open = Purge Off

Closed = Purge On

10–Pin Receptacle

Contains welding power source signals for
weld output command, weld voltage and am­perage feedbacks, mode select, and weld
output enable; contains wire feeder signal for
wire feed speed.

1 Weld Output Command DAC

MIG Mode – 0 to 10 VDC = 10.0 to 38.0 V or

44.0 V depending on welding power source.
See owner’s manual.

Pulse MIG Mode – 0 to 10 VDC = 0 to 100
Arc Length

2 Weld Current Feedback ADC

0 to 10 VDC = 0 to 1000 Weld Amps

3 Weld Voltage Feedback ADC

0 to 10 VDC = 0 to 100 Weld Volts

4 Weld Mode Relay

Open = MIG; Closed = Pulsed MIG

5 Weld Output Relay

Open = Weld Off; Closed = Weld On

6 Wire Feed Speed DAC

0 to 5 VDC = 50 to 780 IPM

OM-286673 Page 12

Analog and digital converters (ADC,

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DAC) must be isolated from earth
(ground).

Wire Feed Speed DAC must be isolated

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from the other ADCs and DAC.

ADCs and DACs must be calibrated

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(gain and offset).

Recommended: use signal conditioner

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for analog inputs/outputs (I/O).

SECTION 4 – INSTALLATION

4-1. Insight Core Quick Installation Guide

Step 1. Download and print Network Connectivity Survey from https://insight.millerwelds.com/download . Have form completed by IT

department.

Step 2. Install Insight Core Configuration Utility from https://insight.millerwelds.com/download to a PC. See Section 4-3.
Step 3. Open Insight Core Configuration Utility using icon that was created on desktop (see Figure 4-9)
Step 4. Update firmware if newer revision is available. Skip to step 5 if firmware is current. See Section 4-5.

a. Click the link text here in Configuration Utility. Download newest firmware files from website.
b. Click Locate Files in Configuration Utility and follow prompts.
Step 5. Using the completed Network Connectivity Survey, fill in the connection information. See Section 4-7.

If using static addressing, the PC must be connected to the Insight Core with an Ethernet cable at this point. Follow instructions in Section

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4-7.

Step 6. Insert USB drive into PC.
Step 7. Click Save to save firmware and connection information to USB drive.
Step 8. Remove USB drive from PC and take it to Insight Core device to be updated and connected.
Step 9. Insert USB drive into Insight Core Device and turn on welding power source.

a. The Network LED (yellow) will flash multiple times. This means that data is being transferred to Insight Core device and files will be written to

USB drive for registration.

b. If the Network LED does not flash, try using a different USB drive. This means data was not transferred between the Insight Core device and

the USB drive.

Step 10. Once device is connected to the network (yellow LED is on) and to the internet (green LED is on), remove the USB drive.

If connecting more than one Insight Core, repeat Steps 9 and 10 for each device with the same USB drive.

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Step 11. Take the USB drive back to a computer that is connected to the internet.
Step 12. Open a web browser on the computer and browse to https://insight.millerwelds.com/ .
Step 13. Click First Time Set Up.
Step 14. Enter data in every field. To find Core Device Serial Number and License Key, see Step 15.
Step 15. Insert USB drive into computer and open to view files and folders. See Section 4-9.
Step 16. Open the Device License Key folder.

One .TXT file will be written for each device being installed.

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Step 17. Open .TXT file associated with the serial number to be registered.
Step 18. Copy and paste Serial Number and License Key from .TXT file to corresponding fields on registration webpage.
Step 19. Click Save.

OM-286673 Page 13

4-2. Downloading Connectivity Survey

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.

4-3. Downloading And Installing Insight Core Setup Application To A PC

1. To download the Insight Core Setup Application, visit https://insight.millerwelds.com/download. See Figure 4-1.

Figure 4-1. Download Web Page

2. In the window that appears, click Download File: MillerInsightCoreConfigurationInstaller.exe (see Figure 4-2).

Figure 4-2. Download File Screen

OM-286673 Page 14

3. Click Next on the Setup Wizard screen to begin installation to your computer (see Figure 4-3).

Figure 4-3. Setup Wizard Screen

4. Read the End-User License Agreement and check the box to accept. Click Next to continue (see Figure 4-4).

Figure 4-4. End-User License Agreement

OM-286673 Page 15

5. By default, the application selects a local drive on your computer with sufficient space to install the program. Click Next to accept the default

location, or change the path before proceeding (see Figure 4-5).

Figure 4-5. Destination Folder

6. Click Install to complete installation of the Configuration Utility (see Figure 4-6).

OM-286673 Page 16

Figure 4-6. Utility Install

7. The installation process displays the status until complete.

8. Click Finish when the application has completed the install process (see Figure 4-7).

Figure 4-7. Install Completed

9. The application is now installed on your computer. The program can be found inside All Programs in a folder named Miller Insight Core
Configuration (see Figure 4-8). A shortcut is also placed on your computer’s desktop during installation.

Figure 4-8. Application Program Folder

OM-286673 Page 17

4-4. 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

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set it for a WiFi connection.

1. To run the application, double-click the shortcut on your desktop, or on the program (.EXE) file inside the application listed in All Programs

(see Figure 4-9).

Figure 4-9. Setup Application Shortcut

2. The application automatically checks 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 4-10).

Figure 4-10. Checking For Newer Version Of Application

If you are running the application on a computer that is not connected to the Internet, this automatic version check will fail. You can continue us­ing the version you have installed by clicking OK, or click Cancel to re-establish an Internet connection (see Figure 4-11).

Figure 4-11. Internet Connection Message Screen

OM-286673 Page 18

4-5. Preparing Firmware For Installation

1. Before entering connectivity information, you must first load the current revision of firmware from the download page. Click the text Click
Here to display the download page if the computer is connected to the Internet.

Figure 4-12. Checking For Latest Firmware

2. Select the appropriate firmware. Save the firmware file to a location on the computer that can be easily found.

Figure 4-13. Firmware Selection

OM-286673 Page 19

3. Click Browse. A dialog box opens.

Figure 4-14. Browsing For Firmware Update Files

4. Locate the firmware files you downloaded previously to your computer. Click the files you plan to upgrade, placing the files inside the browse

box. Click Open.

OM-286673 Page 20

Figure 4-15. Upgrade File(s) In The Browse Box

5. Set the number of days you want the firmware files to be valid. Options are 1 to 7 days. This setting prevents an accidental back rev of old
firmware files after the timeframe has expired.

Figure 4-16. Locating Latest Firmware Update Files

If only updating firmware, proceed to Section 4-8.

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OM-286673 Page 21

4-6. Verifying Accessibility Before Connecting

The Miller Insight Cloud must be accessible before the Insight Core unit will connect to a network.

Using a computer in the same location and connected to the same network as the Insight Core unit will be, navigate to

https://collector.millerwelds.com.

If the connection is valid, a web page validating the connection will appear (see Figure 4-17) and the connection process may be continued.

If the web page does not load correctly, contact your IT Department to resolve any potential firewall limitations before proceeding.

Figure 4-17. Insight Core Collector Web Page

OM-286673 Page 22

4-7. Configuring The Type Of Insight Core Network Connection

Determine what type of network connection Insight will use and select one of the following configurations.

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l To configure a wired Ethernet connection using DHCP (dynamic IP addresses), go to Section A.

l To configure a WiFi connection, go to Section B.

l To configure a wired Ethernet connection using static IP addressing (recommended for ease of use), go to Section C.*

l To configure a WiFi connection using static IP addressing, go to Section D.*

* For static address connections, a computer must be connected directly to the module with an Ethernet cable.

A. 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 PC into the net-

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work jack using a CAT5 patch cord and browsing to https://collector.millerwelds.com. If successful, continue the process below. If not, con­tact your company’s IT support staff.

1. Click Connect Module via Wired Ethernet.

2. By default, the module communicates to the Internet on port 443.

3. Click Save.

4. Select USB drive to save configuration settings to.

Figure 4-18. Setting Network Type

This one-time configuration is stored to a USB memory stick and is used to configure each Insight device.

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To continue with firmware installation, proceed to Section 4-8.

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OM-286673 Page 23

B. Connecting The Insight Core Module To WiFi

If WiFi Settings is selected, use the information supplied by your IT department from your Corporate Network Connectivity Survey of Re-

F

quirements. See Section 4-2.

Connection information must be applied to each unit purchased.

1. Click Connect Module via Wireless / WiFi.

2. Enter the name/SSID of your wireless network.

3. Enter the security type of your wireless network. (Enterprise level security is not available at this time.)

4. Enter the security key (password) of your wireless network. (Note: this field will be disabled if your network is an "open" system.)

5. Click Save.

6. Select USB drive to save configuration settings to.

This one-time configuration is stored to a USB memory stick and is used to configure each Insight device.

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Figure 4-19. Entering Security Key For Wireless Network

7. By default, the Insight Core module communicates to the Internet on port 443.

To continue with firmware installation, proceed to Section 4-8.

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OM-286673 Page 24

C. 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 PC into the net-

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work jack using a CAT5 patch cord and browsing to collector.millerwelds.com. If successful, continue the process below. If not, contact your
company’s IT support staff.

Figure 4-20. Selecting Network Configuration To Edit

1. Click Connect Module via Wired Ethernet.

2. Connect your PC directly to the Insight device network port (RJ45 jack) with an Ethernet cable (common CAT5 or CAT6).

3. Turn on welding power source.

4. Change your PC network adapter settings to interface with the Insight server page.

a. For Windows computers, go to Control Panel / Hardware & Sound / Network & Internet / Network & Sharing Center / Change Adapter Set-

tings. These settings will vary by computer.

b. Right click your Local Area Connection and choose Properties.
c. Click Internet Protocol Version 4 (TCP/IPv4), and click Properties.
d. Note your current network settings before proceeding.
e. Select Use The Following IP Address.
f. Set a static IP address to 169.254.0.1 or alternative (the last digit can be anything except 2).
g. Set the Subnet Mask to 255.255.255.0
h. Click OK when finished and close all network settings windows.

The wireless feature on the PC may need to be turned off in order to connect to the Insight Module via Ethernet cable.

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All these network adapter changes need to be reversed when you are finished with installations to reconnect to your corporate network.

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5. Close all open network setting dialog boxes and browsers. Open another browser window on your desktop. Wait approximately 30 seconds
and browse to the server page at 169.254.0.2 by typing this IP address directly into the browser’s URL text box (in place of a website name).

If the Static Assigned IP address cannot be accessed, turn the power source off, insert the USB stick, and power the unit on. This will write

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a text file to the USB stick labeled IP_MAC_LIC_ADDR.txt. Open this file using Notepad and browse to verify the Static Assigned IP ad­dress that you are attempting to browse to is the same IP address of the Insight device as listed in the IP_MAC_LIC_ADDR.txt file.

6. On the server page, select Wired Ethernet and enter the desired parameters based on your company’s network environment as defined on
the Insight Network Connectivity Requirements Checklist responses (see Section 4-2).

OM-286673 Page 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

Figure 4-24).

MC10001Z

AC1000000X1X1X00XX00X0

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use static IP address in your company, this server page IP address will change permanently once you assign the static IP in the process
below..

Using a static IP address connection enables you to view the server page of any Insight device installed on the shop floor from anywhere

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on your network by browsing to its static IP address.

In the Ethernet Settings section, select Static for Device IP Address and Primary DNS.

Insert the device IP static address, subnet mask, gateway, DNS information, and port number provided by your IT Department (see Figure 4-21).

When finished, click Submit to save your settings for this device.

Figure 4-21. Insight Server Page

7. Unplug the Ethernet (CAT5 or CAT6) patch cord from your PC, and connect the Insight module to your corporate Ethernet network jack using
the patch cord.

8. Turn the welding power source off and remove any USB stick if still inserted.

9. Wait ten seconds.

10.Turn welding power source on. The yellow Network light should turn on first when it identifies your network. The green Internet light should
turn on when it sees open access to the Internet.

11.When both LEDs are illuminated solid, the physical installation for Static IP Address is complete.

If the LEDs are not illuminated and the network connection has been verified (See Section 4-6), please contact your Miller Sales

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representative.

To continue with firmware installation, proceed to Section 4-8.

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OM-286673 Page 26

D. Configuring A WiFi Connection Using A Static IP Address Per An Embedded Server Page

To set up a WiFi connection with a static IP address, the unit must first be connected to a wired Ethernet connection. Before proceeding

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with installation, confirm that your wired Ethernet line has open access to the Internet by plugging your PC into the network jack using a
CAT5 patch cord and browsing to collector.millerwelds.com. If successful, continue the process below. If not, contact your company’s IT
support staff.

Figure 4-22. Selecting Network Configuration To Edit

1. Click Connect Module Via Wired Ethernet.

2. Connect your PC directly to the Insight device network port (RJ45 jack) with an Ethernet cable (common CAT5 or CAT6).

3. Turn on welding power source.

4. Change your PC network adapter settings to interface with the Insight server page.

a. For Windows computers, go to Control Panel / Hardware & Sound / Network & Internet / Network & Sharing Center / Change Adapter Set-

tings. These settings will vary by computer.

b. Right click your Local Area Connection and choose Properties.
c. Click Internet Protocol Version 4 (TCP/IPv4), and click Properties.
d. Note your current network settings before proceeding.
e. Select Use The Following IP Address.
f. Set a static IP address to 169.254.0.1 or alternative (the last digit can be anything except 2).
g. Set the Subnet Mask to 255.255.255.0
h. Click OK when finished and close all network settings windows.

All these network adapter changes need to be reversed when you are finished with installations to reconnect to your corporate network.

F

5. Close all open network setting dialog boxes and browsers. Open another browser window on your desktop and wait approximately 30 sec­onds. Then, if firmware version being used is 1.19.10 or later, type the IP address 169.254.0.2 directly into the browser’s URL text box (in
place of a website name). If firmware version is prior to 1.19.10, use the IP address 169.254.0.2/wifi.shtm.

If the Static Assigned IP address cannot be accessed, turn the power source off, insert the USB stick, and power the unit on. This will write

F

a text file to the USB stick labeled IP_MAC_LIC_ADDR.txt. Open this file using Notepad and browse to verify the Static Assigned IP ad­dress that you are attempting to browse to is the same IP address of the Insight device as listed in the IP_MAC_LIC_ADDR.txt file.

6. On the server page, select wireless WiFi and enter the desired parameters based on your company’s network environment as defined on
the Insight Network Connectivity Requirements Checklist responses (see Figure 4-23).

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

F

OM-286673 Page 27

use static IP address in your company, this server page IP address will change permanently once you assign the static IP in the process

MC10001Z

AC1000000X1X1X00XX00X0

below..

Using a static IP address connection enables you to view the server page of any Insight device installed on the shop floor from anywhere

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on your network by browsing to its static IP address.

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 4-24).

When finished, click Submit to save your settings for this device.

Figure 4-23. Insight Server Page

OM-286673 Page 28

MC10001Z

AC1000000X1X1X00XX00X0

Figure 4-24. Insight Server Page

7. Unplug the Ethernet (CAT5 or CAT6) patch cord from your PC.

8. Turn the welding power source off, and remove any USB stick if still inserted.

9. Wait ten seconds.

10.Turn welding power source on. The yellow Network light should turn on first when it identifies your network. The green Internet light should
turn on when it sees open access to the Internet.

11.When both LEDs are illuminated solid, the physical installation for Static WiFi IP Address is complete.

To continue with firmware installation, proceed to Section 4-8.

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OM-286673 Page 29

4-8. Firmware Update Installation

For help installing or running the Configuration Utility, see Section 4-3 and Section 4-4. For help locating firmware files, see Section 4-5.

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When firmware files are located and any additional configuration settings are made (if necessary), click Save in the Configuration window. You
will be prompted to insert a USB drive. After doing so, click Save. When finished, your USB drive contains a file named boot.cfg and a folder/di­rectory named Firmware that contains the firmware file(s) you have selected. The Insight Core device requires these files/folder to be located on
your USB drive in order to upgrade the firmware.

Figure 4-25. Selecting USB Drive Letter

Figure 4-26. 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 Insight Ethernet jack is connected to a cable providing an Internet accessible network connection for wired connections, or that

F

the wireless network is available for wireless connections.

1. Turn the welding power source off.

2. Insert the USB drive into Insight USB receptacle.

3. Turn the welding power source on.

The USB LED will flash, indicating the transfer of your settings. When flashing stops, both the Internet and Network LED lights turn on solid

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green to indicate successful connection to your network and Internet. Firmware update is complete.

The device is now reading for registration. To continue with registration, proceed to next Section.

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OM-286673 Page 30

4-9. 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 4-8 now contains a

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.txt file that is needed to obtain the license key.

1. Remove USB drive from Insight Core unit and insert into computer. Allow time for computer to recognize the USB drive.

2. Find and open the folder named Device License Keys on the USB drive.

Figure 4-27. Device License Keys Folder

3. With a text editor (i.e. Notepad), open the .txt file called IP_MAC_ADDR_LIC… associated with the unit’s serial number you would like to
register in order to obtain the activation key needed to register the device.

Figure 4-28. Device License Key File

4. Write down the serial number and license key for registration.

Figure 4-29. Device License Key Information

This file also verifies the connection information. Exact information in the file will vary based on connection type and device.

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To continue device registration, proceed to Section 4-10.

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OM-286673 Page 31

4-10. Registering Initial Device And Creating An Account

1. Open a web browser and navigate to https://insight.millerwelds.com/registration.

2. Fill in all information shown in Figure 4-30. Use serial number and license key from Section 4-9.

Figure 4-30. Registering A New Account

3. After clicking Register, the homepage for the company that was just created will appear (see Figure 4-31).

Figure 4-31. Insight Core Company Dashboard

To register additional devices, proceed to Section 4-11.

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OM-286673 Page 32

4-11. Registering Additional Devices

1. Log in to Insight Core website at https://insight.millerwelds.com.

2. Click the Configuration tab.

3. Click Register New Device.

Figure 4-32. Configuration Screen

4. Enter the information for the new device you intend to register.

5. A confirmation screen appears. If the information is correct, click Save.

Figure 4-33. Register Device Confirmation Screen

6. After registration, the device will appear inside the corporate asset tree and begin displaying activity as operators begin welding with the
power source.

OM-286673 Page 33

4-12. Setting Up A Work Shift

https://insight.millerwelds.com/.

https://insight.millerwelds.com/.

Figure 4-2. Setting Up A Work Shift

To make company settings, log in to Insight Core Website at https://insight.millerwelds.com

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1. To set up a work shift for an Insight Core module, click the Configuration tab, then click the Company tab, then click Add Shift (see Figure

4-34).

Figure 4-34. Setting Up A Work Shift

2. Enter the data to set the work shift for the device, then click Save (see Figure 4-35).

Figure 4-35. Adding A New Shift

3. After clicking Save, an Edit screen will appear to allow changes or corrections. When the shift data is acceptable, click Save (see Figure 4-

36).

OM-286673 Page 34

Figure 4-36. Shift Data Edit Screen

Figure 4-4. Shift Data Edit Screen

4. After clicking Save, the shift data will appear under the company tab for the device work shift (see Figure 4-37).

Figure 4-37. Device Work Shift Data Screen

OM-286673 Page 35

4-13. Setting Up A Group

Figure 4-6. Setting Up A Group Of Devices

1. To set up a group to organize your Insight devices into logical groups, click on the Groups tab (see Figure 4-38).

Figure 4-38. Setting Up A Group Of Devices

2. Enter a Group Name and click on the Save button (see Figure 4-39).

3. Once a group is established, return to the beginning of Section 4-11to add more devices. Be sure to have all the serial numbers and access
keys for each additional device.

4. To assign existing devices to a group, select the unit to be assigned, click Configuration, then click Groups. Select the appropriate group for
the unit.

Figure 4-39. Entering A Group Name

OM-286673 Page 36

SECTION 5 – TROUBLESHOOTING

If unit does not connect to the Internet, try connecting to http://collector.millerwelds.com.

If the connection is valid, a web page validating the connection will appear. See Figure 5-1.

Figure 5-1. Insight Core Collector Web Page

OM-286673 Page 37

SECTION 6 – ELECTRICAL DIAGRAMS

286671-C

OM-286673 Page 38

Figure 6-1. Circuit Diagram

SECTION 7 – PARTS LIST

301072002 Cobot 14–Pin Insight Core Module

Item No. Dia. Mkgs. Part No. Description Quantity

286669 Housing, Circuit Control Cobot 14 Pin Insight Core 1
PC1 264624 Assy, CCA Insight Core With Wifi 14 Pin (Includes) 1
PC2 286411 Circuit Card Assy, Filter 1

PLG2 286448 Cable, Interconnection 14 Pin Trigger 1

RC2 286449 Plug Assy, 10 Pin Cobot 1

286670 Cable Assy, Interconnecting Cobot 14 Pin Insight Core (Includes) 1

264880 —Panel, Mtg Components 14 Pin Insight Core 1

PLG1 286443 —Cable, Interconnection 14 Pin Welder 1

RC1 286447 —Plug Assy, 14 Pin Wire Feeder 1

286601 Cable, Interconnecting 15 Ft 1

286603 Cable, Interconnecting 10 Ft 1

289094 Plug Assy, 4 Pin Cobot Cabinet 1

289089 Plug Assy, 10 Pin Cobot Cabinet 1

286450 Plug Assy, 10 Pin Board To Board 1

OM-286673 Page 39

Notes

Effective January 1, 2022 (Equipment with a serial number preface of NC or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war-

ranties expressed or implied.

LIMITED WARRANTY - Subject to the terms and
conditions below, Miller Electric Mfg. LLC, Apple­ton, Wisconsin, warrants to authorized distributors
that new Miller equipment sold after the effective
date of this limited warranty is free of defects in
material and workmanship at the time it is shipped
by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES
OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will
repair or replace any warranted parts or compo­nents that fail due to such defects in material or
workmanship. Miller must be notified in writing
within thirty (30) days of such defect or failure, at
which time Miller will provide instructions on the
warranty claim procedures to be followed. Notifica­tions submitted as online warranty claims must
provide detailed descriptions of the fault and trou­bleshooting steps taken to diagnose failed parts.
Warranty claims that lack the required information
as defined in the Miller Service Operation Guide
(SOG) may be denied by Miller.

Miller shall honor warranty claims on warranted
equipment listed below in the event of a defect
within the warranty coverage time periods listed
below. Warranty time periods start on the delivery
date of the equipment to the end-user purchaser,
or 12 months after the equipment is shipped to a
US or Canada distributor, or 18 months after the
equipment is shipped to an international distributor,
whichever occurs first.

1 5 Years Parts — 3 Years Labor

l Original Main Power Rectifiers Only to Include

SCRs, Diodes, and Discrete Rectifier Modules
in non-inverter products

2 3 Years — Parts and Labor Unless Specified

l Auto-Darkening Helmet Lenses (No Labor)
l Engine Driven Welder/Generators (Including

EnPak) (NOTE: Engines are Warranted
Separately by the Engine Manufacturer.)

l Insight Welding Intelligence Products (Except

External Sensors)

l Inverter Power Sources
l Plasma Arc Cutting Power Sources
l Process Controllers
l Semi-Automatic and Automatic Wire Feeders
l Transformer/Rectifier Power Sources

3 2 Years — Parts and Labor

l Auto-Darkening Weld Masks (No Labor)
l Fume Extractors - Capture 5 and Industrial

Collector Series

4 1 Year — Parts and Labor Unless Specified

l ArcReach Heater
l AugmentedArc, LiveArc, and MobileArc Weld-

ing Systems

l Automatic Motion Devices
l Bernard BTB Air-Cooled MIG Guns (No

Labor)

l CoolBelt, PAPR Blower, and PAPR Face

Shield (No Labor)

l Desiccant Air Dryer System

l Field Options (NOTE: Field options are cov-

ered for the remaining warranty period of
the product they are installed in, or for a
minimum of one year — whichever is
greater.)

l RFCS Foot Controls (Except RFCS-RJ45)
l Fume Extractors - Filtair 130, MWX and SWX

Series, ZoneFlow Extraction Arms and Motor
Control Box

l HF Units
l ICE/XT Plasma Cutting Torches (No Labor)
l Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted
Separately by the Manufacturer.)

l Insight Sensors
l Load Banks
l Motor-Driven Guns (except Spoolmate

Spoolguns)

l Positioners and Controllers
l Racks (For Housing Multiple Power Sources)
l Running Gear/Trailers
l Subarc Wire Drive Assemblies
l Supplied Air Respirator (SAR) Boxes and

Panels

l TIG Torches (No Labor)
l Tregaskiss Guns (No Labor)
l Water Cooling Systems
l Wireless Remote Foot/Hand Controls and

Receivers

l Work Stations/Weld Tables (No Labor)

5 6 Months — Parts

l 12 Volt Automotive-Style Batteries

6 90 Days — Parts

l Accessories (Kits)
l ArcReach Heater Quick Wrap and Air Cooled

Cables

l Canvas Covers
l Induction Heating Coils and Blankets, Cables,

and Non-Electronic Controls

l MDX Series MIG Guns
l M-Guns
l MIG Guns, Subarc (SAW) Torches, and Exter-

nal Cladding Heads

l Remote Controls and RFCS-RJ45
l Replacement Parts (No labor)
l Spoolmate Spoolguns

Miller’s True Blue
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 covered by the manufacturer’s
warranty, if any.

3. Equipment that has been modified by any party
other than Miller, or equipment that has been
improperly installed, improperly operated or

®

Limited Warranty shall not apply

misused based upon industry standards, or
equipment which has not had reasonable and
necessary maintenance, or equipment which
has been used for operation outside of the
specifications for the equipment.

4. Defects caused by accident, unauthorized re­pair, or improper testing.

MILLER PRODUCTS ARE INTENDED FOR
COMMERCIAL AND INDUSTRIAL USERS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

The exclusive remedies for warranty claims are, at
Miller’s option, either: (1) repair; or (2) replace­ment; or, if approved in writing by Miller, (3) the
pre-approved cost of repair or replacement at an
authorized Miller service station; or (4) payment of
or credit for the purchase price (less reasonable
depreciation based upon use). Products may not
be returned without Miller’s written approval. Re­turn shipment shall be at customer’s risk and
expense.

The above remedies are F.O.B. Appleton, WI, or
Miller’s authorized service facility. Transportation
and freight are the customer’s responsibility. TO
THE EXTENT PERMITTED BY LAW, THE REM­EDIES HEREIN ARE THE SOLE AND EXCLU­SIVE REMEDIES REGARDLESS OF THE LEGAL
THEORY. IN NO EVENT SHALL MILLER BE LI­ABLE FOR DIRECT, INDIRECT, SPECIAL, INCI­DENTAL OR CONSEQUENTIAL DAMAGES
(INCLUDING LOSS OF PROFIT) REGARDLESS
OF THE LEGAL THEORY. ANY WARRANTY NOT
PROVIDED HEREIN AND ANY IMPLIED WAR­RANTY, GUARANTY, OR REPRESENTATION, IN­CLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTIC­ULAR PURPOSE, ARE EXCLUDED AND DIS­CLAIMED BY MILLER.

Some US states do not allow limiting the duration
of an implied warranty or the exclusion of certain
damages, so the above limitations may not apply
to you. This warranty provides specific legal rights,
and other rights may be available depending on
your state. In Canada, some provinces provide ad­ditional warranties or remedies, and to the extent
the law prohibits their waiver, the limitations set out
above may not apply. This Limited Warranty pro­vides specific legal rights, and other rights may be
available, but may vary by province.

Warranty Questions?

Call 1-800-4-A-MILLER for
your local Miller distributor.

Your distributor also gives you...

Service

You always get the fast, reliable response you
need. Most replacement parts can be in your
hands in 24 hours.

Support

Need fast answers to the tough welding ques­tions? The expertise of the distributor and Miller
is there to help you, every step of the way.

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date

Distributor

Address

City

State Zip

(Date which equipment was delivered to original customer.)

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Protective Equipment (PPE)

Contact the Delivering Carrier to:

Service and Repair Replacement Parts

Training (Schools, Videos, Books)

Welding Process Handbooks

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller

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.

Miller Electric Mfg. LLC

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: [phone]
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit
www.MillerWelds.com

ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2022-08