Miller Intellx Pro Owner's Manual
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Miller Intellx Pro Owner's Manual

Miller Intellx Pro Owner's Manual

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Intellx Pro
™
Wire Feeder
OM-279248C
2020−05
Processes
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Description
Wire Feeder
File: MIG (GMAW)

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  • Page 1 OM-279248C 2020−05 Processes Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Description Wire Feeder Intellx Pro ™ Wire Feeder File: MIG (GMAW) For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 6 − OPERATION (Continued) ............6-12.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2020−02 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 Indicates special instructions.
  • Page 6 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 7: Additional Hazards For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 8: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2020−02_fre 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.
  • Page 10 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 12: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 14 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Safe63 2012−06 Do not weld on drums or any closed containers. Safe16 2017−04 Do not remove or paint over (cover) the label. Safe20 2017−04 Drive rolls can injure fingers.

  • Page 15: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Amperes Primary Voltage Gas Preflow Volts Filter Gas Postflow Direct Current (DC) Wire Type Rated Welding Degree Of Current Protection Arc Control Line Connection Increase Read Instructions Wire Diameter Gas Input Pulse...

  • Page 16: Section 4 − Specifications

    4-3. 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;...

  • Page 17: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Power Source And Wire Feeder Site Selection Movement Do not put feeder where Do not move or operate welding wire hits cylinder. unit where it could tip. Special installation may be required Location And Airflow where gasoline or volatile liquids are present −...

  • Page 18: Connecting Weld Output Cable

    5-2. Connecting Weld Output Cable Turn off power before connecting to weld terminal or receptacle. Failure to properly connect weld cables may cause excessive heat Tools Needed: and start a fire, or damage your machine. 9/16 in. Ensure all connections are tight. Weld Cable Connection Do not place anything between weld cable terminal and weld terminal.

  • Page 19: Connection Diagram

    5-3. Connection Diagram 281832-A Welding Gun Use of shielding gas is dependant on Wire Turn off power before making Type. connections. Wire Feeder Wire Feeder Cable Gas Hose The connection diagram illustrates Positive (+) Weld Output Terminal Gas Cylinder DCEP (reverse polarity) suitable for Negative (−) Weld Output Terminal 10 Welding Power Source all wires except self-shielded FCAW.

  • Page 20: Arranging Welding Cables To Reduce Welding Circuit Inductance

    5-4. Arranging Welding Cables To Reduce Welding Circuit Inductance Welding Power Source Electrode Cable Feeder Cable Work Cable Voltage Sense Lead Wire Feeder Workpiece The arrangement of the cables has an effect that is significant to the welding properties. As an example, Accupulse welding process can produce high welding circuit inductance depending on cable length and arrangement.

  • Page 21: Control Cable Connections

    5-5. Control Cable Connections Turn off power before connecting control cable. Remote ArcConnect Receptacle Remote ArcConnect Receptacle Connect control cable between recepta- cle RC2 on front of welding power source to receptacle RC1 on rear of wire feeder. Wire Feeder Rear View Welding Power Source Front View...

  • Page 22: Weld Voltage Sense Connection (Optional)

    5-7. Weld Voltage Sense Connection (Optional) Weld Voltage Sense Receptacle RC3 Connect voltage sense lead from weld voltage sense receptacle RC3 on rear of wire feeder to work piece (see Sections 5-3 and 5-4) for more information. Connecting sense lead is optional as required by desired weld process.

  • Page 23: Rotating Drive Assembly

    5-9. Rotating Drive Assembly Drive Assembly Wire Drive Assembly Angle Rotate the drive assembly to re- duce bends in the MIG gun cable. Wire can be setup to feed off either the top or bottom of wire spool. Se- lect the option that results in the straightest possible path into drive assembly.

  • Page 24: Installing Welding Gun

    5-10. Installing Welding Gun Power Clamp Knob Gun Locking Tab Gun Locking Tab Rotated 180 Degrees Power Pin Groove Gun Connection End Installing gun with Accu-Mate connection Loosen power clamp knob to allow power pin of gun to clear the gun locking tab.

  • Page 25: Installing Wire Guides And Drive Rolls

    5-11. Installing Wire Guides And Drive Rolls Ref. 281467-C Installing Wire Guides Insert inlet wire guide into wire entry as taining nut one click to secure in place. Re- shown. Push into place to secure. Repeat peat procedure for remaining drive rolls. Inlet Wire Guide procedure for intermediate guide.

  • Page 26: Installing And Threading Welding Wire

    5-12. Installing And Threading Welding Wire Tools Needed: 15/16 in. Hold wire tightly to keep it from unraveling. 6 in. (150 mm) Pull and hold wire; cut off end. Select wire spool hub mounting position (see Section 5-9). Install wire spool. Adjust tension nut so wire is taut when wire feed stops.
  • Page 27 Notes OM-279248 Page 23...

  • Page 28: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Wire Feeder User Interface Ref. 279273-D OM-279248 Page 24...

  • Page 29: Description Of Front Panel Controls (See Section 6-1)

    6-2. Description Of Front Panel Controls (See Section 6-1) Memory 1-2 Buttons Left Adjust Control - Voltage/Arc 19 Trigger Select Button Length Use to enable and disable trigger select Allows two memory selections to recall function. When active, tap gun trigger to se- Use control to adjust voltage or arc length pre-selected welding process, wire type, lect between Memory 1 or 2.

  • Page 30: Power Switch

    6-3. Power Switch Power Switch (Located on rear of feeder) 281841-A 6-4. Jog/Purge Jog/Purge Switch Pressing the top portion of switch enables wire feeder to feed wire without energizing weld output or gas valve. Pressing bottom portion of switch enables gas valve to purge gas lines.

  • Page 31: Arc Control

    6-5. Arc Control Arc Control Knob Arc Control Indicators Arc control allows the arc characteristics, fluid versus stiff, to be changed for specific applications and wires. The star setting is good for most applications. Use fluid settings (0 −25) to soften the arc, increase puddle fluidity and flatten the weld bead appearance. Use stiff settings (0−25) to stiffen the arc, reduce puddle fluidity and crown the weld bead appearance To adjust or review the arc control setting, begin by turning Arc Control knob.

  • Page 32: Trigger Select

    6-8. Trigger Select Trigger Select Button Trigger Select LED Trigger Select function allows the operator to switch between saved welding setups using the welding gun trigger. The operator momentarily presses and releases the welding gun trigger to switch between Memory 1 or Memory 2. To enable Trigger Select function, press and release button.

  • Page 33: Operational Terms

    6-11. Operational Terms The following is a list of terms and their definitions as they apply to this wire feeder: General Terms: Arc Length Is the physical distance between the wire electrode and the molten weld puddle. It is a term used to represent adjustments in the Pulsed MIG welding process.

  • Page 34: Selecting Welding Arc, Wire Type, Size And Gas

    6-12. Selecting Welding Arc, Wire Type, Size And Gas STEEL .035” 75% AR 25% CO2 Wire and Gas Selection Display The Wire and Gas Selection Display indicates the current welding arc, wire type, wire size and shielding gas. To change parameters, follow the steps below: SELECT WELDING ARC: Selecting Welding Arc To select welding arc, press and release MIG/PULSE button.
  • Page 35 6-12. Selecting Welding Arc, Wire Type, Size And Gas (Continued) SELECT WIRE SIZE: .035” Selecting Wire Size To select wire size, press and release Wire Size button. Indicator will light. Wire Type indicator will turn off. The selected wire size will be displayed. Press Wire Size button again to change wire size.

  • Page 36: Mig - Wire And Gas Selection Table

    6-13. MIG - Wire and Gas Selection Table WIRE TYPES SHIELD GAS TYPES CO2 (CARBON DIOXIDE) .030 (0.8) AR CO2 (ARGON / CARBON DIOXIDE) .035 (0.9) CO2 (CARBON DIOXIDE) .045 (1.2) AR CO2 (ARGON / CARBON DIOXIDE) Steel .052 (1.4) AR O2 (ARGON / OXYGEN) AR CO2 (ARGON / CARBON DIOXIDE) .062 (1.6)*...

  • Page 37: Accu-Power

    6-15. Accu-Power The Accu-Power feature displays the instantaneous output power while welding, which can then be used with the equation below to compute the heat input for a particular weld operation. At end of the weld the total average power in kilojoules per second and total arc time in seconds are displayed for up to 30 seconds on the Wire and Gas selection display.

  • Page 38: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent l Unreadable Labels ~ Weld Terminals nl Weld Cables...

  • Page 39: Cleaning Debris From Shielding Gas Filter Fitting

    7-2. Cleaning Debris From Shielding Gas Filter Fitting Disconnect power before maintaining. Shielding Gas Filter Fitting Remove fitting from gas valve on back panel of feeder. Blow compressed air through the threaded male end of fitting to dis- lodge debris from internal mesh screen.

  • Page 40: Diagnostics Table For Fault Codes

    7-3. Diagnostics Table For Fault Codes Unit Display Toggles Message Description HELP SET HELP 10XX Indicates an issue with the weld program library, or the wire feeder attempted to use an invalid memory. Select a different memory (PRO feeder only). If the prob- lem persists, contact a Factory Authorized Service Agent.

  • Page 41: Troubleshooting

    7-4. Troubleshooting Disconnect power before troubleshooting Trouble Remedy Wire feeds, shielding gas flows, but Check and secure weld cable connections (see Section 5-2). electrode wire is not energized. Electrode wire feeding stops or feeds Check welding gun trigger connection. See gun Owner’s Manual. erratically during welding.

  • Page 42: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-279248 Page 38...
  • Page 43 279241-B OM-279248 Page 39...

  • Page 44: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. Fig.9−3 Fig.9−2 283383-A Figure 9-1. Main Assembly OM-279248 Page 40...
  • Page 45 Item Part Description Quantity Figure 9-1. Main Assembly ....Figure 9-2 Control Box ........... .
  • Page 46 ..275747 Circuit Card Assy, Intellx Pro UI W/Program ......
  • Page 47 Item Dia. Part Mkgs. Description Quantity Figure 9-2. Control Box (Continued) ..PLG2, 19 . . . 280003 Plugs, W/Leads (UI Board To Motor Board) (Not Shown) ... . .
  • Page 48 Hardware is common and not available unless listed. See Table 9-1 For Drive Roll & Wire Guide Kits 282450-B Figure 9-3. Drive Assembly, Wire Item Dia. Part Mkgs. Description Quantity Figure 9-3. Drive Assembly, Wire (Figure 9-1 Item 30) ..
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 9-3. Drive Assembly, Wire (Continued) ....279181 Lever, Mtg Pressure Gear Rear (Single Drive) ..... . .
  • Page 50 Table 9-1. Drive Roll & Wire Guide Kits (4 Drive Roll) Base selection of drive rolls upon the following recommended usages: 1. V-Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4.
  • Page 51 Effective January 1, 2020 (Equipment with a serial number preface of NA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Supplied Air Respirator (SAR) Boxes and Panels below, Miller Electric Mfg.
  • Page 52 Contact the Delivering Carrier to: 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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2020 Miller Electric Mfg. LLC 2020−01...

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