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Summary of Contents for Miller Intellx Elite
- Page 1 OM-288610J 2025-05 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Welding Flux Cored (FCAW) Welding Description Wire Feeder Intellx Elite Wire ™ Feeder 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.
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Page 3: Table Of Contents
Intellx Elite Administrator Settings (Continued) Auto Thread Disable ....... . . - Page 4 TABLE OF CONTENTS SECTION 7 – ELECTRICAL DIAGRAMS ..................48 SECTION 8 –...
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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 � Porter un harnais de sécurité si l’on doit travailler au-dessus du LES ACCUMULATIONS DE GAZ sol. risquent de provoquer des blessures � S’assurer que tous les panneaux et couvercles sont correctement ou même la mort. en place. � Fixer le câble de retour de façon à obtenir un bon contact métal- �...
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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 - Specifications
� Complete Parts List is available at www.MillerWelds.com SECTION 3 – SPECIFICATIONS 3-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. -
Page 15: Section 4 - Installation
Power Source And Wire Feeder Site Selection � Complete Parts List is available at www.MillerWelds.com SECTION 4 – INSTALLATION 4-1. Selecting A Location Do not put feeder where welding Movement wire hits cylinder. Do not move or operate unit where it could tip. -
Page 16: Connecting Weld Output Cable
1-1. Connecting Weld Output Cable � Complete Parts List is available at www.MillerWelds.com 4-2. Connecting Weld Output Cable Turn off power before connecting to weld terminal or receptacle. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. -
Page 17: Connection Diagram
� Complete Parts List is available at www.MillerWelds.com 4-3. Connection Diagram Ref. 289975-A 7 Wire Feeder Use of shielding gas is dependant on Wire Turn power before making Type. connections. 8 Gas Hose � 1 Wire Feeder Cable The connection diagram illustrates 9 Gas Cylinder DCEP (reverse polarity) suitable for all 2 Positive (+) Weld Output Terminal... -
Page 18: Arranging Welding Cables To Reduce Welding Circuit Inductance
� Complete Parts List is available at www.MillerWelds.com 4-4. Arranging Welding Cables To Reduce Welding Circuit Inductance 1 Welding Power Source 2 Electrode Cable 3 Feeder Cable 4 Work Cable 5 Voltage Sense Lead 6 Wire Feeder 7 Workpiece The arrangement of the cables has an effect that is significant to the welding properties. -
Page 19: Control Cable Connections
1-1. Control Cable Connections � Complete Parts List is available at www.MillerWelds.com 4-5. Control Cable Connections Turn off power before connecting control cable. Remote ArcConnect Receptacle Remote ArcConnect Receptacle Turn off power before connecting control cables. Connect control cable between recepta- cle RC2 on front of welding power source Welding Power Source Front View to receptacle RC1 on rear of wire feeder. -
Page 20: Wire Feeder Lower Front Panel Connections
� Complete Parts List is available at www.MillerWelds.com 4-6. Wire Feeder Lower Front Panel Connections 1 4-Socket Gun Trigger Receptacle RC2 Connect gun trigger plug to receptacle RC2 on lower front panel of wire feeder. 2 Push/Pull Aluminum MIG Gun Trigger Receptacle Connect push/pull gun trigger plug to 14-pin receptacle on lower front panel of wire... -
Page 21: Connecting Shielding Gas
1-1. Connecting Shielding Gas � Complete Parts List is available at www.MillerWelds.com 4-8. Connecting Shielding Gas NOTICE – This feeder has a shielding gas filter that requires special attention when cleaning. See Section 6-2 for proper clean- ing instructions. 1 Gas Hose With 5/8-18... -
Page 22: Wire Drive Angle Adjustment
� Complete Parts List is available at www.MillerWelds.com 4-10. Wire Drive Angle Adjustment 1 Wire Drive Assembly Rotation Knob 2 Wire Drive Assembly Rear View Rotate the drive assembly to reduce bends in the MIG gun cable. To rotate the drive assembly, loosen drive assembly rotation knob, rotate drive assem- bly to desired position and tighten knob to secure. -
Page 23: Spool Hub Mounting Locations
� Complete Parts List is available at www.MillerWelds.com 4-11. Spool Hub Mounting Locations tools/ 1 Spool Retaining Ring wrench allen_set flathead philips head wrench crescent wrench 2 Wire Spool 3 Spool Hub 4 Low Position 5 Middle Position 6 High Position 7 Spool Hub Mounting Screw needlenose knife... -
Page 24: Installing Welding Gun
� Complete Parts List is available at www.MillerWelds.com 4-12. Installing Welding Gun 1 Power Clamp Knob 2 Gun Locking Tab 3 Gun Locking Tab Rotated 180 Degrees 4 Power Pin Groove 5 Gun Connection End 6 Installing 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
1-1. Installing Wire Guides And Drive Rolls � Complete Parts List is available at www.MillerWelds.com 4-13. Installing Wire Guides And Drive Rolls Ref. 281467-C Insert inlet wire guide into wire entry as retaining nut one click to secure in place. Installing Wire Guides shown. -
Page 26: Installing And Threading Welding Wire
1-1. Installing And Threading Welding Wire � Complete Parts List is available at www.MillerWelds.com 4-14. Installing And Threading Welding Wire 6 in. (150 mm) tools/ allen_wrench allen_set flathead philips head wrench crescent wrench Ref. 156929-A / 281838-A / 242517-A 15/16 in. pliers needlenose Step 4. -
Page 27: Threading Welding Wire For Aluminum Push-Pull Guns
� Complete Parts List is available at www.MillerWelds.com 4-15. Threading Welding Wire For Aluminum Push-Pull Guns Ref. 290195-A / 281467-C / 242517-A / 291900-A Loosen Tighten tools/ Recommended Pressure Range Recommended Pressure Range allen_wrench allen_set flathead philips head wrench Wire Size crescent wrench 4XXX Series 5XXX Series... -
Page 28: Section 5 - Operation
� Complete Parts List is available at www.MillerWelds.com SECTION 5 – OPERATION 5-1. 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 29: Power Switch
� Complete Parts List is available at www.MillerWelds.com wer Switch 5-2. Power Switch Power Switch (Located on rear of feeder) 1 Power Switch (Located on rear of feeder) 281841-A 5-3. Jog/Purge 1 Jog/Purge Switch Pressing the top portion of switch enables wire feeder to feed wire without energizing weld output or gas valve. -
Page 30: Intellx Elite Home Screen
� Complete Parts List is available at www.MillerWelds.com 5-4. Intellx Elite Home Screen Indicates trigger status. The display shows details of the actively 1 Menu Tabs loaded weld program (Process, Wire Type, Wire Size, and Gas). 5 Sequence Icons Status Bar This menu indicates which action will be se- lected by the corresponding soft keys. -
Page 31: Intellx Elite Administrator Settings
� Complete Parts List is available at www.MillerWelds.com 5-5. Intellx Elite Administrator Settings 2 Memory Limits � � An authorized user may use the pass- Administrator settings allow the user to code recovery feature to recover a lost set Voltage/Arc Length upper and low- Allows the Administrator to set and activate passcode. -
Page 32: Intellx Elite Administrator Settings (Continued) Auto Thread Disable
� Complete Parts List is available at www.MillerWelds.com 5-6. Intellx Elite Administrator Settings (Continued) Auto Thread Disable 1 Auto Thread Allows the Administrator to disable the Auto � Administrator settings can be locked in Thread Function place with a Passcode to restrict ac- cess to these parameters. -
Page 33: Intellx Elite Trigger Settings
� Complete Parts List is available at www.MillerWelds.com 5-7. Intellx Elite Trigger Settings trigger must be held for at least 2 seconds 2 Trigger Select 1 Trigger Control before being released to enter Trigger Hold mode. If the trigger is released before 2 sec-... -
Page 34: Intellx Elite Process Settings
� Complete Parts List is available at www.MillerWelds.com 5-8. Intellx Elite Process Settings Steel, Metal Core, Flux Core, Stainless .030”, .035”, .040”, .052”, .062”, 5/64". 1 Weld Processes Steel, Aluminum 4XXX, Aluminum 5XXX, Nickel, Copper Nickel, Silicon Bronze, Tita- 4 Gas Types MIG, Accu-Pulse, Versa-Pulse, RMD, HD nium, Aluminum 4943. -
Page 35: Intellx Elite Sequence Settings (Beginning)
� Complete Parts List is available at www.MillerWelds.com 5-9. 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. -
Page 36: Intellx Elite Sequence Settings (Ending)
� Complete Parts List is available at www.MillerWelds.com 5-10. 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. -
Page 37: Intellx Elite Insight Settings
� Complete Parts List is available at www.MillerWelds.com 5-11. Intellx Elite Insight Settings Displays status of Insight Peripheral. 1 Information Status OM-288610 Page 33... -
Page 38: Intellx Elite Usb Menu
� Complete Parts List is available at www.MillerWelds.com 5-12. Intellx Elite USB Menu Load or Save settings files from and to USB. Load a custom weld library file from USB or 1 Operator ID Used for copying settings from system to remove the currently loaded custom weld li- system. -
Page 39: Intellx Elite Localization (Language Select)
� Complete Parts List is available at www.MillerWelds.com 5-13. Intellx Elite Localization (Language Select) Choose from available languages — English 1 Language Selection (Default), Spanish, French. OM-288610 Page 35... -
Page 40: Intellx Elite Unit Selection
� Complete Parts List is available at www.MillerWelds.com 5-14. Intellx Elite Unit Selection Select either IPM, FEET, INCHES or MPM, 1 Unit Selection METERS, MILLIMETERS. OM-288610 Page 36... -
Page 41: Intellx Elite Remote Gouge
� Complete Parts List is available at www.MillerWelds.com 5-15. Intellx Elite Remote Gouge � Gouge functionality is accessible from EZ-ACCESS in System Menu. 1 EZ-ACCESS Menu OM-288610 Page 37... -
Page 42: Intellx Elite Remote Gouge (Continued)
� Complete Parts List is available at www.MillerWelds.com 5-16. Intellx Elite Remote Gouge (Continued) � Once gouge functionality is enabled in the EZ-ACCESS system menu it is added to the home screen soft key menu. If gouge is disabled from EZ- ACCESS system menu the soft key is removed. -
Page 43: Operational Terms
Feed Speed) resulting in higher depositions at the same current. The spray mode of transfer is the only recommended mode of transfer for this process. These recommended settings are avail- able using the EZ-Set function on the Intellx Elite. Extended nozzles for High Deposition Mig are available from Tregaskiss and Bernard. -
Page 44: Mig - Wire And Gas Selection Table
� Complete Parts List is available at www.MillerWelds.com 5-18. MIG - Wire And Gas Selection Table WIRE TYPES SHIELD GAS TYPES .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) -
Page 45: Accu-Pulse - Wire And Gas Selection Table
� Complete Parts List is available at www.MillerWelds.com 1.0 *** AR O2 (ARGON / OXYGEN) 1.2 *** AR CO2 (ARGON / CARBON DIOXIDE) * Available with Deltaweld 500 only. ** Not available in CE market machines. *** CE market machines only. 5-20. -
Page 46: Rmd - Wire And Gas Selection Table
� Complete Parts List is available at www.MillerWelds.com 5-21. RMD - Wire And Gas Selection Table WIRE TYPES SHIELD GAS TYPES .030 (0.8) AR CO2 (ARGON / CARBON DIOXIDE) .052 (1.4) Steel .035 (0.9) CO2 (CARBON DIOXIDE) .045 (1.2) AR CO2 (ARGON / CARBON DIOXIDE) Metal Core .045 (1.2) AR CO2 (ARGON / CARBON DIOXIDE) -
Page 47: Section 6 - Maintenance And Troubleshooting
� Complete Parts List is available at www.MillerWelds.com SECTION 6 – MAINTENANCE AND TROUBLESHOOTING 6-1. 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. -
Page 48: Diagnostics Table For Fault Codes
� Complete Parts List is available at www.MillerWelds.com 6-3. 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. - Page 49 � Complete Parts List is available at www.MillerWelds.com 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.
- Page 50 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.
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Page 51: Troubleshooting
� Complete Parts List is available at www.MillerWelds.com 6-4. Troubleshooting Trouble Remedy Wire feeds, shielding gas flows, but Check and secure weld cable connections (see Section 4-2). 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 52: Section 7 - Electrical Diagrams
SECTION 7 – ELECTRICAL DIAGRAMS 50V INPUT RC16-1 5OV UNSWITCHED RC16-3 +50V RC18-1 +50V RC18-2 +50V RC18-3 50V RET RC18-4 50V RET RC18-5 50V RET RC18-10 PWR SHIELD RC18-6 VSENSE FDBK RC18-8 REMOTE VSENSE REF ARCCONNECT RC18-9 ORN/WHT ETH RX+ RC21-1 RJ45 ETH RX-... - Page 53 RC8-1 RC2-1 RC6-2 RC8-2 RC2-2 RC6-1 RC8-3 RC2-3 RC8-4 RC2-4 RC8-5 RC2-5 RC8-6 RC2-6 RC8-7 RC2-7 RC5-1 RC8-8 RC2-8 RC5-2 RC8-9 RC2-9 RC5-3 RC8-10 RC2-10 RC5-4 RC8-11 RC2-11 RC5-5 RC8-12 RC2-12 RC5-6 RC8-13 RC2-13 RC5-7 RC8-14 RC2-14 RC5-8 RC8-16 RC2-16 TRIGGER BOARD RC5-9...
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Page 54: Section 8 - Definitions
Some symbols are found only on CE products. Some symbols are found only on CE products. 1-1. Additional Safety Symbols And Definitions 1-1. Additional Safety Symbols And Definitions 1-1. Additional Safety Symbols And Definitions SECTION 8 – DEFINITIONS Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. -
Page 55: Miscellaneous Symbols And Definitions
at job site. Double-check all connections, relinking board position, a Keep your head out of the fumes Keep flammables away from welding. Do not weld near flammables. input voltage before applying power. Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. Do not cut on drums or any closed containers. -
Page 56: Symbol Definitions
Symbol Definitions Shielded Metal mperage Battery (Engine) Arc Welding (SMAW) Purge By Gas Trigger Hold On Read Instructions Read Operator’s Gas Metal Arc Voltage Manual Welding (GMAW) Gas Type Gas Preflow Pulse Gas Tungsten Arc Welding (GTAW) / Negative Engine Oil Tungsten Inert Gas (TIG) Gas Metal Arc... -
Page 57: Section 9 - Regulatory And Compliance Information
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 58 Notes...
- Page 59 Effective January 1, 2025 (Equipment with a serial number preface of NF or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � Field Options (NOTE: Field options are cov-...
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Page 60: 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 2025-05...
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