Kemppi Smart Reader User manual

Smart Reader
OPERATING MANUAL

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Contents
1 Introduction................................................................................................. 4
1.1 Introduction to Smart Reader................................................................................................................... 4
1.2 Introduction to WeldEye..............................................................................................................................4
1.3 Security................................................................................................................................................................6
2 Structure....................................................................................................... 7
2.1 Parts......................................................................................................................................................................7
2.2 Main screen and navigation.................................................................................................................... 10
3 Getting started.......................................................................................... 11
3.1 Smart Reader operating principle.........................................................................................................11
3.1.1 How welding data is recorded............................................................................................... 12
3.1.2 Identifier database.......................................................................................................................12
3.1.3 Measurement of parameters................................................................................................... 12
3.1.4 Time-keeping................................................................................................................................. 13
3.2 Connect Smart Reader to the welding machine............................................................................. 13
3.2.1 Connect Smart Reader to Kemppi FastMig KMS/M/Pulse/X, KempArc KMS/
Pulse, Kemppi A7.............................................................................................................................. 14
3.2.2 Connect Smart Reader to other welding machines....................................................... 15
3.3 Switch Smart Reader ON and OFF....................................................................................................... 19
3.4 Link Smart Reader to your company WeldEye account............................................................... 20
3.5 Configure Smart Reader's network connection............................................................................... 20
3.6 Internet connectivity requirements.......................................................................................................21
4 Collecting welding data........................................................................... 22
4.1 Welder's workflow with Smart Reader................................................................................................ 22
4.2 Identifiers shown on Smart Reader......................................................................................................24
4.3 Alerts shown on Smart Reader.............................................................................................................. 25
4.4 Reason codes.................................................................................................................................................26
4.5 Heat input tracking..................................................................................................................................... 27
4.6 Weld Data view after welding................................................................................................................ 28
5 Other Smart Reader features.................................................................. 29
5.1 Cable compensation................................................................................................................................... 29
5.2 Real-time WPS monitoring.......................................................................................................................29
5.3 Channel WPS..................................................................................................................................................30
5.4 WPS suggestion for weld identifiers....................................................................................................31
5.5 TIG drop-down filtering.............................................................................................................................31
5.6 Smart Reader usage and WPS limit enforcement.......................................................................... 31
6 Administration...........................................................................................32

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6.1 Administrator section views.....................................................................................................................32
6.2 Updating Smart Reader firmware..........................................................................................................34
6.3 Factory reset...................................................................................................................................................35
7 Technical specifications............................................................................ 36
8 Contact information................................................................................. 37
9 Glossary...................................................................................................... 38

WELDEYE 1.1 Introduction to Smart Reader
1 Introduction
1.1 Introduction to Smart Reader
Smart Reader is a device that enables automated monitoring of the quality and productivity of arc
welding.
Smart Reader records welding parameter data, and transmits the data to the WeldEye cloud
service through a wireless network.
Smart Reader is the welder's user interface to WeldEye for inputting identifying information, such
as welder identification, the WPS in use, the weld or welding piece, or filler material heat (batch)
number.
Smart Reader also displays useful information to the welder. For example, before welding,
the welder sees the current and voltage limits of the WPS, and after welding, the welder gets
feedback, such as whether the welding parameters stayed within the WPS limits.
Smart Reader can be connected to any arc welding machine through an adapter, and directly
(without an adapter) to certain Kemppi welding machines.
In a typical use case, every welding machine performing critical welding in the factory has a Smart
Reader connected to it. For factory-wide productivity use cases, all welding machines can be
equipped with one.
Smart Reader is available in the following user interface languages: Chinese, Danish, Dutch,
English, Finnish, French, German, Italian, Norwegian, Polish, Portuguese, Russian, Spanish,
Swedish.
1.2 Introduction to WeldEye
WeldEye is a comprehensive system for collecting and managing welding data, and your primary
tool and storage space for keeping your welding-related documents in order.
OPERATING MANUAL | EN 4© KEMPPI | 2017-12-22

WELDEYE 1.2 Introduction to WeldEye
Figure 1: 1. X8 MIG Welder 2. Kemppi FastMig, KempArc or A7 MIG Welder 3. Other welding
machines
WeldEye's modular structure is based on various useful functions that serve the needs of wide-
ranging industries and welding-related tasks:
Welding procedures
Includes the digital library and management of pWPS, WPQR and WPS templates according to
the most important welding standards.
Personnel and qualifications
Includes the management and renewal processes of all personnel - welders and inspectors -
qualification certificates.
Quality management
Includes quality verification functionalities with digital WPS and qualification compliance
control against automatically collected digital welding data.
Welding management
Includes document register functionalities and features for comprehensive welding project
documentation and management.
For more information on the full system and other modules, see www.weldeye.com.
OPERATING MANUAL | EN 5© KEMPPI | 2017-12-22

WELDEYE 1.3 Security
1.3 Security
Smart Reader is a handheld IoT device, and the related security issues have been taken into
account accordingly.
Smart Reader is a locked-down, embedded Linux-based device. It connects to a WiFi network,
communicates via encrypted HTTPS channel, and continuously uploads data as it is recorded.
Smart Reader is not dependent on an uninterrupted stable Internet connection; it works
seamlessly offline with reduced capability (no new data sent to or received from the server) until
the connection becomes available again.
A security inspection was conducted for Smart Reader in May 2016 by a third party. Quote from
the final report:
As a summary, the security status of the Smart Reader is good since no significant security issues
were found.
The Smart Reader device was found quite secure in normal mode thus not being a threat to the
underlying network infrastructure. Using the device as attack tool against the client infrastructure
was not found feasible during testing.
OPERATING MANUAL | EN 6© KEMPPI | 2017-12-22

WELDEYE 2.1 Parts
2 Structure
2.1 Parts
1. Display
Use the keyboard to scroll and select items.
2. Keyboard
• Up and down arrow buttons: press to highlight items on the display.
• Middle button: press to select the highlighted item.
• Left and right arrow buttons: press to change the pass within a WPS.
3. Barcode scanner
Smart Reader is delivered with either 1d or 2d barcode scanner.
4. Connection cable port:
Power DC+ in 50V 200mA
5. Back cover
Removable
OPERATING MANUAL | EN 7© KEMPPI | 2017-12-22

WELDEYE 2.1 Parts
6. Buttons on the back under the sticker: BMS, RST, PWR
For resetting and troubleshooting purposes. Use a thin object, for example, a paper clip, to
press the buttons.
7. USB port
For maintenance purposes. Only USB flash storages (USB sticks) may be connected to the
port. Smart Reader configuration files and update packages are transferred to the Smart
Reader via USB port.
8. Micro USB connector
For troubleshooting purposes.
9. Ethernet connector (100 Mbit)
For troubleshooting purposes.
10. Micro SD card slot
By default, a 4 Gb memory card is connected. Smart Reader stores all welding and barcode
data on the memory card. The first time you power on Smart Reader, the SD card is formatted.
Removing the back cover
Use, for example, a coin to open the back cover lock.
Silicon cover
Silicon cover is available as an accessory, ordered separately. It protects the device from metal
dust and provides additional protection if the device, for example, falls from heights.
OPERATING MANUAL | EN 8© KEMPPI | 2017-12-22

WELDEYE 2.1 Parts
2
1
Figure 2: Attaching the silicon cover
Hanging Smart Reader
You can hang Smart Reader by the hook on the handle of the wire feeder.
OPERATING MANUAL | EN 9© KEMPPI | 2017-12-22

WELDEYE 2.2 Main screen and navigation
2.2 Main screen and navigation
1. WPS pass number
To change the pass, press left/right arrow buttons.
2. Wifi icon
See Configure Smart Reader's network connection on page 20.
3. Qualification deviation alert
The alert is shown if the welder has no valid qualification certificate for the seelcted WPS.
4. Identified feature
The barcode for the feature has been scanned and the device has recognized the item.
5. Unidentified feature
The barcode for the feature has not been scanned. In WeldEye cloud service, you can select
which features are always shown on the display. See Identifiers shown on Smart Reader on
page 24.
6. Menu
Select Menu to go to other views and settings.
OPERATING MANUAL | EN 10 © KEMPPI | 2017-12-22

WELDEYE 3.1 Smart Reader operating principle
3 Getting started
To take Smart Reader into use:
1. Connect Smart Reader to the welding machine.
2. Power on the Smart Reader. The first time you power on Smart Reader, the SD card is
formatted.
3. Link Smart Reader to your company WeldEye account.
4. Configure Smart Reader's network connection.
To get the all the benefits of WeldEye, also adjust other features, such as cable compensation.
3.1 Smart Reader operating principle
Smart Reader is a handheld IoT device with multiple functionalities: it connects to the welding
machine or adapter for recording welding parameter data, provides a user interface and reporting
tool for the welder, and communicates with the WeldEye servers to send and receive data to/from
the WeldEye cloud service.
OPERATING MANUAL | EN 11 © KEMPPI | 2017-12-22

WELDEYE 3.1 Smart Reader operating principle
3.1.1 How welding data is recorded
Smart Reader collects welding parameter data automatically. Every weld is recorded, and the data
is stored.
Smart Reader communicates with the welding machine via a data link, reading information such
as current, voltage, and wire feed speed. This is possible natively with some Kemppi-branded
welding machines. For other arc welding machines, an additional adapter device is needed.
The adapter has a sensor that measures the current and voltage from the poles of the welding
machine's power source.
Smart Reader knows when the welding arc is ignited and stopped, and can thus distinguish
individual welding runs and tally arc time.
Smart Reader stores welding parameter data on an SD card. After every weld run, the data is
sent to the WeldEye cloud service for analysis and reporting. In a normal situation, the welding
data is visible in WeldEye within a few seconds after welding has ended. It is not possible to see
ongoing welding in the WeldEye cloud service; the information is transmitted only after welding
has ended.
If Smart Reader is not connected to WiFi or cannot connect to the Internet, the data is kept in
the buffer/queue until network becomes available again. The SD card has enough space to store
several months' welding data (in three shifts around the clock). When network connectivity is
restored, the data is sent to WeldEye.
Smart Reader is battle-tested in production use in numerous different environments, with all sorts
of arc welding: manual, mechanized and fully automated robotic welding, including MMA, MIG,
TIG and SAW processes. Smart Reader can handle welds of all lengths, be it a small tack weld of
under a second or long mechanized weld where the arc is it lit for many hours.
Smart Reader collects the welding parameters with a resolution of 1/10th of a second (10 samples
per second). Some averaging is performed in the WeldEye cloud service to reduce the natural
jitter in weld data. It is possible to filter away starts and stops of the weld, as hot start and crater
fill mechanisms of welding machines are not compliant with WPSes.
3.1.2 Identifier database
Smart Reader can provide 100 % traceability to every weld. To do this, various identifiers are
entered to the system before welding in order to give meaning to the welding data; for example,
the person welding, the WPS, and the weld number.
The identifying data is created and managed in the WeldEye cloud service. Smart Reader receives
this information from the cloud service and matches it with the identifiers that the welder enters
manually or with barcodes.
The identifier database is synchronized from WeldEye to the Smart Reader every 15 minutes when
the device is online. In Smart Reader, the database is stored in the SD card, so Smart Reader can
be used reliably in times when network connectivity is poor. If a new barcode (for example, a new
filler batch number) is entered to the system, it becomes available in the cloud service and for all
the Smart Readers connected to the service.
The 15 minute delay in updating the identifier database means that it will take up to 15 minutes
for Smart Reader to recognize any new identifiers that are added to the WeldEye database.
3.1.3 Measurement of parameters
OPERATING MANUAL | EN 12 © KEMPPI | 2017-12-22

WELDEYE 3.2 Connect Smart Reader to the welding machine
Because of voltage drop and fluctuation in parameters, the measurement values are not
necessarily measured and displayed in WeldEye exactly as they are shown on the welding
machine, but they are still displayed in a meaningful manner and according to welding norms.
Fluctuation and averaging
Welding parameters always fluctuate during the welding. To show parameter data in a useful
format, WeldEye uses averaging to filter out extremes and to show the average graph of the
welding performance. You can adjust the averaging according to your needs in the Settings view.
Voltage drop
In MIG welding machines with long cables (from power source to wire feeder to gun), the voltage
drop can be significant due to electrical resistance. Therefore, welding machine power sources
generate a voltage ("pole voltage") that is higher than the voltage in the welding arc. Therefore,
voltage can be measured either at the poles of welding machine or at/near the arc. WeldEye
always tries to measure the effective arc voltage, but if this is not possible, WeldEye calculates it
based on cable lengths.
It is possible to define the cable length in Smart Reader to compensate for the voltage drop.
When you use WeldEye with Kemppi X8 MIG Welder and Kemppi FastMig X welding machines,
the compensation is done automatically.
Accuracy of measurements
Welding machine power sources often conform to the standard IEC 60974-1, which states that
2.5% accuracy is required when displaying amps and volts. It means that the displayed value must
be within 2.5% of the actual value, measured at the maximum power. For example, for a power
source rated capable of producing 300A, the error may be up to ±7.5A. Therefore, the power
source display may not always show the true value.
Standard IEC 60974-1 and accuracy also applies to WeldEye's Universal Adapters. Thus, there can
be quite a large difference between what the welding machine displays and what the sensors
measure. However, in practice, the error is usually much smaller than what the standard allows.
Welding machines and measurement devices must be validated every two years to ensure they
are still accurate.
3.1.4 Time-keeping
To provide an accurate picture of welding activities, Smart Reader has a built-in real-time clock.
It is used to record the time of weld run starts, stops, parameter samples, and other events. It is
automatically kept synchronized through the cloud service.
Internally, Smart Reader uses global UTC time (Coordinated Universal Time), but adjusts it to the
time zone of the user. The time zone is controlled site-wide in the WeldEye cloud service.
The time is displayed as the user's local time in the Smart Reader's display and in the WeldEye
cloud service. In the cloud service, it is possible to search for weld runs according to the time the
welding took place.
3.2 Connect Smart Reader to the welding machine
OPERATING MANUAL | EN 13 © KEMPPI | 2017-12-22

WELDEYE 3.2 Connect Smart Reader to the welding machine
Smart Reader needs to be connected to a welding machine to be able to record the measured
current and voltage parameters.The way to connect it depends on the type of welding machine. In
most cases,you need an additional adapter that measures the current and voltage.
With the following welding machines you do not need an adapter, as the machines have native
measurement functionality: Kemppi FastMig KMS/M/Pulse/X, KempArc KMS/Pulse, Kemppi A7
MIG Welder.
Figure 3: Welding machines and accessories for WeldEye usage. * Other brand welding machines can
be any welding machines.
When you are using Smart Reader together with:
• An adapter for measuring voltage and current - connect Smart Reader to the adapter with the
connection cable.
• Kemppi welding machine with Kemppi MSF wire feeder – connect Smart Reader directly to the
power source with the connection cable.
• Kemppi welding machine (with no Kemppi MSF wire feeder) – connect Smart Reader either to
the power source or to the wire feeder, depending on which is more convenient to you.
Note: Smart Reader cannot be connected to Kemppi FastMig KM machines. Smart
Reader is not required for Kemppi X8 MIG Welder, as it has built-in WeldEye functionality.
3.2.1 Connect Smart Reader to Kemppi FastMig KMS/M/Pulse/X,
KempArc KMS/Pulse, Kemppi A7
You do not need an adapter, when you connect Smart Reader to one of these welding machines.
OPERATING MANUAL | EN 14 © KEMPPI | 2017-12-22

WELDEYE 3.2 Connect Smart Reader to the welding machine
1. Connect the 4-pin connector of the connection cable to the Smart Reader: align the pins,
push, and turn.
2. Connect the 7-pin round connector of the connection cable either to the welding machine
power source or to the wire feeder, whichever is more convenient for you.
3.2.2 Connect Smart Reader to other welding machines
Use an adapter for measuring voltage and current. Available adapters include:
ARC Universal Adapter - CV
Compatible with all MIG/MAG and MMA machines, and with TIG welding machines without
High frequency ignition. Connects to the power source. Rated for maximum 500 A welding
current.
ARC Euro Adapter - CV
Compatible with MIG/MAG welding machines with Euro gun connector. Connects to the wire
feeder. Rated for maximum 500 A welding current.
ARC Universal Adapter TIG
Always use this adapter with TIG welding machines with High Frequency ignition. Shielded
against the high voltage ignition spark. Rated for maximum 500 A welding current.
ARC SAW Adapter
Always use this adapter with (high-voltage) submerged arc welding machines. Compatible
with heavy automatized welding machines used for SAW/121/125 welding processes. Rated
for maximum 1600 A welding current.
For detailed information, see the user manual of each device.
Warning: Universal Adapter -CV, TIG and SAW Adapter must be installed by a licensed
electrician.
OPERATING MANUAL | EN 15 © KEMPPI | 2017-12-22

WELDEYE 3.2 Connect Smart Reader to the welding machine
3.2.2.1 Connect Smart Reader with ARC Universal Adapter - CV
1. Connect the connection cable from Smart Reader to the adapter.
2. Connect the adapter to a separate power supply with ARC Control Cable (required to power
the Smart Reader).
3. Connect the adapter to the welding machine ground connector, and the Dix branch
connector to the opposite pole.
Figure 4: Connecting ARC Universal Adapter CV and Smart Reader to a welding machine
3.2.2.2 Connect Smart Reader with ARC Euro Adapter -CV
1. Connect the connection cable from Smart Reader to the adapter.
2. Connect the adapter to a separate power supply with ARC Control Cable (required to power
the Smart Reader).
3. Connect the adapter to the wire feeder’s Euro gun connector, and the Dix branch connector
between the power source and ground cable.
OPERATING MANUAL | EN 16 © KEMPPI | 2017-12-22

WELDEYE 3.2 Connect Smart Reader to the welding machine
Figure 5: Connecting ARC Euro Adapter and Smart Reader to welding machine
3.2.2.3 Connect Smart Reader with ARC Universal Adapter - TIG
1. Connect the connection cable from Smart Reader to the adapter.
2. Connect the adapter to a separate power supply with ARC Control Cable (required to power
the Smart Reader).
3. Connect the adapter to the welding machine ground connector, and the Dix branch
connector to the opposite pole.
OPERATING MANUAL | EN 17 © KEMPPI | 2017-12-22

WELDEYE 3.2 Connect Smart Reader to the welding machine
Figure 6: Connecting ARC Universal Adapter TIG and Smart Reader to a welding machine
3.2.2.4 Connect Smart Reader with ARC SAW Adapter
1. Connect the connection cable from Smart Reader to the adapter.
2. Connect the adapter to a separate power supply with ARC Control Cable (required to power
the Smart Reader).
3. Bolt the adapter to the welding cable.
OPERATING MANUAL | EN 18 © KEMPPI | 2017-12-22

WELDEYE 3.3 Switch Smart Reader ON and OFF
Figure 7: Connecting ARC SAW Adapter and Smart Reader to a welding machine
3.3 Switch Smart Reader ON and OFF
If the Smart Reader is directly connected to the welding machine, Smart Reader is automatically
switched on or off when the welding machine is powered on or off.
If Smart Reader is connected to an adapter, it is powered on continuously. To switch Smart Reader
off, unplug the adapter power source.
When Smart Reader is powering on, the booting phase takes a couple of minutes. During
the booting, a logo is displayed. When Smart Reader has started, it asks the user to log in by
scanning a barcode.
Smart Reader's barcode reader is automatically turned off after 2 minutes of inactivity to ensure
the barcode scanner camera's long life. To read barcodes again, press the middle button in Smart
Reader.
Smart Reader has a built-in Li-Ion battery, which is used to gracefully switch off Smart Reader
in the case of power loss. The battery helps keep the device functional if the power is unstable.
Smart Reader stays powered on for up to 2 minutes after the main is powered off. On the
backside of the device, under the plastic cover, there is a red LED light to indicate that the device
is still on.
If Smart Reader's battery has been discharged during a long period of shelving or other non-use
period, Smart Reader needs to be connected and powered on for up to 2 hours for the battery to
become charged and for the Smart Reader to start up.
OPERATING MANUAL | EN 19 © KEMPPI | 2017-12-22

WELDEYE 3.4 Link Smart Reader to your company WeldEye account
3.4 Link Smart Reader to your company WeldEye account
Only WeldEye support personnel can link a Smart Reader to your WeldEye account. Contact the
support personnel and give them the serial number of the Smart Reader printed on the sticker on
the back of the device under the cover.
See Contact information on page 37.
3.5 Configure Smart Reader's network connection
Select the wireless network and enter the password in WeldEye cloud service, and transfer the
settings configuration file to Smart Reader.
Follow these steps:
1. In WeldEye, go to Administration view, and select Configurations.
2. Click Add new.
3. Fill in the information.
4. Click Save. The settings are saved in the Configuration list.
5. To download the settings file to your computer, check the box next to the configuration, and
click Actions > Download.
Note: Link Smart Reader to WeldEye before downloading the configuration file. The
configuration file only applies to Smart Readers that are in the Devices list at the
time of the download.
6. Copy the downloaded file on a USB stick, and disconnect it from the computer.
7. Connect the USB stick to Smart Reader.
8. Smart Reader asks whether to change the network settings. Answer YES.
Smart Reader now automatically connects to the network. WiFi icon on the top right corner of the
display shows the connection state:
•No icon - Smart Reader is not connected to WiFi.
•White icon - Smart Reader is connected to WiFi, but cannot communicate with the WeldEye
server.
•Green icon - Smart Reader is connected to WiFi, and WeldEye communication works.
If the icon is constantly toggling between no-icon and white-icon states, wifi reception may be
poor at that spot. Move the device closer to the WiFi access point, or install additional access
points.
If the icon is toggling between white-icon and green-icon states, wifi reception may be poor at
that spot, or there may be an error. Contact WeldEye support. See Contact information on page
37.
OPERATING MANUAL | EN 20 © KEMPPI | 2017-12-22