Miller Intellx Elite ROI Owner's Manual
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Miller Intellx Elite ROI Owner's Manual

Miller Intellx Elite ROI Owner's Manual

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Intellx
™
Dual ROI
OWNER'S MANUAL
OM-289411B
Processes
Description
Elite ROI And
2023-01
MIG (GMAW) Welding
Pulsed MIG (GMAW-P) Welding
Flux Cored (FCAW) Welding

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Summary of Contents for Miller Intellx Elite ROI

  • Page 1 OM-289411B 2023-01 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Welding Flux Cored (FCAW) Welding Description Intellx Elite ROI And ™ Dual ROI OWNER’S MANUAL 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 Symbol Usage .

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

    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.

  • Page 6: Electric And Magnetic Fields

    HOT PARTS can burn. WELDING can cause fire or explosion. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. �...

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

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

  • Page 8: California Proposition 65 Warnings

    � To reduce possible interference, keep weld cables as short as ARC WELDING can cause possible, close together, and down low, such as on the floor. interference. � Locate welding operation 100 meters from any sensitive electronic equipment. � Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, �...

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

    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.
  • Page 10 � S’assurer que tous les panneaux et couvercles sont correctement LES ACCUMULATIONS DE GAZ en place. risquent de provoquer des blessures � Fixer le câble de retour de façon à obtenir un bon contact métal- ou même la mort. métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

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

    � Brancher le câble de masse sur la pièce le plus près possible de � Les porteurs d’implants médicaux doivent consulter leur médecin la zone de soudage pour éviter le transport du courant sur une lon- et le fabricant du dispositif avant de s’approcher de la zone où se gue distance par des chemins inconnus éventuels en provoquant déroule du soudage à...

  • Page 12: Proposition Californienne 65 Avertissements

    � Affûter l'électrode au tungstène uniquement à la meuleuse dotée LIRE LES INSTRUCTIONS. de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l'on porte l'équipement homologué de protection du vi- � Lire et appliquer les instructions sur les étiquettes sage, des mains et du corps.

  • Page 13: Informations Relatives Aux Cem

    Safety in Welding, Cutting, and Allied Processes, CSA Standard Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website: W117.2 from Canadian Standards Association. Website: www. csa- www.osha.gov. group.org. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.

  • Page 14: Section 3 - Definitions

    Read Operator’s Gas Metal Arc Voltage Manual Welding (GMAW) Gas Tungsten Arc SECTION 3 – DEFINITIONS Welding (GTAW) / Negative Engine Oil Tungsten Inert Gas (TIG) Welding 3-1. Miscellaneous Symbols And Definitions Positive Engine Flux Cored Arc Welding (FCAW) Alternating Engine Stop Current (AC) Amperage...

  • Page 15: Section 4 - Specifications

    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 16: Section 5 - Installation

    SECTION 5 – INSTALLATION 5-1. Remote Operator Interface Mounting Bracket Hole Layout Top View 1 Extruded holes in mounting bracket for 1/ 9.0 in. 4 in. self-tapping screws (8). (229 mm) 3.0 in. 0.375 in. (9.5 mm) (76 mm) 4.0 in. (102 mm) Front View 7.875 in.

  • Page 17: Mounting Remote Operator Interface To Boom

    5-2. Mounting Remote Operator Interface To Boom Ref. 286947-A Turn off unit and disconnect input power before making connections. 1 Remote Operator Interface 2 Mounting Bracket 3 Mounting Plate 4 0.250-20 x 0.5 in. Screws (8) Attach mounting bracket to mounting plate using four screws.

  • Page 18: Equipment Connection Diagram (Single Boom)

    5-3. Equipment Connection Diagram (Single Boom) 287025-A 7 Boom 15 Pipe Post And Base 1 Welding Power Source 8 Gun 16 Gas Hose 2 Positive (+) Weld Cable 9 Trigger Connection 17 ArcConnect Cable (Wire Drive) 3 Negative (-) Weld Cable 10 Voltage Sensing Cable 18 ArcConnect Cable (Power Source) 4 Workpiece...

  • Page 19: Equipment Connection Diagram (Dual Boom)

    5-4. Equipment Connection Diagram (Dual Boom) 287026-A 7 Boom 15 Pipe Post And Base 1 Welding Power Source 8 Gun 16 Gas Hose 2 Positive (+) Weld Cable 9 Trigger Connection 17 ArcConnect Cable (Wire Drive) 3 Negative (-) Weld Cable 10 Voltage Sensing Cable 18 ArcConnect Cable (Power Source) 4 Workpiece...

  • Page 20: Remote Operator Interface Connections

    5-5. Remote Operator Interface Connections 1 ArcConnect From Welder 2 ArcConnect To Wire Drive 3 Volt Sense To Wire Drive 4 Volt Sense To Work 286937-A OM-289411 Page 16...

  • Page 21: Section 6 - Operation

    SECTION 6 – OPERATION 6-1. Intellx Elite User Interface 4 Left Adjust Control Knob-Voltage/Arc 7 Arc Control Button and Light Bar 1 LCD Display Length Indicator The LCD display is used as an interactive Use control to adjust voltage or arc length Use control to adjust arc characteristics.

  • Page 22: Power Switch

    6-2. Power Switch 1 Power Switch (Located on side of remote operator interface) Ref. 290028-B 6-3. Jog/Purge Switch (Single ROI) 1 Jog/Purge Switch (Located on side of re- mote operator interface) Pressing top portion of switch enables wire feeder to feed wire without energizing weld output or gas valve.

  • Page 23: Intellx Elite Home Screen

    6-5. Intellx Elite Home Screen 5 Sequence Icons Status Bar settings for Frequency, WFS Change and 1 Menu Tabs Arc Length Change. Indicates the status of the weld sequence This menu indicates which action will be se- processes. When a process is enabled, the 8 Weld Wire Feed Speed / Amperage lected by the corresponding soft keys.

  • Page 24: Intellx Elite Administrator Settings

    Arc Control upper and lower slot to contact Miller Service. limits. These settings can be locked in place with a Passcode to restrict ac- 3 System Lock 4 Settings Reset cess to these parameters.

  • Page 25: Intellx Elite Trigger Settings

    6-7. Intellx Elite Trigger Settings holding the trigger again caused the unit to 3 Dual Schedule 1 Trigger Control stay in Crater until the trigger is released and Crater parameter times out. Dual Schedule allows the operator to select Allows the operator to select Standard 2T, between a pair of weld programs by using Trigger Hold, Tack Time and 4T.

  • Page 26: Intellx Elite Process Settings

    6-8. Intellx Elite Process Settings Steel, Metal Core, Flux Core, Stainless .030”, .035”, .040”, .052”, .062”. 1 Weld Processes Steel, Aluminum 4XXX, Aluminum 5XXX, Nickel, Copper Nickel, Silicon Bronze, 4 Gas Types MIG, Accu-Pulse, Profile-Pulse Titanium. When setting weld process, refer to weld ta- 2 Wire Type 3 Wire Size ble (see Section 6-14).

  • Page 27: Intellx Elite Sequence Settings (Beginning)

    6-9. Intellx Elite Sequence Settings (Beginning) With the desired function active, use the 3 Start At the Home screen, use the memory but- right scroll knob to adjust the selected tons to select the program number to be function. changed. Adjusts starting wire speed, voltage/arc length, time, and ramp time.

  • Page 28: Intellx Elite Sequence Settings (Ending)

    6-10. Intellx Elite Sequence Settings (Ending) In the weld sequence configuration section 2 Burnback At the Home screen, use the memory but- (left side), rotate the scroll knob to desired tons to select the program number to be function. changed. Adjusts burnback time and voltage.

  • Page 29: 6-11. Intellx Elite Insight Settings

    6-11. Intellx Elite Insight Settings Displays status of Insight Peripheral. 1 Information Status OM-289411 Page 25...

  • Page 30: 6-12. Intellx Elite Usb Menu

    6-12. Intellx Elite USB Menu Operator ID is used when an operator plugs operator ID file. Operator ID is only available 1 Operator ID in an Operator ID USB containing an with the Insight Core peripheral. OM-289411 Page 26...

  • Page 31: 6-13. Operational Terms

    6-13. Operational Terms The following is a list of terms and their definitions as they apply to this wire feeder: Cold-Wire Jog Feeding wire without contactor or gas valve being energized. Sequence A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow. Weld Program A group of sequences that make up a weld cycle.

  • Page 32: 6-14. Mig - Wire And Gas Selection Table

    6-14. MIG - Wire And Gas Selection Table WIRE TYPES SHIELD GAS TYPES CO2 (CARBON DIOXIDE) .030 (0.8) Steel AR CO2 (ARGON / CARBON DIOXIDE) .035 (0.9) CO2 (CARBON DIOXIDE) .045 (1.2) AR CO2 (ARGON / CARBON DIOXIDE) .052 (1.4) AR O2 (ARGON / OXYGEN) AR CO2 (ARGON / CARBON DIOXIDE) .062 (1.6)*...

  • Page 33: 6-15. Accu-Pulse - Wire And Gas Selection Table

    6-15. Accu-Pulse - Wire And Gas Selection Table WIRE TYPES SHIELD GAS TYPES .035 (0.9) .045 (1.2) AR O2 (ARGON / OXYGEN) Steel .052 (1.4)* AR CO2 (ARGON / CARBON DIOXIDE) .062 (1.6)* .045 (1.2) Metal Core AR CO2 (ARGON / CARBON DIOXIDE) .052 (1.4) .062 (1.6)* .035 (0.9)

  • Page 34: Section 7 - Maintenance And Troubleshooting

    SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance A complete Parts List is available at www.MillerWelds.com Complete Parts List is available at www.MillerWelds.com SECTION 17 MAINTENANCE & TROUBLESHOOTING Disconnect power before maintaining. 17-1. Routine Maintenance � Service equipment more often if used in severe conditions. �...

  • Page 35: Diagnostics Table For Fault Codes

    7-2. Diagnostics Table For Fault Codes Error ID Help Code Title Description Solution HELP 1XX 100, 102, 103, 105, 106, Primary Input Circuit Malfunction Indicates a malfunction in the pri- Contact a Factory Authorized mary power circuit. Service Agent 101, 104 Indicates a malfunction in the pri- Cycle power.
  • Page 36 Error ID Help Code Title Description Solution Invalid Weld Voltage Feedback Indicates a malfunction in the sec- Verify weld voltage sense lead is ondary power circuit of the unit. connected correctly. If fault re- mains, contact a Factory Author- ized Service Agent. Secondary Current Above Limit Indicates a malfunction in the sec- Check external weld circuit config-...
  • Page 37 Purge Held Too Long HELP 28XX 2801 Field Trial Time Expired Indicates the field trial time has Please contact Miller Electric Serv- ended. ice or a Factory Authorized Service Agent. � The last two digits in the right display (shown with XX in the table) will indicate a specific fault a Factory Authorized Service Agent can use to troubleshoot the wire feeder.

  • Page 38: Troubleshooting

    7-3. Troubleshooting Trouble Remedy Wire feeds, shielding gas flows, but Check and secure weld cable connections (see Section 5-3 or 5-4). electrode wire is not energized. Electrode wire feeding stops or feeds Check welding gun trigger and connection. See gun Owner’s Manual. erratically during welding.
  • Page 39 Notes...

  • Page 40: Section 8 - Electrical Diagrams

    SECTION 8 – ELECTRICAL DIAGRAMS Figure 8-1. Circuit Diagram OM-289411 Page 36...
  • Page 41 291256-B OM-289411 Page 37...

  • Page 42: Section 9 - Parts List

    SECTION 9 – PARTS LIST Ref. 290858-A Figure 9-1. Intellx Elite ROI Control Box OM-289411 Page 38...
  • Page 43 Intellx Elite ROI Control Box Item Dia. Mkgs. Part No. Description Quantity Quantity (Single (Dual ROI) ROI) 288293 Panel Assy, Front Intellx Elite Feeder 289594 Panel Assy, Front Intellx Elite Feeder (Dual) 285179 Label, Nameplate Miller Intellx ROI Lower 284946...
  • Page 44 Notes...
  • Page 45 Notes...
  • Page 46 Notes...
  • Page 47 Effective January 1, 2023 (Equipment with a serial number preface of ND or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � CoolBelt, PAPR Blower, and PAPR Face...

  • Page 48: Owner's Record

    Appleton, WI 54914 USA tact your distributor and/or equipment manu- facturer’s Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2023-01...

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