Miller Electric XLi, Elitet, XLix User Manual
OM-217 741C
May 2006
®
Auto-Darkening Helmets
Models: XLi, XLix and Elitet
XLi
XLix
Elite
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − OPERATION INSTRUCTIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − BATTERY REPLACEMENT 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − TROUBLESHOOTING 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS 12 . . . . . . . . . . . . . . . . . . . .
SECTION 8 − REPLACEMENT PARTS 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − LIMITED WARRANTY 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS −
READ BEFORE USING
Warning! Watch Out! There are possible hazards as shown
in the adjoining symbols.
D Read and follow Section 1 for all safety symbols.
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 Section 2.
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.
Page 1
SECTION 2 − SPECIFICATIONS
Viewing Field (XLi, Xlix) 97mm x 47mm/3.81” x 1.85”
Viewing Field (Elite) 97mm x 60mm/3.81” x 2.62”
Reaction Time (XLi) 0.0000555sec (1/18,000)
Reaction Time (Xlix, Elite) 0.0000500sec (1/20,000)
Available Shades Darkened State: No. 9 − No. 13 / Light State: No. 4
Sensitivity/Grind Mode Control Adjusts for varying ambient light and welding arc
Delay Control Slows lens dark-to-light state between 0.1 and
Automatic Power Off Shuts lens Off 15−20 minutes after last arc is struck
Low Battery Indicator Red LED light illuminates to indicate 2−3 days
Power Supply CR2450 Lithium Batteries (Miller Part No. 217 043)
Sensors Independent/Redundant (Two−XLi, Xlix) (Four−Elite)
Operating Temperature 14_F to 131_F / −10_C to +55_C
provides continuous UV and IR protection
1.0 seconds
remaining battery life
. When stored in extremely cold temperatures, warm
helmet to ambient temperature before welding.
Storage Temperature −4_F to 158_F / −20_C to +70_C
. When stored in extremely cold temperatures, warm
helmet to ambient temperature before welding.
Total Weight XLi & Xlix: 453.6g (16oz.) / Elite: 510.3g (1lb 2oz.)
Standards ANSI Z87.1 and DIN/CE/TUV (CSA: Xlix, Elite)
Warranty 2 years from date of purchase (see Section 9)
. 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
Page 2
SECTION 3 − OPERATION INSTRUCTIONS
Auto-Darkening Lens
Controls
1 234
5
1 23 4 5
. Two different lens assemblies
are shown. Refer to the illustration that matches the lens on your
helmet.
Auto-On Lens Assembly
1 Reset/Auto-On Button
2 Variable Shade Control
3 Sensitivity/Grind Mode Control
4 Lens Delay Control
5 Low Battery Indicator
Manual-On Lens Assembly
1 On/Auto-Off Button
2 Low Battery Indicator
3 Variable Shade Control
4 Sensitivity Control
5 Lens Delay Control
804 090
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Reset/Auto-On Button (Auto−On Lens Assembly)
Press the Reset button to check lens operation. If working properly, the
lens will automatically darken twice and then return to the light state.
. The lens will Auto Off (light state − No. 4) 15 − 20 minutes after the last arc. It
is not necessary to press the Reset button to resume welding.
On/Auto-Off Button (Manual-On Lens Assembly)
Locate the ON button and press ON to weld, the lens will automatically
darken twice and then return to the light state, the helmet is then ready
to weld.
Note: The lens will Auto-Off (clear state − No. 4) after 15−20 minutes after
the last arc. It will be necessary to press the ON button to resume welding.
Variable Shade Control (No. 9 − No. 13)
Use the shade chart below to select proper shade control setting based
on your welding process. We recommend starting at shades 12 or 13 and
adjust lighter based on the welding application and 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
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Less than 50
40−80
80−175
175−300
300−500
100−175
175−300
300−500
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
Sensitivity/Grind Mode Control (Auto-On Lens Assembly)
Sensitivity Control (Manual-On Lens Assembly)
The sensitivity control is used to make the lens more responsive to differing
light levels experienced in various welding processes. We recommend a
Mid-Range or 30−50% sensitivity setting for most applications. See Ad-
justing Sensitivity and Recommended Sensitivity Settings sections following.
Adjusting Sensitivity
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.
1 Turn sensitivity control to lowest setting.
2 Press Reset button (Auto-On Lens) or On/Off button (Manual-On Lens)
to turn helmet On. Helmet lens will darken twice and then clear.
3 Face the helmet in the direction of use, exposing it to the surrounding light
conditions.
4 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.
Using Grind Mode (Auto-On Lens)
To use the Grind mode, turn the Sensitivity control clockwise to the far right
position (Grind). To resume welding, return the control to the desired sensitivity setting.
. Do not weld in the Grind mode; the lens will not darken.
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
Grind Mode Grind Position − Far Right (Clockwise)
Page 5
Lens Delay Control
The lens delay control is used to slow the lens-switching time 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 0.10 second (Min) to 1.0 second (Max).
Low Battery Indicator
The low battery indicator lights when 2−3 days of battery life remain.
Replace the battery with a readily available coin type CR2450 Lithium Battery or
equivalent. (Miller Part No. 217043) (see Section 4).
NOTES
Page 6
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