Miller Pro-Hobby Series Manual

®

Auto-Darkening Helmets

Pro-HobbytSeries

OM-231 425-A
2006−10

To help us serve you better, go to www.MillerWelds.Com/Helmet/Reg/

TABLE OF CONTENTS

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

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

1-2. Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

3-2. On Button And Low Battery Indicator (Variable Shade Models Only) 4 . . . . . . . . . . . . . . . .

3-3. Lens Delay Control (Variable Shade Models Only) 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Variable Shade Control (No. 8 − 12) (Variable Shade Models Only) 5 . . . . . . . . . . . . . . . . .

3-5. Sensitivity Control (Variable Shade Models Only) 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − Adjusting Headgear 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − REPLACING THE LENS COVERS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Replacing Outside Lens Cover 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Replacing Inside Lens Cover 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − REPLACING THE BATTERY 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Variable Shade Models 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Fixed Shade No. 10 Models 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS 11 . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − MAINTENANCE 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − TROUBLESHOOTING 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − LIMITED WARRANTY 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-231 425 Page 1

SECTION 1 − SAFETY PRECAUTIONS −

READ BEFORE USING

Y Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out!
There are possible hazards with
this procedure! The possible
hazards are shown in the ad­joining symbols.

Y Marks a special safety message.

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

. Means “Note”; not safety related.

1-2. Hazards

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.

D 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 Sensitivity charts in Sections 3-4
and 3-5.

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

warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant material

(leather and wool) and foot protection.

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

D Use impact resistant safety spectacles or goggles and ear protection at all

times when using this welding helmet.

D Do not use this helmet while working with or around explosives or

corrosive liquids.

D Do not weld in the overhead position while using this helmet.
D 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.
D Wear approved ear protection if noise level is high.

OM-231 425 Page 2

SECTION 2 − SPECIFICATIONS

Specification Variable Shade Model Fixed Shade No. 10 Model

Viewing Field 95 x 40mm (3.75 x 1.55 in) 95 x 35mm (3.75 x 1.375 in)
Reaction Time (XLi) 0.000083sec (1/12,000) 0.000277sec (1/3,600)
Available Shades Darkened State: No. 8 − No. 12

Light State: No. 3 − Provides
continuous UV and IR protection

Darkened State: No. 10
Light State: No. 3 − Provides
continuous UV and IR protection

Sensitivity Control Adjusts for varying ambient light

and welding arc

Not Applicable

Delay Control Slows lens dark-to-light state

(slow − fast)

Not Applicable

Automatic Power Off Shuts lens Off 15−20 minutes after last arc is struck
Low Battery Indicator Red LED light illuminates to indi-

cate 2−3 days remaining battery
life

Not Applicable

Power Supply AAA Lithium Batteries Only (Two) Rechargeable, non-replaceable

solar cell

Sensors Independent/Redundant (Two)
Operating Temperature 14_F to 131_F / −10_C to +55_C

. When stored in extremely cold temperatures, warm helmet to ambi-

ent temperature before welding.

Storage Temperature −4_F to 158_F / −20_C to +70_C

. When stored in extremely cold temperatures, warm helmet to ambi-

ent temperature before welding.

Total Weight 453.6g (16oz.)
Standards ANSI Z87.1 and DIN/CE/TUV, CSA
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
DE. Patent − No. 199 59 944 C2, No. 199 59 945 C2
FR. Patent − No. 9916004

OM-231 425 Page 3

SECTION 3 − OPERATING INSTRUCTIONS

3-1. Helmet Controls

LOCK

OPEN

ON

. Two different lens assemblies are

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

Variable Shade Model

1 On Button

(See Section 3-2)

2 Low Battery Indicator

(See Section 3-2)

3 Lens Delay Control (See

Section 3-3)

4 Variable Shade Control

(No. 8 − 12) (See Section 3-4)

5 Sensitivity Control

(See Section 3-5)

Fixed Shade No. 10 Model

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

. Always make sure the lens is fully

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

1 23 45

804 792

Variable Shade Lens Assembly

Fixed Shade No. 10 Lens Assembly

OM-231 425 Page 4

3-2. On Button And Low Battery Indicator

(Variable Shade Models Only)

1 On Button
Press button to turn on lens and be-

gin welding. The lens will automati­cally darken twice and then return to
the light state.

. The lens will automatically turn

Off (clear state − No. 3) 15−20
minutes after the last arc. Press
the On button to resume
welding.

2 Low Battery Indicator
The low battery indicator lights

when 2−3 days of battery life re­main.

If battery power is low, replace with
AAA Lithium Batteries only (see
Section 6).

804 792

LOCK

OPEN

ON

1 2

3-3. Lens Delay Control (Variable Shade Models Only)

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 bright after-rays pres­ent in higher amperage applica­tions where the molten puddle re­mains bright momentarily after
welding. Adjusts from slow to fast.

804 792

LOCK

OPEN

ON

1

OM-231 425 Page 5

3-4. Variable Shade Control (No. 8 − 12) (Variable Shade Models Only)

1 Variable Shade Control

(No. 8 − 12)

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 welding process.

Start at shade 12 and adjust lighter
to suit the welding application and
your personal preference.

804 792

LOCK

OPEN

ON

1

Application Welding Arc Current in Amperes Protective Shade No.

Stick Electrodes Less than 40

40−80

80−175
175−300
300−500

9
10
11
12
13

MIG Less than 100

100−175
175−300
300−500

10
11
12
13

Gas Tungsten Arc Welding

(TIG)

Less than 50

50−100
100−200
200−400

10
11
12
13

Air Carbon Less than 500

500−700

12
13

Plasma Arc Cutting 60−150

150−250
250−400

11
12
13

Plasma Arc Welding Less than 50

50−200
200−400

9
10
12

OM-231 425 Page 6

3-5. Sensitivity Control (Variable Shade Models Only)

1 Sensitivity Control
Use control to make the lens more re-

sponsive to different light levels in vari­ous welding processes. Use a Mid-

Range or 30−50% sensitivity setting
for most applications.

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:

. Adjust helmet sensitivity in lighting

conditions helmet will be used in.

S Turn sensitivity control to lowest

setting.

S Press On button to turn helmet On.

Helmet lens will darken twice and
then clear.

S Face the helmet in the direction of

use, exposing it to the surrounding
light conditions.

S 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.

804 792

LOCK

OPEN

ON

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

OM-231 425 Page 7

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

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.)

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.

. When using either the front or

back distance adjustment
positions, only the center
three angle adjustment pins
can be used.

804 793

1

2

3

4

OM-231 425 Page 8

SECTION 5 − REPLACING THE LENS COVERS

5-1. Replacing Outside Lens Cover

Y 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.

1 Outside Lens Cover Frame
2 Lens
3 Gasket
Remove lens cover frame by grasp-

ing the outside corners and pulling
the frame away from the helmet.

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

. 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.

1

804 794

1

2

3

Be sure flat side of gasket
faces lens frame.

OM-231 425 Page 9

5-2. Replacing Inside Lens Cover

Y 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.

1 inside Lens Cover
Remove the inside lens cover by pry-

ing the lens up at the thumbnail open­ing located at the top center of the lens
cover.

Replace the lens 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 auto-darkening
lens assembly.

. Be sure the cover lens is seated

properly (flat) to prevent fogging.

804 793 / 804 794

1

OM-231 425 Page 10

SECTION 6 − REPLACING THE BATTERY

6-1. Variable Shade Models

804 792

1 Battery Cover
Slide cover to left and remove batter-

ies. Install two AAA lithium batteries
and replace cover.

LOCKOPEN

ON

AAA BATTERY

1

6-2. Fixed Shade No. 10 Models

804 792

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.

1

OM-231 425 Page 11

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
the bottom holding pins.

Reinstall auto-darkening lens as­sembly and lens cover frame.

Lift helmet lip with thumb
and push lens out.

804 794 / 804 795

1

2

OM-231 425 Page 12

SECTION 8 − MAINTENANCE

. Never use solvents or abrasive cleaning detergents. 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.

SECTION 9 − TROUBLESHOOTING

Trouble Remedy

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

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

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

Stop welding immediately: Press the On 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.

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

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.

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

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).

Auto lens switching or
Flickering; lens darkens
then lightens while the
welding 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 and spatter that may be blocking the arc sensors. Increas­ing Lens Delay to Fast position may also reduce switching.

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

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-231 425 Page 13

SECTION 10 − PARTS LIST

10

8

7

9

4

3

2

1

5

6

11

Miller

804 796

Figure 10-1. Pro-Hobby Auto-Darkening Welding Helmet

OM-231 425 Page 14

Description

Part

No.

Item

No. Quantity

Figure 10-1. Pro-Hobby Auto-Darkening Welding Helmet

1 213 415 Helmet Shell, Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 213 416 Helmet Shell, American Eagle II 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 213 419 Helmet Shell, Red Flame 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 213 417 Helmet Shell, Millermatic® 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 213 418 Helmet Shell, Camouflage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 231 410 Lens Cover, Inside (4.25 − 1.75 in) (5 Per Pkg.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

3 231 409 Auto-Darkening Lens Assy. (Variable Shade) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 231 571 Auto-Darkening Lens Assy. (Fixed Shade) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 413 Cover, Battery (Variable Shade) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 231 412 Gasket, Front Lens 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 231 411 Lens, Front Cover (4.5 x 3.6875 in) (5 Per Pkg.) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

6 231 572 Holder, Front Lens (Black) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 231 573 Holder, Front Lens (Gray) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 231 574 Holder, Front Lens (Red) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 231 575 Holder, Front Lens (Blue) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 231 576 Holder, Front Lens (Camouflage) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 770 246 Ratchet Headgear Assy. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 770 248 Adjustment Angle/Stop Hardware Kit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 770 249 Headband, Fabric 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 216 336♦ Comfort Cushion, Foam Rubber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 770 250♦ Bag Helmet, Miller 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 975♦ O-Rings, Replacement (For Item 8) (5 Per Pkg.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

222 003♦ Adapters, Hard Hat (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 235♦ Lens, 0.75 Magnification (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 236♦ Lens, 1.00 Magnification (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 237♦ Lens, 1.25 Magnification (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 238♦ Lens, 1.50 Magnification (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 239♦ Lens, 1.75 Magnification (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 240♦ Lens, 2.00 Magnification (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 241♦ Lens, 2.25 Magnification (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 242♦ Lens, 2.50 Magnification (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦Optional

OM-231 425 Page 15

NOTES

OM-231 425 Page 16

NOTES

OM-231 425 Page 17

SECTION 11 − LIMITED WARRANTY

Effective January 1, 2006

LIMITED WARRANTY – Subject to the terms and conditions below. Miller
Electric Mfg. Co., 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 OR MERCHANTABILITY AND FITNESS.

Miller XLi, Xlix and 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.

NOTES

PRINTED IN USA © 2006 Miller Electric Mfg. Co.

Visit our website at

www.MillerWelds.com

®

Miller Electric Mfg. Co.

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