Miller Electric Digital Elitet User's Manual
Contents
1. 14 SECTION 10 PARTS LIST 121 1 4 38 Haan ir led s 15 SECTION 11 LIMITED WARRANTY 000s cece eee II nn nnn 17 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING A Protect yourself and others from injury read and follow these precautions 1 1 Symbol Usage DANGER Indicates a hazardous Indicates special instruction A situation which if not avoided will pe ia EEE result in death or serious injury The A possible hazards are shown in the adjoining symbols or explained in gt gt the text Indicates a hazardous situation This group of symbols means Warning Watch which if not avoided could result in Out ELECTRIC SHOCK MOVING PARTS death or serious injury The possible and HOT PARTS hazards Consult symbols hazards are shown in the adjoining and related instructions below for necessary symbols or explained in the text actions to avoid the hazards NOTICE Indicates statements not related to personal injury 1 2 Hazards ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultravio let and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Refer to Shade and Sensitivi2. Application Welding Arc Current in Amperes Protective Shade No Stick Electrodes Less than 40 9 40 80 10 80 175 11 175 300 12 300 500 13 MIG Less than 100 10 100 175 11 175 300 12 300 500 13 Gas Tungsten Arc Welding Less than 50 10 TIG 50 100 11 100 200 12 200 400 13 Air Carbon Less than 500 12 500 700 13 Plasma Arc Cutting 60 150 11 150 250 12 250 400 13 Plasma Arc Welding Less than 50 9 50 200 10 200 400 12 OM 234 388 Page 6 3 5 Sensitivity Control E y y 1 Sensitivity Control Buttons Use Sensitivity Control Low and Hi buttons to make the lens more responsive to differ ent light levels in various welding pro cesses Use a sensitivity setting of 5 for most applications The sensitivity ranges for each mode are as follows Weld Cutting X Modes 0 10 Grind Mode No sensitivity adjustment It may be necessary to adjust helmet sensi tivity to accommodate different lighting con ditions or if lens is flashing On and Off Ad just helmet sensitivity as follows EF Adjust helmet sensitivity in lighting con ditions helmet will be used in Press Sensitivity Low button to lower setting to 0 Face the helmet in the direction of use exposing it to the surrounding light con ditions Press Sensitivity Hi button repeatedly until the lens darkens then press Low button until lens clears
3. OM 234 388B Mill 2007 08 mer Auto Darkening Helmets Model Digital Elite gt To help us serve you better go to www MillerWelds Com HelmetReg TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 121 Symbol Usage ser arten nn ehe inne ets de bare 1 1 2 Hazards oe van ener DA geo amen eed a E E ELEC ERI PIC EEG Re 1 SECTION 2 SPECIFICATIONS oane eneen ene eee eee eene ee 2 SECTION OPERATING INSTRUCTIONS 3 321 Helmet Controls inne sentent Neten ilena nn teven ay 3 3 2 On Off Button And Low Battery Indicator 4 323 Mode Control nat Ratha deed Re een anne Viven de a4 5 3 4 Variable Shade Control 6 3 5 Sensitivity Control a unse nen nen welken WOO RU GR D x ce 7 3 6 Lens Delay Control nn sec peers Pewee de CRY YR EY e REX 8 3 7 Lens Adjustment Procedure 9 SECTION 4 ADJUSTING HEADGEAR 10 SECTION 5 REPLACING THE LENS COVERS 11 SECTION 6 REPLACING THE BATTERY 12 SECTION 7 INSTALLING OPTIONAL MAGNIFYING LENS 13 SECTION 8 MAINTENANCE ssee nh hh nn 13 SECTION 9 TROUBLESHOOTING
4. 1 An Ee Metab 212242 Lens 2 50 Magnification Not Shown 1 Adjustment Hardware Kit With O rings OM 234 388 Page 16 SECTION 11 LIMITED WARRANTY I H H r sr Hm msd r 7 Effective January 1 2007 LIMITED WARRANTY Subject to the terms and conditions below Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail pur chaser that the new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OR MERCHANTABILITY AND FITNESS Miller Elite Series auto darkening lens helmets are warranted for 2 years from the date of purchase Proof of purchase is required for warranty transactions so it is imperative that a copy of the original invoice or sales receipt be retained For warranty transactions contact your Miller Distributor OM 234 388 Page 17 Visit our website at www MillerWelds com Miller Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA PRINTED IN USA 2007 Miller Electric Mfg Co
5. 2 1 On Off Button See Section RE 3 2 2 Mode Control Button See Section 3 3 3 Display Screen 4 Variable Shade Control Buttons See Section 3 4 U U 5 Sensitivity Control Buttons See Section 3 5 6 Lens Delay Control Buttons See Section 3 6 EF The lens assembly saves the shade sensitivity and delay settings when the lens turns off 805 010 OM 234 388 Page 3 3 2 On Off Button And Low Battery Indicator Q OOC 1 On Off Button Press On Off button to check if the lens is working properly and to be gin lens shade sensitivity and delay adjustments When the On Off button is pressed the lens should darken and return to the clear state Do not use the hel met if the lens does not function as described See Section 9 Trouble shooting 2 Low Battery Indicator The message Low Battery ap pears on the display screen when 2 3 days of battery life remains If battery power is low replace with CR2450 lithium batteries 2 re quired Miller Part No 217 043 See Section 6 805 010 OM 234 388 Page 4 3 3 Mode Control OOC 1 Mode Control Button Press button to select the mode ap propriate for the work activity Wel
6. Gasket Front Lens Cover 1 Doc nbus 234 758 Gasket Auto Darkening Lens Assembly 1 Oraal ha 216326 Outside Lens Cover 4 11 16 X 5 5 8 5 Per Pkg 1 Y esie tns 234759 Frame an anus wine de UR Nera eke 1 Biss itd 770246 Ratchet Headgear Assembly Includes Items 9 And 10 1 770 248 Adjustment Angle Stop Hardware Kit 1 770249 Fabric Headb nd oi 23 en 1 iyu adu Rud 079 975 Replacement O rings For Kit 770 248 5 PerPkg 1 Alicia bus 216 336 Comfort Cushion Foam Rubber 1 Tea 216339 Battery Tray Kit Left Right 220 1 a 217 043 Battery Lithium CR2450 2 EN 222 003 Hard Hat Adapters Not Shown 1 139 ha 770250 Helmet Bag Miller 1 212 235 Lens 0 75 Magnification Not Shown 1 D Fen er 212 236 Lens 1 00 Magnification Not Shown 1 Spot ETE 212 237 Lens 1 25 Magnification Not Shown 1 epe 212238 Lens 1 50 Magnification Not Shown 1 212 239 Lens 1 75 Magnification Not Shown 1 A M 212 240 Lens 2 00 Magnification Not Shown 1 212244 Lens 2 25 Magnification Not Shown
7. stays light and does not darken when welding or cutting Stop welding or cutting immediately Make sure the lens is turned On If power is On check the mode settings Also review sensitivity recommendations and adjust sensitivity if possible Clean lens cover and sensors of any obstructions Make sure the sensors are facing the arc angles of 45 or more may not allow the arc light to reach the sensors Not Switching auto lens stays dark after the arc is extinguished or the auto lens stays dark when no arc is present Reduce Sensitivity setting see Section 3 5 In extreme light con ditions it may be necessary to reduce the surrounding light levels If the lens remains dark press the On Off button to return lens to the clear state Sections of the auto lens are not going dark distinct lines separate the light and dark areas Stop welding or cutting immediately The auto lens may be cracked which can be caused by the impact of dropping the hel met Weld spatter on the auto lens may also cause cracking The lens may need to be replaced most cracked lenses are not covered by warranty Switching or Flickering the auto lens darkens then lightens while the welding or cutting arc is present Review the sensitivity setting recommendations and increase the sensitivity if possible Be sure the arc sensors are not being blocked from direct access to the arc light Check the lens cover for dirt a
8. 388 Page 12 SECTION 7 INSTALLING OPTIONAL MAGNIFYING LENS 1 Optional Magnifying Lens xe Starting at the top slide magnifying lens into the helmet retaining brack ets Align the magnifying lens with the auto darkening lens assembly 1 Reverse procedure to remove magnifying lens To prevent lens fogging install flat side of magnifying lens to ward auto darkening lens 805 011 SECTION 8 MAINTENANCE NOTICE Never use solvents or abrasive cleaning detergents NOTICE Do not immerse the lens assembly in water The helmet requires little maintenance However for best performance clean after each use Using a soft cloth dampened with a mild soap and water solution wipe the cover lenses clean Allow to air dry Occasionally the filter lens and sensors should be cleaned by gently wiping with a soft dry cloth OM 234 388 Page 13 SECTION 9 TROUBLESHOOTING Trouble Remedy Auto lens not ON auto lens does not darken mo mentarily when the On button is pressed Check batteries and verify they are in good condition and installed properly Check battery surfaces and contacts and clean if necessary Check battery for proper contact and gently adjust contact points if necessary This is particularly important if the helmet has been dropped Verify left and right battery trays are installed on the correct sides Not switching auto lens
9. Helmet is ready for use Slight readjustment may be necessary for certain applications or if lens is flashing on and off 805 010 Recommended Sensitivity Settings Stick Electrode Mid Range Short Circuiting MIG Low Mid Range Pulsed amp Spray MIG Mid Range Gas Tungsten Arc TIG Mid High Range Plasma Arc Cutting Welding Low Mid Range Grinding No sensitivity setting use Grind mode OM 234 388 Page 7 3 6 Lens Delay Control AK Q U OQ Q AE 1 Lens Delay Control Use the Lens Delay Control Fast and Slow buttons to adjust the time for the lens to switch to the clear state after welding or cutting The delay is particularly useful in eliminating bright after rays pres ent in higher amperage applica tions where the molten puddle re mains bright momentarily after welding Use the Lens Delay Con trol buttons to adjust delay from 0 to 10 0 1 to 1 0 second EF There is no lens delay adjust ment in the Grind mode 805 010 OM 234 388 Page 8 3 7 Lens Adjustment Procedure 2 EF Lens assembly displays prior RZ settings when turned On Re tained settings are not shown in example U U
10. MODE SHADE In the Grind mode the lens is fixed shade No 3 No lens ad SENSITIVITY justments are possible DELAY Adjusting Lens Assembly Oo Turn lens On Display screen po e D l appears Select mode Weld Cutting Grind X Mode U U MODE SHADE Select Shade By Pressing WELD Down Up Buttons SENSITIVITY Select Sensitivity By Pressing DELAY Low Hi Buttons m gt Select Delay by Pressing Se l Fast Slow Buttons Begin work U U MODE SHADE 7 2 WELD Ic SENSITIVITY DELAY lt Cx So U U MODE SHADE ig WELD SENSITIVI 5 DELAY gt x O0 So l U U MODE shape J WELD Ic SENSITIVITY 5 DELAY 5 OC So 8 805 010 OM 234 388 Page 9 SECTION 4 ADJUSTING HEADGEAR 2 WS Q EF There are four headgear adjust ments headgear top tightness angle adjustment and distance adjustment 1 Headgear Top Adjusts headgear for proper depth on the head to ensure correct bal ance and stability 2 Headgear Tightness To adjust push in the adjusting knob located on the back of the headgear and turn left or right to desired tight ness If adjustment is limited it may be necessary to remove the com fort cushion 3 Distance Adjustment Adjusts the distance between the face and the lens To adjust loosen both outside tension knobs and press inward to free from adjustment slots Move forward or back to de sired position a
11. Sensitivity Settings Adjusts for varying ambient light and welding cutting arc Weld Mode No 0 No 10 Cutting Mode No 0 No 10 Grind Mode Not Applicable X Mode No 0 No 10 Delay Settings Slows lens dark to light state Weld Mode No 0 No 10 Cutting Mode No 0 No 10 Grind Mode Not Applicable X Mode No 0 No 10 Automatic Power Off Shuts lens Off 15 20 minutes after last arc is struck Low Battery Indicator Display indicates 2 3 days remaining battery life Power Supply CR2450 Lithium Batteries Miller Part No 217 043 Sensors Independent Redundant Four Operating Temperature 14 F to 131 F 10 C to 55 C 7 When stored in extremely cold temperatures warm hel met to ambient temperature before welding Storage Temperature 4 F to 158 F 20 C to 70 C When stored in extremely cold temperatures warm hel met to ambient temperature before welding Total Weight 510 3 g 1 Ib 20z Standards ANSI Z87 1 and CSA TUV Warranty 2 years from date of purchase see Section 11 The helmets in this manual are covered by one or more of the following patents U S Patent No 6 552 316 No 6 483 090 No 6 614 409 U S Patent Application No 29 223 100 No 11 053 977 No 10 565 858 No 11 589 542 DE Patent No 199 59 944 C2 No 199 59 945 C2 FR Patent No 9916004 OM 234 388 Page 2 SECTION 3 OPERATING INSTRUCTIONS 3 1 Helmet Controls
12. d Mode used for most welding applications In this mode the lens turns on when it optically senses a welding arc Adjust shade sensitivity and delay settings as needed Cutting Mode used for cutting ap plications In this mode the lens turns on when it optically senses a cutting arc Adjust shade sensitivity and delay settings as needed Grind Mode used for metal grinding applications In this mode the shade is fixed shade No 3 No lens adjust ments are possible X Mode used for outdoor or low cur rent welding applications In this mode the lens turns on when it senses weld current Adjust shade sensitivity and delay settings as needed Nearby welding may affect hel met operation when lens is in X Mode Stay at least 12 ft 3 7 m away from other welding activity 805 010 OM 234 388 Page 5 3 4 Variable Shade Control E Q U U O 066 1 Shade Control Buttons Use the shade control Down and Up buttons to select the lens shade in the darkened state The shade ranges for each mode are as follows Weld No 8 No 13 Cutting No 5 No 8 Grind No 3 only X Mode No 8 No 13 Start at the highest setting and ad just lighter to suit the application and your personal preference Use the table below to select prop er shade control setting based on your welding process 805 010
13. lens assembly Ref 805 012 EF Be sure the flat side of lens cover gasket faces the helmet shell Inside Lens Cover To replace the inside lens cover remove the lens as sembly from the lens frame by pushing up on the top two retaining tabs while gently pushing the lens free Remove the lens cover by sliding it out of either side Replace with the new cover lens and reinstall the assem bly in the helmet OM 234 388 Page 11 SECTION 6 REPLACING THE BATTERY AD sure Positive side of battery faces up Ss Ga dek h 066 QUU To replace the batteries re move the auto darkening lens assembly see Section 5 1 Battery Tray After removing the lens as sembly slide the battery hold ing trays out and remove the old batteries Replace with CR2450 lithium type batteries 2 required or equivalent Miller Part No 217043 Be sure Positive side of the battery faces up to ward inside of helmet Reinstall the battery trays To test press the On button The display screen should turn on Reinstall the lens assembly EF Left and right battery trays are not interchangeable The auto darkening hel met will not work if battery trays are installed on the wrong sides 805 010 OM 234
14. nd retighten Both sides must be equally positioned for proper vision 4 Angle Adjustment Four pins on the right side of the headband top provide adjustment for the forward tilt of the helmet To adjust loosen the right outside ten sion adjustment knob then lift on the control arm tab and move it to the de sired position Retighten tension ad justment knob E When using the back distance adjustment positions only the back three angle adjustment pins can be used 804 118 OM 234 388 Page 10 SECTION 5 REPLACING THE LENS COVERS an E Q Be sure wide edge of gasket faces helmet shell Be sure flat side of gasket faces helmet shell Never use the auto darkening lens with out the inside and out side lens covers prop erly installed Welding spatter will damage the auto darkening lens and void the warranty Front Lens Gasket Outside Lens Cover Lens Assembly Gasket Lens Assembly Inside Lens Cover oa A Om Lens Frame Remove the lens assembly to remove either lens cover To remove the lens assem bly push down on the helmet bottom retaining arms and push the retaining clips to ward the outside of the hel met Lift up on the assembly and pull free of the helmet Outside Lens Cover Remove the outside lens cover by pushing cover into the helmet Remove the rub ber lens gasket and install on the new lens cover Reinstall the
15. nd spatter that may be blocking the arc sensors Increasing Lens Delay 0 1 0 3 second may also reduce switching Inconsistent or lighter auto lens shading in the dark state noticeable on the outside edges and cor ners Referred to as an angle of view effect auto darkening lenses have an optimum viewing angle The optimum viewing angle is perpendicular or 90 to the surface of the auto lens When that angle of view varies in the dark state welders may notice slightly lighter areas at the outside edges and the corners of the lens This is normal and does not represent any health or safety hazard This effect may also be more noticeable in applications where magnifying lenses are used OM 234 388 Page 14 SECTION 10 PARTS LIST 804 111 Figure 10 1 Digital Elite Auto Darkening Welding Helmet OM 234 388 Page 15 Item Part No No Description Quantity Figure 10 1 Digital Elite Auto Darkening Welding Helmet MC 216331 Helmet Shell Black 1 T oes 227189 Helmet Shell The Joker 1 Abit tee nf 234 066 Helmet Shell Stars And Stripes II 1 T raden 223454 Helmet Shell Inferno 1 216 327 Inside Lens Cover 4 1 4 2 1 2 5 Pkg 1 CR EN ns 234 760 Auto darkening Lens Assembly 1 4 trans idee 216 337
16. ty charts in Sections 3 4 and 3 5 e Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather and wool and foot protection d Ss WELDING HELMETS do not provide unlimited eye ear and face protection e Do not weld in the overhead position while using this helmet e Inspect the auto lens frequently Immediately replace any scratched cracked or pitted cover lenses or auto lenses NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high e Use impact resistant safety spectacles or goggles and ear protection at all times when using this welding helmet e Do not use this helmet while working with or around explosives or corrosive liquids OM 234 388 Page 1 SECTION 2 SPECIFICATIONS Viewing Field 97 x 60mm 3 81 x 2 62 in Reaction Time 0 0000500sec 1 20 000 Operating Modes 4 Modes Weld Cutting Grind X Mode Available Shades Weld Mode Darkened State No 8 No 13 Light State No 3 All shades provide continu Cutting Mode Darkened State No 5 No 8 ous UV and IR protection Light State No 3 Grind Mode Light State No 3 X Mode Darkened State No 8 No 13 Light State No 3
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