Miller Intellx Pro, Owner'S Manual

Page 1: ...s OM 279248C 2020 05 Intellx Pro Wire Feeder Processes Description Wire Feeder MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding For product information Owner s Manual translations and more visit www MillerWelds com ...

Page 2: ...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 a...

Page 3: ...l Location 12 4 2 Software Licensing Agreement 12 4 3 Information About Default Weld Parameters And Settings 12 4 4 Specifications 12 4 5 Environmental Specifications 12 4 6 Duty Cycle 12 SECTION 5 INSTALLATION 13 5 1 Power Source And Wire Feeder Site Selection 13 5 2 Connecting Weld Output Cable 14 5 3 Connection Diagram 15 5 4 Arranging Welding Cables To Reduce Welding Circuit Inductance 16 5 5 ...

Page 4: ...ion Table 32 6 14 Accu Pulse Wire and Gas Selection Table 32 6 15 Accu Power 33 SECTION 7 MAINTENANCE TROUBLESHOOTING 34 7 1 Routine Maintenance 34 7 2 Cleaning Debris From Shielding Gas Filter Fitting 35 7 3 Diagnostics Table For Fault Codes 36 7 4 Troubleshooting 37 SECTION 8 ELECTRICAL DIAGRAM 38 SECTION 9 PARTS LIST 40 WARRANTY ...

Page 5: ...llow 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 unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomati...

Page 6: ...not possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas D Watch for fire and keep a fire extinguisher nearby D Be aware that welding on a ceiling fl...

Page 7: ...to move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment OVERUSE can cause OVERHEATING D Allow cooling period follow r...

Page 8: ...cuments Website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protection Association Website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 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 csagrou...

Page 9: ... de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures 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 inévitab...

Page 10: ...udure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incen dies et des brûlures Le contact accidentel de l électrode avec des objets métalliques peut provoquer des étincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage vérifier et s assurer que l endroit ne présente pas de danger D Déplacer toutes les substances inflamma...

Page 11: ...e mettre l appareil en service LA CHUTE DE L ÉQUIPEMENT peut provoquer des blessures D Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire D Utilisez les procédures correctes et des équipements d une capa cité appropriée pour soulever et supporter l appareil D En utilisant des fourches de levage pour déplacer l unité s...

Page 12: ...ards Institute Website www ansi org Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents Website www global ihs com Safe Practices for Welding and Cutting Containers that have Held Com bustibles American Welding Society Standard AWS A6 0 from Global Engineering Documents Website www global ...

Page 13: ...ycling office or your local distributor for further information Safe37 2017 04 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves Safe2 2017 04 Protect yourself from electric shock by insulating yourself from work and ground Safe3 2017 04 Disconnect input plug or power before working on machine Safe5 2017 04 Keep your head out of the fumes Safe6 2017...

Page 14: ...olls can injure fingers Safe32 2012 05 Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away Safe33 2017 04 Pinch points can injure Safe102 2012 09 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Safe66 2012 06 Become trained and read the instruction...

Page 15: ...Degree Of Protection Increase Gas Input Input Output Percent Purge By Gas Gas Preflow Gas Postflow I2 Rated Welding Current Line Connection Wire Diameter Cold Jog Inch Towards Workpiece Trigger Hold On Gas Type Gas Metal Arc Welding GMAW Gun U1 Primary Voltage Filter Wire Type Arc Control Read Instructions Pulse Done Voltage Sense Input Notes ...

Page 16: ...ation 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 4 4 Specifications Input ...

Page 17: ...imilar device to move unit 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Line Disconnect Device Locate unit near correct input power supply 5 1 Power Source And Wire Feeder Site Selection 3 18 in 460 mm 18 in 460 mm 1 Movement Location And Airflow 2 OR Do not move or operate unit where it could tip Do not put feeder...

Page 18: ...nection Do not place anything between weld cable terminal and weld terminal Make sure that all surfaces are clean 1 Weld Terminal 2 Weld Terminal Bolt 3 Weld Cable Terminal 4 Supplied Nut Remove supplied nut from weld terminal Install cable on weld terminal bolt Screw nut onto bolt and tighten to 250 in lb 28 2 N m Tools Needed 9 16 in Wire Feeder Side View with Door Open 1 Ref 281839 A 5 2 Connec...

Page 19: ... 5 Workpiece 6 Welding Gun 7 Wire Feeder 8 Gas Hose 9 Gas Cylinder 10 Welding Power Source 11 Electrode Cable 12 Volt Sense Lead Optional Use of shielding gas is dependant on Wire Type The connection diagram illustrates DCEP reverse polarity suitable for all wires except self shielded FCAW The majority of self shielded FCAW wires require DCEN straight polarity 5 6 9 1 2 3 4 7 8 10 11 12 ...

Page 20: ...o the welding puddle The work sense lead connects to the rear of the wire feeder This work sense lead automatically compen sates for work cable voltage drop when connected Do not coil excess cables Use cables that are the appropriate length for the application Whenever using long weld cables longer than 50 ft 15 m try to arrange positive and negative weld cables together to reduce the magnetic fie...

Page 21: ...ct Receptacle RC1 Connect control cable between recepta cle RC2 on front of welding power source to receptacle RC1 on rear of wire feeder Welding Power Source Front View Wire Feeder Rear View 1 2 5 6 Wire Feeder Lower Front Panel Connections 1 4 Socket Gun Trigger Receptacle RC2 Connect gun trigger plug to recep tacle RC2 on lower front panel on wire feeder Ref 281841 A 1 ...

Page 22: ...der Rear View 1 5 8 Connecting Shielding Gas Ref 281841 A 256620 A NOTICE This feeder has a shield ing gas filter that requires special attention when cleaning See Sec tion 7 2 for proper cleaning instruc tions 1 Gas Hose With 5 8 18 Right hand Thread Fittings Customer Supplied Tighten gas hose fitting to a maximum of 100 in lbs 12 N m 2 Shielding Gas Cylinder Shielding gas pressure not to exceed ...

Page 23: ... 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 3 Drive Assembly Rotation Knob To rotate the drive assembly loosen drive assembly rotation knob rotate drive assembly to de sired position and tighten knob to secure Wire Feeds Off Bottom Of Spool Wire Feeds Off Top Of Spool 2 Good Bad 2 3 1 ...

Page 24: ...un with the gun locking tab Secure gun by tightening power clamp knob Installing gun without Accu Mate connection When using a gun without the groove in the power pin loosen power clamp knob and rotate gun locking tab 180 degrees This pre vents the locking tab from extend ing into the power pin gun connec tion Push power pin into power clamp as far as possible Secure gun by tightening power clamp ...

Page 25: ...place to secure Repeat procedure for intermediate guide To remove wire guides push on wire guide securing button and remove guide Installing Drive Rolls 6 Drive Roll Carrier 7 Drive Roll Retaining Nut 8 Drive Roll With upper drive roll carriers open slide drive roll onto carrier Rotate drive roll re taining nut one click to secure in place Re peat procedure for remaining drive rolls To remove driv...

Page 26: ...alf that of the front rolls To adjust drive roll pressure hold nozzle about 2 in 51 mm from nonconductive surface and press gun trigger to feed wire against surface Tighten knob so wire does not slip Do not overtighten If contact tip is completely blocked wire should slip at the feeder see pressure adjustment above Cut wire off Close cover 5 12 Installing And Threading Welding Wire Ref 156929 A 28...

Page 27: ...OM 279248 Page 23 Notes ...

Page 28: ...OM 279248 Page 24 SECTION 6 OPERATION 6 1 Wire Feeder User Interface Ref 279273 D 2 1 9 10 13 4 5 6 7 8 11 26 12 14 15 16 17 18 19 20 21 22 23 24 25 3 27 28 ...

Page 29: ...istics Rotate to review and adjust desired setting 12 Wire And Gas Selection Display Indicates selected weld process wire type wire size and gas type 13 MIG Pulse Button Used to select desired welding process 14 Wire Button Use to select desired welding wire type 15 Wire Size Button Use to select desired welding wire size 16 Gas Button Use to select desired welding gas type 17 Done Button Use to s...

Page 30: ...s jogging wire The unit dis plays wire speed while the unit is being jogged 3 Gun Trigger Receptacle The wire feeder can also be jogged by using the gun trigger However the weld output is energized for 3 seconds If the welding arc does not initiate in 3 seconds after the gun trigger is activated the unit will perform a jog operation for a maxi mum of one minute If the gun trig ger is still activat...

Page 31: ...ing setups To save welding setups to a memory press and release desired memory button Indicator will be lit Choose welding parameters using Section 6 12 The welding setup is now saved to this memory Repeat process for other memory button Operator can now recall either setup by pressing correspondingmemory button Each memory has independent preset voltage or arc length wire speed arc control preflo...

Page 32: ...low time can be adjusted from 0 1 to 30 seconds To enable preflow function press and release button Indicator will light Immediately after enabling the preflow time will be displayed in the Right Display Turn Right Adjust Control knob below Right Display to adjust desired preflow time To disable press and release button Indicator will not be lit 1 2 6 10 Postflow 1 Postflow Button 2 Postflow LED P...

Page 33: ...g process is selected To adjust setting turn Left Adjust Control knob Use settings of 0 to 10 0 to decrease arc length Use settings of 0 to 10 0 to increase arc length EZ Set A synergic operation which automatically determines weld parameters by using the wirefeed speed knob to select the thickness of the material being welded Once the material thickness is selected the welding parameters are set ...

Page 34: ...the steps below SELECT WELDING ARC MIG Selecting Welding Arc To select welding arc press and release MIG PULSE button Indicator will light The selected welding arc will be displayed Press MIG PULSE button again to change welding arc selection SELECT WIRE TYPE STEEL Selecting Wire Type To select wire type press and release Wire button Indicator will light MIG PULSE indicator will turn off The selec...

Page 35: ...select shielding gas press and release Gas button Indicator will light Wire Size indicator will turn off The selected gas type will be displayed Press Gas button again to change gas type MIG STEEL 035 75 AR 25 CO2 Saving Selected Parameters To save selected parameters press and release the Done button The Gas indicator will turn off The selected welding arc wire type wire size and gas type will be...

Page 36: ... CO2 ARGON CARBON DIOXIDE Stainless Steel 035 0 9 045 1 2 062 1 6 AR CO2 ARGON CARBON DIOXIDE AR HE CO2 ARGON HEL CARBON DIOXIDE AR O2 ARGON OXYGEN HE AR CO2 HELIUM ARGON CARBON DIOXIDE Available With Deltaweld 500 only 6 14 Accu Pulse Wire and Gas Selection Table WIRE TYPES SHIELD GAS TYPES Steel 035 0 9 045 1 2 052 1 4 062 1 6 AR CO2 ARGON CARBON DIOXIDE AR O2 ARGON OXYGEN Metal Core 045 1 2 052...

Page 37: ...e Wire and Gas selection display To calculate the weld heat input multiply the instantaneous power by the arc time and divide by the weld bead length To convert from kilojoules to joules multiply this result by 1000 Enabling Accu Power Accu Power is always displayed when using Accu Pulse To enable in other welding arc modes connect voltage sense lead from weld volt age sense receptacle on rear of ...

Page 38: ...ten during severe conditions n Check Z Change Clean l Replace To be done by Factory Authorized Service Agent Reference Every 3 Months l Unreadable Labels Weld Terminals nl Weld Cables nl Gun Cables nl Cords nl Cracked Parts Weld Connections n Tighten Weld Cable Connections l Damaged Gas Hose Every 6 Months OR Drive Rolls Inside Unit ...

Page 39: ...e 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 Replace fitting if blowing com pressed air through fitting does not clear obstructions Reinstall fitting into gas valve Tighten fitting to 150 in lbs 17 N m Rear View of Feeder Tools Needed 3 4 in 1 ...

Page 40: ... tension gun liner wire guides and contact tip for anything that could cause excessive drag on the wire feeding HELP DUTY HELP 2501 or HELP 2502 Indicates the wire feeder motor s are operating at too high of a current over a period of time Check the drive rolls spool tension gun liner wire guides and contact tip for anything that could cause excessive drag on the wire feeding HELP 2500 indicates a...

Page 41: ...ction 6 3 Check ArcConnect cable connection at wire feeder and power source Check supplementary protector at power source See power source Owner s Manual Wire feeds when Jog switch is pressed but not when gun trigger is pressed Check welding gun trigger connection at wire feeder Check gun trigger leads and trigger switch See gun Owner s Manual Wire does not feed until trigger is pressed but contin...

Page 42: ...OM 279248 Page 38 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 43: ...OM 279248 Page 39 279241 B ...

Page 44: ... 40 SECTION 9 PARTS LIST 283383 A Hardware is common and not available unless listed 22 21 3 20 1 Fig 9 2 8 9 10 11 12 13 14 6 4 5 7 15 16 17 16 15 14 18 19 23 30 Fig 9 3 24 25 28 27 26 2 29 Figure 9 1 Main Assembly ...

Page 45: ...Thk 2 16 058628 Washer Brake Stl 2 17 058428 Hub Spool 1 18 248974 Tubing Stl 875 Od X12Ga Wall X 562 1 19 135205 Nut Stl Slflkg Hex Reg 625 11 W Nylon Insert 1 20 279240 Support Spool Tilted 1 21 281994 Base 1 22 134306 Foot Rubber 1 250 Dia X 1 375 High No 10 Screw 4 23 281535 Bracket Stiffener Rear Feeder 1 24 124778 Knob T 2 000 Bar W 312 18 Stud 1 000 Lg 1 25 279842 Extension Knob Clamp 1 26 ...

Page 46: ...11989 Fitting W Screen 1 7 220805 Nut 750 14 Nps 1 48Hex 41H Nyl 1 8 Label Rear Panel Order By Model And Serial Number 1 9 GS1 226819 Valve 12VDC 1Way 750 14 Thd 2MM Orf 100PSI 1 10 RC1 PLG17 18 280119 Receptacle W Leads Plug 19Pin Ethernet Feeder 1 11 279264 Enclosure Feeder 1 12 Label Lower Order By Model And Serial Number 1 13 279169 Bezel Feeder For Door 1 14 PC2 275747 Circuit Card Assy Intel...

Page 47: ...n 1 PLG16 280007 Plug W Leads Power Switch Not Shown 1 PLG1 280008 Plug W Leads Volt Sense Not Shown 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributo...

Page 48: ...rsn 180 Od X 018 Wire X 531 Pld 1 6 279259 Clamp Power Pin 1 7 237188 Lock Pin Power 1 8 124778 Knob T 2 000 Bar W 312 18 Stud 1 000 Lg 1 9 172077 Carrier Drive Roll Keyed 24 Pitch 1 10 605308 Ring Rtng Ext 500 Shaft X 035 Thk 1 11 166072 Spacer Gear 2 12 279262 Button Lock Guide Intermediate 1 13 279263 Spring Cprsn 312 Od X 250 Id Rate 5 2 Lbs In 2 14 279261 Button Lock Guide Inlet 1 15 221030 G...

Page 49: ...er Hair 042 X 750 3 26 252217 Knob Assy Tension Adjust 2 27 281348 Screw 312 18x 50 Flathd Phl Stl Pld W Lkg Patch 2 28 092865 Key Stl 1215 1230 X 750 1 Recommended Spare Parts To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Notes ...

Page 50: ...n 0 6 mm 0 8 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 2 0 mm 0 9 mm 1 2 mm 1 3 mm 1 6 mm 2 0 mm 1 2 mm 1 6 mm 2 0 mm Kit No 087132 046780 046781 046782 046783 046784 044750 046785 046786 046787 046788 046792 046793 046794 046795 046796 083319 046800 046801 Drive Roll Part No Type 087130 053695 053700 053697 053698 053699 072000 053701 053702 053706 053704 132958 132957 132956 132...

Page 51: ...r SAR Boxes and Panels TIG Torches No Labor Tregaskiss Guns No Labor Water Cooling Systems Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessories Kits ArcReach Heater Quick Wrap and Air Cooled Cables Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls MDX Series MIG Guns M Guns MIG...

Page 52: ...personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Protective Equipment PPE Service and Repair Replacement Parts Training Schools Videos Books Welding Process Handbooks Contact the Delivering Carrier to For Service Owner s Record File a claim for loss or damage during ...