Miller Classic Owner's Manual

OM-252052G 2019−07

Classic Series

Welding Helmets

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TABLE OF CONTENTS

SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −READ BEFORE USING 1......

1-1. Symbol Usage 1............................................................

1-2. Arc Welding Hazards 1.......................................................

1-3. Proposition 65 Warnings 2....................................................

1-4. Lens Shade Selection Table 3.................................................

1-5. Principal Safety Standards 3..................................................

SECTION 2 − SPECIFICATIONS 4.....................................................

SECTION 3 − OPERATING INSTRUCTIONS 5..........................................

3-1. Helmet Controls 5...........................................................

3-2. Reset Button And Low Battery Indicator 7.......................................

3-3. Mode Control (Vsi Helmet Only) 8..............................................

3-4. Lens Delay Control 9.........................................................

3-5. Variable Shade Control 10.....................................................

3-6. Sensitivity Control 11..........................................................

SECTION 4 − ADJUSTING HEADGEAR 12.............................................

SECTION 5 − REPLACING THE LENS COVERS 13.....................................

5-1. Replacing Outside Lens Cover On Variable Shade And Standard Fixed Shade Helmets 13
5-2. Replacing Inside Lens Cover On Variable Shade and Standard Fixed Shade Helmets 14.

5-3. Replacing Lens Covers On VSi Helmet 15........................................

5-4. Replacing Grinding Shield On VSi Helmet 16......................................

5-5. Replacing Lens Covers And Grinding Shield On Fixed Shade Flip-Up Helmets 17.......

SECTION 6 − REPLACING THE BATTERY 18..........................................

6-1. Replacing Battery On Variable Shade Helmets 18..................................

6-2. Replacing Battery On Vsi Helmet 18.............................................

6-3. Solar Cell On Fixed Shade Helmets 19...........................................

SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS 20...........................

SECTION 8 − MAINTENANCE AND STORAGE 21......................................

SECTION 9 − TROUBLESHOOTING 22................................................

SECTION 10 − PARTS LIST 24.......................................................

SECTION 11 − LIMITED WARRANTY 29...............................................

SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −

READ BEFORE USING

helmet 2018-08

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.

Indicates a hazardous situation
which, if not avoided, could result in
death or serious injury. The possible
hazards are shown in the adjoining
symbols or explained in the text.

NOTICE − Indicates statements not related to

personal injury.

 Indicates special instructions.

This group of symbols means Warning! Watch
Out! ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols
and related instructions below for necessary
actions to avoid the hazards.

1-2. Arc Welding Hazards

Only qualified persons should install, operate, maintain, and repair this equipment. A
qualified person is defined as one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge, training and experience, has
successfully
matter, the work, or the project and has received safety training to recognize and avoid
the hazards involved.

demonstrated ability to solve or resolve problems relating to the subject

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultravio­let and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

 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 Lens
Shade Selection table in Section 1-4.

 Wear approved safety glasses with side shields under your helmet.
 Use protective screens or barriers to protect others from flash, glare, and sparks; warn

others not to watch the arc.

 Wear body protection made from durable, flame−resistant material (leather, heavy cotton,

wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

• Before welding, adjust the auto-darkening lens sensitivity setting to meet the application.

• Stop welding immediately if the auto-darkening lens does not darken when the arc is struck.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

 Wear approved ear protection if noise level is high.

OM-252052 Page 1

WELDING HELMETS do not provide unlimited eye, ear, and
face protection.

Arc rays from the welding process produce intense visible and invisible (ultraviolet
and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

 Use helmet for welding/cutting applications only. Do not use helmet for laser welding/cutting.

 Use impact resistant safety spectacles or goggles and ear protection at all times when using

this welding helmet.

 Do not use this helmet while working with or around explosives or corrosive liquids.
 This helmet is not rated for overhead welding. Do not weld in the direct overhead position

while using this helmet unless additional precautions are taken to protect yourself from arc
rays, spatter, and other hazards.

 Inspect the auto-lens frequently. Immediately replace any scratched, cracked, or pitted cover

lenses or auto-lenses.

 Lens and retention components must be installed as instructed in this manual to ensure

compliance with ANSI Z87.1 protection standards.

READ INSTRUCTIONS.

 Read and follow all labels and the Owner’s Manual carefully before in-

stalling, operating, or servicing unit. Read the safety information at the be­ginning of the manual and in each section.

 Use only genuine replacement parts from the manufacturer.

 Perform installation, maintenance, and service according to the Owner’s Manuals, industry

standards, and national, state, and local codes.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be
hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.
 Ventilate the work area and/or use local forced ventilation at the arc to remove welding fumes

and gases. The recommended way to determine adequate ventilation is to sample for the com­position and quantity of fumes and gases to which personnel are exposed.

 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for

adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

 Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator.

Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays

of the arc can react with vapors to form highly toxic and irritating gases.

 Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the

coating is removed from the weld area, the area is well ventilated, and while wearing an air­supplied respirator. The coatings and any metals containing these elements can give off toxic
fumes if welded.

1-3. Proposition 65 Warnings

WARNING: Cancer and Reproductive Harm − www.P65W

OM-252052 Page 2

arnings.ca.gov

1-4. Lens Shade Selection Table

Process

Shielded Metal Arc

Welding (SMAW)

Gas Metal

Arc Welding

(GMAW)

Flux Cored

Arc Welding

(FCAW)

Gas Tungsten Arc

Welding (TIG)

Air Carbon

Arc Cutting (CAC-A)

Plasma Arc

Cutting (PAC)

Plasma Arc Welding

(PAW)

Electrode Size

in. (mm)

Less than 3/32 (2.4)

3/32−5/32 (2.4−4.0)

5/32−1/4 (4.0−6.4)

More than 1/4 (6.4)

Light

Heavy

Arc Current

in

Amperes

Less than 60

60−160
160−250
250−550

Less than 60

60−160
160−250
250−500

Less than 50

50−150
150−500

Less than 500

500−1000

Less than 20

20−40
40−60
60−80

80−300
300−400
400−800

Less than 20

20−100
100−400
400−800

Minimum
Protective
Shade No.

7

8
10
11

7
10
10
10

8

8
10

10
11

4

5

6

8

8

9
10

6

8
10
11

Suggested

Shade No.
(Comfort)*

−−

10
12
14

−−

11
12
14

10
12
14

12
14

4
5
6
8

9
12
14

6−8

10
12
14

Reference: ANSI Z49.1:2012

* Start with a shade that is too dark to see the weld zone. Then, go to a lighter shade which gives a

sufficient view of the weld zone without going below the minimum.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free down­load from the American Welding Society at http://www.aws.org or purchased from Global Engineering
Documents (phone: [phone], website: www

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone:
212-642-4900, website: www.ansi.org).

Industrial Head Protection, ANSI/ISEA Standard Z89.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], website: www.ansi.org).

.global.ihs.com).

OM-252052 Page 3

SECTION 2 − SPECIFICATIONS

Specification

Viewing Field 95 x 34 mm

Reaction Time 0.0000833 sec

Available
Shades

Sensitivity
Control

Delay Control Slows Lens Dark-

Automatic
Power Off

Low Battery
Indicator

Power Supply AAA Alkaline

Sensors

Operating
T

emperature

Storage
T

emperature

Total Weight 453.6g (16oz.) 640.2g (22.58oz.) 453.6g (16 oz.) 396g (13.96oz.)

Standards Meets ANSI Z87.1+ (2015) and CSA Z94.3 (2015) Standards

Warranty 2 Years From Date Of Purchase (See Section 11)

Variable Shade

Helmet

(3.75 x 1.375 in.)

(1/12,000)

Darkened State:

No. 8 − No. 12
Light State: No. 3
Provides Continu-

ous UV And IR

Protection

Adjusts For Varying

Ambient Light And

Welding Arc

To-Light State

(Slow − Fast)

Shuts Lens Off 15−20 Minutes After Last Arc Is Struck

Red Led Light Illuminates To Indicate 2−3

Days Remaining Battery Life

Batteries Only

(Two)

Independent/

Redundant (Two)

VSi Helmet

95 x 40 mm

(3.75 x 1.57 in.)

0.00005 sec
(1/20,000)

Darkened State:

No. 8 − No. 13
Light State: No. 3
Provides Continu-

ous UV And IR

Protection

Adjusts For Varying

Ambient Light And

Welding Arc;

X-Mode

Slows Lens Dark-

To-Light State

(Between 0.1 And 1

Second)

Panasonic CR2450

Lithium Battery

(Part No. 217043)

Independent/

Redundant (Three)

14F to 131F / −10C to +55C

 When stored in extremely cold temperatures, warm helmet to ambient

temperature before welding.

−4F to 158F / −20C to +70C

 When stored in extremely cold temperatures, warm helmet to ambient

temperature before welding.

Standard

Fixed Shade

No. 10 Helmet

(3.75 x 1.375 in.)

0.000277 sec (1/3,600)

Darkened State: No. 10

Light State: No. 3

Provides Continuous UV And

Not Applicable

Not Applicable

Not Applicable

Rechargeable,

Non-Replaceable Solar Cell

Redundant (Two)

Fixed Shade

2 x 4 No. 10

Flip-Up Helmet

95 x 35 mm

IR Protection

Independent/

OM-252052 Page 4

SECTION 3 − OPERATING INSTRUCTIONS

3-1. Helmet Controls

1 23 45

Variable Shade
Lens Assembly

 Four different lens assemblies are

shown. Refer to the illustration that
matches the lens on your helmet.

Variable Shade Helmet

1 Reset Button

(See Section 3-2)

2 Low Battery Indicator

(See Section 3-2)

3 Lens Delay Control (See Section

3-4)

4 Variable Shade Control

(No. 8 − 12) (See Section 3-5)

5 Sensitivity Control

(See Section 3-6)

VSi Lens Assembly

67 8 9 10 11

VSi Helmet

6 Reset Button

(See Section 3-2)

7 Low Battery Indicator

(See Section 3-2)

8 Variable Shade Control

(No. 8 − 13) (See Section 3-5)

9 Sensitivity Control

(See Section 3-6)

10 Mode Control (See Section

3-3)

11 Lens Delay Control (See

Section 3-4)

OM-252052 Page 5

3-1. Helmet Controls − Continued

Fixed Shade No. 10 Helmets

The fixed shade models have no
buttons or controls. The lens turns
on (darkens) automatically when
welding begins and turns off when
welding stops.

To ensure proper function, charge
lens internal battery prior to first
use or after extended storage
(about 30 days). Charge battery by
either of these methods:

 Expose lens to direct sunlight

for 10 seconds.

 Expose lens to light bulb for 20

minutes.

After initial charging, the welding
arc will maintain the charge in the
battery.

Notes

OM-252052 Page 6

3-2. Reset Button And Low Battery Indicator

1

2

Variable Shade Lens Assembly

 The auto-darkening lens turns

on (darkens) automatically
when welding begins and turns
off when welding stops.

1 Reset Button

Press Reset button to check if the
lens is working properly.

When the Reset button is pressed,
the lens should darken twice and re­turn to the clear state. Do not use the
helmet if the lens does not function
as described. (See Section 9, Trou­bleshooting.)

2 Low Battery Indicator

The low battery indicator lights when
2−3 days of battery life remain.

If battery power is low, install new
AAA Alkaline batteries (Variable
Shade helmet) or Panasonic
CR2450 Lithium battery (VSi helmet)
(see Section 6).

2

VSi Lens Assembly

1

OM-252052 Page 7

3-3. Mode Control (VSi Helmet Only)

1 Mode Control Button

Slide Mode Control switch to select
the mode appropriate for the work
activity.

1

 Slide switch away from the de-

sired mode (Weld or X-Mode).
When the switch is moved, “On” is
revealed next to the active mode.

Weld 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.

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 helmet

operation when lens is in X-Mode.
Stay at least 12 ft (3.7 m) away
from other welding activity.

OM-252052 Page 8

3-4. Lens Delay Control

1

Variable Shade Lens Assembly

1 Lens Delay Control

The lens delay control is used to
adjust the time for the lens to switch
to the clear state after welding.

The delay is particularly useful in
eliminating
ent in higher amperage applica­tions where the molten puddle re­mains bright momentarily after
welding.

Variable Shade helmet adjusts
from Slow to Fast and VSi helmet
adjusts from Min to Max (0.1 to 1.0
second).

bright after-rays pres-

VSi Lens Assembly

1

OM-252052 Page 9

3-5. Variable Shade Control

Variable Shade Lens Assembly

1 Variable Shade

Control

Lens shade can be adjusted
from No. 8 − 12 on Variable
Shade helmet, and from No.
8 − 13 on VSi helmet.

1

Use the control to adjust the
lens shade in the darkened
state. Use the table below to
select proper shade control
setting based on your weld-

1

VSi Lens Assembly

ing process.

Start at darkest shade and
adjust lighter to suit the
welding application and
your personal preference.

Application Welding Arc Current in Amperes Protective Shade No.

Stick Electrodes Less than 40

MIG Less than 100

Gas Tungsten Arc Welding

(TIG)

Air Carbon Less than 500

Plasma Arc Cutting 60−150

Plasma Arc Welding Less than 50

OM-252052 Page 10

40−80

80−175
175−300
300−500

100−175
175−300
300−500

Less than 50

50−100
100−200
200−400

500−700

150−250
250−400

50−200
200−400

9
10
11
12
13

10
11
12
13

10
11
12
13

12
13

11
12
13

9
10
12

3-6. Sensitivity Control

Variable Shade Lens Assembly

1 Sensitivity Control

Use control to make the lens more re­sponsive to different light levels in vari-

1

ous welding processes. Use a Mid-

Range or 30−50% sensitivity setting
for most

It may be necessary to adjust helmet
sensitivity to accommodate different
lighting conditions or if lens is flashing
On and Off. Adjust helmet sensitivity as
follows:

applications.

 Adjust helmet sensitivity in lighting

conditions helmet will be used in.

 Turn sensitivity control to lowest

setting.

 Press On button to turn helmet On.

Helmet lens will darken twice and
then clear.

 Face the helmet in the direction of

use, exposing it to the surrounding
light conditions.

 Gradually turn sensitivity setting

clockwise until the lens darkens,
then turn sensitivity control coun­terclockwise until slightly past set­ting where lens clears. Helmet is
ready for use. Slight readjustment
may be necessary for certain ap­plications or if lens is flashing on
and off.

VSi Lens Assembly

1

Recommended Sensitivity Settings

Stick Electrode Mid-Range

Short Circuiting (MIG) Low/Mid-Range

Pulsed & Spray (MIG) Mid-Range

Gas Tungsten Arc (TIG) Mid/High-Range

Plasma Arc Cutting/Welding Low/Mid-Range

804 792

OM-252052 Page 11

SECTION 4 − ADJUSTING HEADGEAR

 There are four headgear ad-

justments: headgear top,
tightness, distance adjust­ment, and angle adjustment.

1 Headgear Top Adjustment

Adjusts headgear for proper

1

3

depth on the head to ensure cor­rect balance and stability.

2 Headgear Tightness

Adjustment

Adjusts headgear for a secure fit.
To adjust, push in the adjusting
knob located on the back of the
headgear. Turn knob left or right
to obtain desired tightness.

 If adjustment is limited, it may

be necessary to remove the
comfort 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 desired position and re­tighten. (Both sides must be
equally positioned for proper vi­sion.)

2

4

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
tension adjustment knob then lift
on the control arm tab and move
it to the desired position. Retigh­ten tension adjustment knob.

OM-252052 Page 12

 When using the back dis-

tance adjustment position,
only the back three angle ad­justment pins can be used.

804 793

SECTION 5 − REPLACING THE LENS COVERS

5-1. Replacing Outside Lens Cover On Variable Shade And Standard Fixed

Shade Helmets

! Never use the auto-darkening

lens without the inside and
outside lens covers properly
installed. Welding spatter will
damage the auto-darkening
lens and void the warranty.

 See Section 5-5 for information

on replacing lens covers and
grinding shield on Fixed Shade
Flip-Up Helmets.

1 Outside Lens Cover Frame

2 Lens Cover

3 Gasket

Remove lens cover frame by grasp­ing the outside corners and pulling
the frame away from the helmet.

Remove lens cover and gasket from
the six-prong lens frame. Replace
lens cover and reinstall gasket and
lens in frame. Reinstall frame in hel­met.

1

3

2

1

 Be sure the flat side of lens gas-

ket faces the six-prong lens
frame.

 Be sure all six prongs of lens

frame are securely fastened in
slots in helmet.

Be sure flat side of gasket
faces lens frame.

804 794

OM-252052 Page 13

5-2. Replacing Inside Lens Cover On Variable Shade and Standard Fixed

Shade Helmets

! Never use the auto-darkening

lens without the inside and out­side lens covers properly
installed. Welding spatter will
damage the auto-darkening
lens and void the warranty.

 See Section 5-5 for information

on replacing lens covers and
grinding shield on Fixed Shade
Flip-Up Helmets.

1 inside Lens Cover

Remove the inside lens cover by pry­ing the lens up at the thumbnail open­ing located at the top center of the lens
cover.

Replace the lens cover by gently bow­ing it in the center and inserting it, one
end at a time, into the retaining clips
located on the outside of the auto­darkening lens assembly.

 Be sure the cover lens is seated

properly (flat) to prevent fogging.

OM-252052 Page 14

1

804 793 / 804 794

5-3. Replacing Lens Covers On VSi Helmet

2

2

1

! Never use the auto-dark-

ening lens without the in­side and outside lens
covers properly instal­led. Welding spatter will
damage the auto-darken­ing lens and void the war­ranty.

Outside Lens Cover

1 Lens Holder

2 Release Points

3 Outside Lens Cover

Remove lens holder by press­ing release points and pulling
the holder away from the hel­met.

Remove lens cover from hold­er. Replace lens cover in lens
holder. Reinstall lens holder in
helmet.

3

Inside Lens Cover

4 Gasket

5 Lens

6 Inside Lens Cover

Remove the inside lens cover
by prying cover from groove in
gasket.

Replace the lens cover by gent­ly bowing it in the center and in­serting it, one end at a time, into
the gasket.

456

 Be sure the cover lens is

seated properly (flat) to
prevent fogging.

OM-252052 Page 15

5-4. Replacing Grinding Shield On VSi Helmet

1

2

3

! Never use the auto-dark-

ening lens without the in­side and outside lens
covers properly installed.
Welding spatter will dam­age the auto-darkening
lens and void the
warranty.

1 Grinding Shield

2 Retaining Clip

3 Tab

Rotate both retaining clips to the
Open position.

Gently push shield toward bot­tom tab and remove shield from
helmet.

Remove retaining clips from
shield. Install clips in same loca­tion on new shield. (Retaining
clips are not interchangeable.)

Install new shield in helmet and
rotate clips to the Lock position.

Tear-Away Protective Sheets

Tear-away sheets are available
to prolong the life of the griding
shield (see Parts List).

To install tear-away sheets, pull
backing from both sides of the
tear-away, remove white ad­hesive backing strips, and
place on clear shield.

OM-252052 Page 16

Ref. 804 109

5-5. Replacing Lens Covers And Grinding Shield On Fixed Shade Flip-Up

Helmets

1

2

! Never use the auto-

darkening lens with­out the inside and
outside lens covers
properly installed.
Welding spatter will
damage the auto­darkening lens and
void the warranty.

 See Sections 5-1 and

5-2 for lens cover re­placement informa-

Notes

4

tion on standard Fixed
Shade Helmets.

1 Outside Lens Cover

2 Lens

3 Inside Lens Cover

Lift flip-up frame and slide
lens and covers together
out of the open side of the
frame. Replace lens cov­ers. Slide lens and covers
together back into frame.

3

4 Grinding Shield

Remove grinding shield
from front of helmet by
pushing shield from the in­side. Reinstall shield by
placing one edge of shield
in track. Using both hands,
bend shield outward until
the loose end of the shield
can be installed in the open
track.

OM-252052 Page 17

SECTION 6 − REPLACING THE BATTERY

6-1. Replacing Battery On Variable Shade Helmets

1 Battery Cover

Slide cover to left and remove batter­ies. Install two AAA alkaline batteries
and replace cover.

1

LOCKOPEN

AAA BATTERY

6-2. Replacing Battery On VSi Helmet

1 Battery Cover

Insert a coin into the slot on the bat­tery cover. Rotate cover counter­clockwise to remove battery.

Install Panasonic CR2450 lithium
battery or equivalent (Miller Part No.

217043).

 Be sure Positive (+) side of the

battery faces up (toward inside
of helmet).

To reinstall battery cover, position
cover with arrows at 6 and 12
o’clock positions, then turn cap 1/4
turn clockwise.

OM-252052 Page 18

1

OTOS / 804 847

6-3. Solar Cell On Fixed Shade Helmets

1

Standard Fixed

Shade No. 10

Lens Assembly

Fixed Shade

2 x 4 No. 10

Flip-Up Helmet

1 Solar Cell (Internal)

Fixed shade models are powered by
a rechargeable, non-replaceable so­lar cell. No service is required.

 Always make sure the lens is fully

charged before welding. Place
helmet in direct sunlight for 20
minutes to charge lens solar cell.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-252052 Page 19

SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS

1 Outside Lens Cover Frame

2 Optional Magnifying Lens

Remove lens cover frame by
grasping the outside corners and
pulling the frame away from the hel­met.

Remove the auto-darkening lens
assembly by gently lifting the hel­met lip above the assembly and
pushing assembly free of the re­taining brackets.

Starting at the top, slide magnifying
lens into the helmet retaining brack­ets. Position the lens tightly against

1

Lift helmet lip with thumb
and push lens out.

the bottom holding pins.

Reinstall auto-darkening lens as­sembly and lens cover frame.

2

OM-252052 Page 20

804 794 / 804 795

SECTION 8 − MAINTENANCE AND STORAGE

NOTICE − Do not use solvents or abrasive cleaning detergents to clean the helmet. Do not immerse
the lens assembly in water.

NOTICE − Keep helmet dry; do not expose helmet to rain or snow. Keep helmet away from fire and
other sources of heat.

NOTICE − The auto-darkening lens uses sensitive electronics. Do not drop helmet or handle it in
a rough manner.

The helmet requires little maintenance. However, for best performance clean helmet 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.

Store helmet in a clean, dry, cool place free of solvent−based vapors. To prevent battery from losing
power, store helmet in helmet bag or in a dark location. Remove battery(s) if helmet will be stored
longer than six months.

End Of Useful Life

The welding helmet has no expiration date, and with proper care and maintenance it can provide
many years of eye and face protection. The helmet can continue to be used, provided that the helmet
shell/shroud is undamaged (no cracks, gaps, or holes) and the lens functions normally (switches

from a light state to a dark state.)

helm main 2019-05

Notes

OM-252052 Page 21

SECTION 9 − TROUBLESHOOTING

Trouble Remedy

Auto lens not On; lens
does not darken momen­tarily when the Reset but­ton is pressed.

Auto lens not switching;
lens stays light and does
not darken when welding.

Auto lens not Switching;
lens stays dark after the
weld arc is extinguished,
or the lens stays dark
when no arc is present.

Sections of the auto-lens
are not going dark; distinct
lines separate the light and
dark areas.

Auto lens switching or
flickering; lens darkens
then lightens while the
welding arc is present.

Inconsistent or lighter
auto-lens shading in the
dark-state, noticeable on
the outside edges and
corners.

Check batteries and verify they are in good condition and installed
properly. Also, check battery surfaces and contacts and clean if
necessary.

Stop welding immediately. Press the Reset button on variable
shade helmets. On fixed-shade helmets, make sure the lens solar
cell is properly charged by placing the helmet in direct sunlight for
20 minutes. If power is on, review the sensitivity recommenda­tions and adjust sensitivity. 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.

Fine-tune the sensitivity setting by making small adjustments to
the control by turning it toward the “min” setting. In extreme light
conditions, it may be necessary to reduce the surrounding light
levels.

Stop welding immediately. The auto-lens may be cracked which
can be caused by the impact of dropping the helmet. 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).

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 and spatter that may be blocking the arc sensors. Increas­ing Lens Delay to Fast position may also reduce switching.

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-252052 Page 22

Notes

OM-252052 Page 23

SECTION 10 − PARTS LIST

10

7

Miller

9

8

2

3

4

5

6

 See Figure 10-3 for Fixed Shade

11

12

1

No. 10 Flip-Up helmet parts list.

Figure 10-1. Variable Shade And Standard Fixed Shade No. 10

Auto-Darkening Welding Helmets

OM-252052 Page 24

804 796

Item

No. Quantity

Part

No.

Description

Figure 10-1. Variable Shade And Standard Fixed Shade No. 10

Auto-Darkening Welding Helmets

 See Figure 10-3 for Fixed Shade No. 10 Flip-Up helmet parts list.

1 231415 Helmet Shell, Black (Includes) 1............ ......... .....................

1 260087 Helmet Shell, Metalworks (Includes) 1............ ......... ................

1 265707 Helmet Shell, Stars And Stripes (Includes) 1............ ......... ...........

1 231419 Helmet Shell, Red Flame (Includes) 1............ ......... .................

1 231418 Helmet Shell, Camouflage (Includes) 1............ ......... ................

2 231410 Lens Cover, Inside (4.25 − 1.75 in.) (5 Per Pkg.) 1............ ......... ......

3 251293 Auto-Darkening Lens Assy. (Variable Shade) 1............ ......... .........

3 231571 Auto-Darkening Lens Assy. (Fixed Shade) 1............ ......... ...........

4 231412 Gasket, Front Lens 1............ ......... ...............................

5 231411 Lens, Front Cover (4.5 x 3.6875 in) (5 Per Pkg.) 1............ ......... ......

6 231572 Holder, Front Lens (Black) 1............ ......... .........................

6 231573 Holder, Front Lens (Gray) 1............ ......... .........................

6 231574 Holder, Front Lens (Red) 1............ ......... ..........................

6 231575 Holder, Front Lens (Blue) 1............ ......... ..........................

6 231576 Holder, Front Lens (Camouflage) 1............ ......... ...................

7 770246 Ratchet Headgear Assy. 1............ ......... ..........................

8 *770248 Adjustment Angle/Stop Hardware Kit 1........... ........... ..............

9 770249 Headband, Fabric 1............ ........... ..............................

10 ♦216336 Comfort Cushion, Foam Rubber 1......... ......... ....................

11 ♦770250 Bag Helmet, Miller 1......... ......... ...............................

12 ♦212235 Lens, 0.75 Magnification 1......... ......... ..........................

12 ♦212236 Lens, 1.00 Magnification 1......... ......... ..........................

12 ♦212237 Lens, 1.25 Magnification 1......... ......... ..........................

12 ♦

12 ♦212239 Lens, 1.75 Magnification 1......... ......... ..........................

12 ♦212240 Lens, 2.00 Magnification 1......... ......... ..........................

12 ♦212241 Lens, 2.25 Magnification 1......... ......... ..........................

12 ♦212242 Lens, 2.50 Magnification 1......... ......... ..........................

216714 Label, Warning En/SP/FR 1.............. ........... .......................

231413 Cover, Battery (Variable Shade) 1.............. ......... ....................

♦222003 Adapters, Hard Hat (Not Shown) 1............ ......... ...................

♦260940 Adapters, Slotted Hard Hat (Not Shown) 1............ ......... .............

212238 Lens, 1.50 Magnification 1......... ......... ..........................

* Adjustment Hardware Kit With O-rings.

♦Optional

OM-252052 Page 25

13

10

14

12

9

11

8

Figure 10-2. VSi Auto-Darkening Welding Helmet

OM-252052 Page 26

2

3

4

5

6

7

15

1

Item

No. Quantity

Part

No.

Description

Figure 10-2. VSi Auto-Darkening Welding Helmet

1 261824 Shell, Helmet − I Series (Black) (Includes) 1............ ......... ...........

2 245819 Clip, Retaining Grinding Shield 2............ ......... .....................

3 245818 Lens, Grinding Shield (Clear) 1............ ......... ......................

4 231410 Lens Cover, Inside 4.25in x 1.75 in 1............ ......... .................

5 261826 Lens Assembly, Auto−dark VSi 1............ ......... .....................

6 261827 Gasket, Lens Assembly VSi (Qr) 1............ ......... ...................

7 235628 Lens Cover, Front 4.5 in x 5.25 in 1............ ......... ..................

8 261828 Lens Holder, Front − I Series (Black) 1............ ......... ................

9 255070 Clips, Visor Hinge − I Series 2............ ......... .......................

10 770246 Headgear, Gray (Includes Items 11 And 12) 1........... ......... ..........

11 *770248 Kit, Adjustment Angle/Stop Hardware Kit 1.......... ........... ...........

12 770249 Headband, Fabric 1........... ........... ..............................

13 ♦216336 Cushion, Comfort (Foam Rubber) 1......... ......... ...................

14 ♦770250 Bag, Helmet (Miller Logo) 1......... ......... .........................

15 ♦212235 Lens, 0.75 Magnification 1......... ......... ..........................

* Adjustment Hardware Kit With O-rings.

216714 Label, Warning En/SP/FR 1.............. ........... .......................

♦254278 Lens, Tear Away Grinding Shield (Clear) 1............ ......... .............

217043 Battery, Panasonic Lithium (CR2450) 2.............. ......... ...............

079975 Replacement O-rings For Kit 770 248 (5 Per Pkg.) 1.............. ......... ....

♦222003 Adapters, Hard Hat (Not Shown) 1............ ......... ...................

♦260940 Adapters, Slotted Hard Hat (Not Shown) 1............ ......... .............

♦212236 Lens, 1.00 Magnification 1............ ......... ..........................

♦212237 Lens, 1.25 Magnification 1............ ......... ..........................

♦212238 Lens, 1.50 Magnification 1............ ......... ..........................

♦212239 Lens, 1.75 Magnification 1............ ......... ..........................

♦212240 Lens, 2.00 Magnification 1............ ......... ..........................

♦212241 Lens, 2.25 Magnification 1............ ......... ..........................

♦212242 Lens, 2.50 Magnification 1............ ......... ..........................

♦Optional

OM-252052 Page 27

7

10

11

9

8

2

6

5

3

4

12

Figure 10-3. Fixed Shade No. 10 Flip-Up Welding Helmet

1

OM-252052 Page 28

Item

No. Quantity

Part

No.

Description

Figure 10-3. Fixed Shade No. 10 Flip-Up Welding Helmet

1 231415 Shell, Helmet (Black) (Includes) 1............ ......... ....................

2 770237 Lens Cover, Inside 4.25 x 2 In. (5 Per Pkg.) 2............ ......... ..........

3 770226 Lens Assembly, 2 x 4 In. Fixed Shade No. 10 1............ ......... .........

4 770237 Lens Cover, Outside 4.25 In. x 2 In. 1............ ......... .................

5 261829 Frame, Lens Holding, Flip-Up 1............ ......... ......................

6 261830 Lens, Grinding Shield, Flip-Up (Clear) 1............ ......... ...............

7 770246 Headgear, Gray 1............ ......... .................................

8 *770248 Kit, Adjustment Angle/Stop Hardware Kit 1........... ......... .............

9 770249 Headband, Fabric 1............ ......... ................................

10 ♦216336 Cushion, Comfort (Foam Rubber) 1......... ......... ...................

11 ♦770250 Bag, Helmet (Miller Logo) 1......... ......... .........................

12 ♦212235 Lens, 0.75 Magnification 1......... ......... ..........................

* Adjustment Hardware Kit With O-rings.

216714 Label, Warning En/SP/FR 1.............. ........... .......................

♦770660 Lens Assembly, 2 x 4 In. Fixed Shade No. 8 1............ ......... ..........

♦770659 Lens Assembly, 2 x 4 In. Fixed Shade No. 9 1............ ......... ..........

079975 Replacement O-rings For Kit 770 248 (5 Per Pkg.) 1.............. ......... ....

♦222003 Adapters, Universal Hard Hat (Not Shown) 1............ ......... ...........

♦260940 Adapters, Slotted Hard Hat (Not Shown) 1............ ......... .............

♦212236 Lens, 1.00 Magnification 1............ ......... ..........................

♦212237 Lens, 1.25 Magnification 1............ ......... ..........................

♦212238 Lens, 1.50 Magnification 1............ ......... ..........................

♦212239 Lens, 1.75 Magnification 1............ ......... ..........................

♦212240 Lens, 2.00 Magnification 1............ ......... ..........................

♦212241 Lens, 2.25 Magnification 1............ ......... ..........................

♦212242 Lens, 2.50 Magnification 1............ ......... ..........................

♦Optional

SECTION 11 − LIMITED WARRANTY

LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric

Mfg. LLC, Appleton, Wisconsin, warrants to its original retail purchaser 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 OF MERCHANTABILITY AND FITNESS.

Miller Classic 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 impera-

tive that a copy of the original invoice or sales receipt be retained.

This warranty provides specific legal rights, and other rights may be available
depending on your state or province.

For warranty transactions, contact your Miller Distributor.

Miller Helmet Warr 2019-02

Effective January 1, 2019

OM-252052 Page 29

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

®

Miller Electric Mfg. LLC

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

ORIGINAL INSTRUCTIONS © 2019 Miller Electric Mfg. LLC