Miller Electric Digital Elitet User Manual

Page 1
OM-234 388B
200708
®
Auto-Darkening Helmets
Model: Digital Elitet
To help us serve you better, go to www.MillerWelds.Com/HelmetReg/
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . .
1-2. Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 OPERATING INSTRUCTIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Helmet Controls 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. On-Off Button And Low Battery Indicator 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Mode Control 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Variable Shade Control 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Sensitivity Control 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Lens Delay Control 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 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 PARTS LIST 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − LIMITED WARRANTY 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS −
READ BEFORE USING
Protect yourself and others from injury — read and follow these precautions.
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.
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.
. 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.
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.
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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
All shades provide continu­ous UV and IR protection.
Sensitivity Settings Adjusts for varying ambient light and welding/cutting arc
Delay Settings Slows lens dark-to-light state
Automatic Power Off Shuts lens Off 1520 minutes after last arc is struck
Low Battery Indicator Display indicates 23 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
Weld Mode: Darkened State: No. 8 − No. 13
Light State: No. 3
Cutting Mode: Darkened State: No. 5 − No. 8
Light State: No. 3 Grind Mode: Light State: No. 3 X Mode: Darkened State: No. 8 No. 13
Light State: No. 3
Weld Mode: No. 0 No. 10 Cutting Mode: No. 0 No. 10 Grind Mode: Not Applicable X Mode: No. 0 No. 10
Weld Mode: No. 0 No. 10 Cutting Mode: No. 0 No. 10 Grind Mode: Not Applicable X Mode: No. 0 No. 10
. 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 lb 2oz.)
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
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SECTION 3 OPERATING INSTRUCTIONS
3-1. Helmet Controls
1 On-Off Button (See Section
3-2)
2 Mode Control Button
(See Section 3-3) 3 Display Screen 4 Variable Shade Control
Buttons (See Section 3-4) 5 Sensitivity Control Buttons
(See Section 3-5) 6 Lens Delay Control Buttons
(See Section 3-6)
. The lens assembly saves the
shade, sensitivity, and delay
settings when the lens turns
off.
4
5
6
12 3
805 010
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3-2. On-Off Button And Low Battery Indicator
1 On-Off Button
Press On-Off button to check if the lens is working properly and to be­gin 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 hel­met if the lens does not function as described. (See Section 9, Trouble­shooting.)
2 Low Battery Indicator
The message “Low Battery” ap­pears on the display screen when 23 days of battery life remains.
If battery power is low, replace with CR2450 lithium batteries (2 re­quired Miller Part No. 217 043) See Section 6.
12
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805 010
Page 7
3-3. Mode Control
1 Mode Control Button
Press button to select the mode ap­propriate for the work activity:
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.
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 adjust­ments 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.
1
805 010
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3-4. Variable Shade Control
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 ad­just lighter to suit the application
1
and your personal preference.
Use the table below to select prop­er shade control setting based on your welding process.
805 010
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 60150
Plasma Arc Welding Less than 50
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4080
80175 175300 300500
100175 175300 300500
Less than 50
50100 100200 200400
500700
150250 250400
50200 200400
9 10 11 12 13
10 11 12 13
10 11 12 13
12 13
11 12 13
9 10 12
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3-5. Sensitivity Control
1 Sensitivity Control Buttons
Use Sensitivity Control Low and Hi buttons to make the lens more responsive to differ­ent light levels in various welding pro­cesses. 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 sensi­tivity to accommodate different lighting con­ditions or if lens is flashing On and Off. Ad­just helmet sensitivity as follows:
1
. Adjust helmet sensitivity in lighting con-
ditions helmet will be used in.
S Press Sensitivity Low button to lower
setting to 0.
S Face the helmet in the direction of use,
exposing it to the surrounding light con­ditions.
S Press Sensitivity Hi button repeatedly
until the lens darkens, then press Low button until lens clears. Helmet is ready for use. Slight readjustment may be necessary for certain applications or if lens is flashing on and off.
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
Grinding No sensitivity setting; use Grind mode
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3-6. Lens Delay Control
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 pres­ent in higher amperage applica­tions where the molten puddle re­mains bright momentarily after welding. Use the Lens Delay Con­trol buttons to adjust delay from 0 to 10 (0.1 to 1.0 second).
. There is no lens delay adjust-
ment in the Grind mode.
1
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3-7. Lens Adjustment Procedure
MODE SHADE
SENSITIVITY
DELAY
MODE
WELD
SHADE
SENSITIVITY
DELAY
. Lens assembly displays prior
settings when turned On. Re­tained settings are not shown in example.
. In the Grind mode the lens is a
fixed shade No. 3. No lens ad­justments are possible.
Adjusting Lens Assembly:
S Turn lens On. Display screen
appears.
S Select mode (Weld, Cutting,
Grind, X-Mode)
S Select Shade By Pressing
Down/Up Buttons.
S Select Sensitivity By Pressing
Low/Hi Buttons.
S Select Delay by Pressing
Fast/Slow Buttons.
S Begin work.
MODE
WELD
MODE
WELD
MODE
WELD
SHADE
SENSITIVITY
DELAY
SHADE
SENSITIVITY
DELAY
SHADE
SENSITIVITY
DELAY
12
12
6
12
6 5
805 010
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SECTION 4 − ADJUSTING HEADGEAR
. 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-
1
3
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 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
2
4
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-234 388 Page 10
. When using the back distance
adjustment positions, only the back three angle adjustment pins can be used.
804 118
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SECTION 5 − REPLACING THE LENS COVERS
Be sure wide edge of gasket faces helmet shell.
Be sure flat side of gasket faces helmet shell.
3
2
1
6
5
4
! 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 Front Lens Gasket
2 Outside Lens Cover
3 Lens Assembly Gasket
4 Lens Assembly
5 Inside Lens Cover
6 Lens Frame
Remove the lens assembly to remove either lens cover.
To remove the lens assem­bly, push down on the helmet bottom retaining arms and push the retaining clips to­ward the outside of the hel­met. 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 rub­ber lens gasket and install on the new lens cover. Reinstall the lens assembly.
Ref. 805 012
. 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 as­sembly 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 assem­bly in the helmet.
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SECTION 6 REPLACING THE BATTERY
To replace the batteries, re­move the auto-darkening lens assembly (see Section 5).
1 Battery Tray
After removing the lens as-
1
++
Be sure Positive (+) side of battery faces up.
sembly, slide the battery hold­ing 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 (to­ward inside of helmet).
Reinstall the battery trays. To test, press the On button. The display screen should turn on. Reinstall the lens assembly.
. Left and right battery trays
are not interchangeable. The autodarkening hel­met will not work if battery trays are installed on the wrong sides.
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SECTION 7 INSTALLING OPTIONAL MAGNIFYING LENS
1 Optional Magnifying Lens
Starting at the top, slide magnifying lens into the helmet retaining brack­ets. 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 to­ward 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.
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SECTION 9 − TROUBLESHOOTING
Trouble Remedy
Auto lens not ON – auto­lens does not darken mo­mentarily when the On button is pressed.
Not switching – auto-lens stays light and does not darken when welding or cutting.
Not Switching – auto-lens stays dark after the arc is extinguished, or the auto­lens stays dark when no arc is present.
Sections of the auto-lens are not going dark, distinct lines separate the light and dark areas.
Switching or Flickering – the auto-lens darkens then lightens while the welding or cutting arc is present.
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.
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.
Reduce Sensitivity setting (see Section 3-5). In extreme light con­ditions, 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.
Stop welding or cutting 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 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 cor­ners.
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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.
Page 17
SECTION 10 PARTS LIST
13
Miller
8
9
1
11
10
12
7
2
3
5
6
4
Figure 10-1. Digital Elite Auto-Darkening Welding Helmet
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804 111
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Item
No. Quantity
Part
No.
Description
Figure 10-1. Digital Elite Auto-Darkening Welding Helmet
1 216 331 Helmet Shell, Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 227 189 Helmet Shell, The Joker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 234 066 Helmet Shell, Stars And Stripes II 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 223 454 Helmet Shell, Inferno 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 216 327 Inside Lens Cover (4-1/4 X 2-1/2) (5 Per Pkg.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 234 760 Auto-darkening Lens Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 216 337 Gasket, Front Lens − Cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 234 758 Gasket, Auto-Darkening Lens Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 216 326 Outside Lens Cover (4-11/16 X 5-5/8) (5 Per Pkg.) 1. . . . . . . . . . . . . . . . . . . . . . . .
7 234 759 Frame, Lens 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 770 246 Ratchet Headgear Assembly (Includes Items 9 And 10) 1. . . . . . . . . . . . . . . . . . . .
9 770 248* Adjustment Angle/Stop Hardware Kit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 770 249 Fabric Headband 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 975 Replacement O-rings For Kit 770 248 (5 Per Pkg.) 1. . . . . . . . . . . . . . . . . . . . . . . . . .
11 216 336 Comfort Cushion, Foam Rubber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 216 339 Battery Tray Kit (Left/Right) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
217 043 Battery, Lithium (CR2450) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
222 003 Hard Hat Adapters (Not Shown) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 770 250 Helmet Bag − Miller 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Adjustment Hardware Kit With O-rings.
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Page 19
SECTION 11 LIMITED WARRANTY
Effective January 1, 2007
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 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.
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Page 20
Visit our website at
www.MillerWelds.com
®
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.
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