Specifications

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Models: Digital Elitet

Digital Pro-Hobby

)

Digital Performance Series

)

OM-256 476A

2012−02

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Auto-Darkening Helmets

Summary of content (32 pages)

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OM-256 476A 2012−02 ® Auto-Darkening Helmets Models: Digital Elitet Digital Pro-Hobby) Digital Performance Series) To help us serve you better, go to www.MillerWelds.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS − READ BEFORE USING helmet 2012−02 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 special instructions.
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NOISE can damage hearing. Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high. READ INSTRUCTIONS. Read and follow all labels and the Owner’s Manual carefully before installing, 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.
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1-4. Lens Shade Selection Table Process Electrode Size in. (mm) Arc Current in Amperes Minimum Protective Shade No. Suggested Shade No. (Comfort)* Shielded Metal Arc Welding (SMAW) 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.
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SECTION 2 − SPECIFICATIONS Digital Pro-Hobby Helmet Digital Performance Helmet Digital Elite Helmet 3.75 x 1.55 in. (95 x 40 mm) 3.81 x 1.85 in. (97 x 47 mm) 3.81 x 2.62 in. (97 x 60mm) Operating Modes Two Modes: Weld, Grind Three Modes: Weld, Cut, Grind Four Modes: Weld, Cut, Grind, X-Mode Reaction Time 0.0000500 sec (1/20,000) 0.0000500 sec (1/20,000) 0.0000500 sec (1/20,000) Available Shades Weld Mode Darkened State: No. 8 − No. 13 Light State: No. 3 Weld Mode Darkened State: No. 8 − No.
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Sensors Operating Temperature Independent/Redundant (Two) Independent/Redundant (Three) Independent/Redundant (Four) And Magnetic (In X-Mode) 14 F to 131 F / −10 C to +55 C 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 16 oz. (453.6g) 17 oz. (481.9 g) 18oz. (510.
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SECTION 3 − OPERATING INSTRUCTIONS 3-1. Helmet Controls 1 2 3 Digital Elite Lens Shown 4 5 Auto On/Off Button (See Section 3-2) Grind Mode / Low Battery Light (Section 3-2) Mode Control Button (See Section 3-3) Display Screen Lens Adjustment Buttons (Sections 3-3 Thru 3-6) Use adjustment buttons to change shade, delay, and sensitivity settings. The lens assembly saves the shade, sensitivity, and delay settings.
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3-2. Auto On/Off Button And Low Battery Light 1 Auto On/Off Button Press On/Off button to check if the lens is working properly and to begin lens shade, sensitivity, and delay adjustments. Digital Elite Lens Shown 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 Grind / Low Battery Light The Grind / Low Battery light blinks when the lens is in the Grind mode.
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3-3. Mode Control 1 Mode Control Button Press Mode button to select the mode appropriate for the work activity: Digital Elite Lens Shown 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. Cut Mode − used for cutting applications. In this mode the lens turns on when it optically senses a cutting arc. Adjust shade, sensitivity, and delay settings as needed.
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3-4. Variable Shade Control Digital Elite Lens Shown 1 1 Variable Shade Adjustment Buttons 2 Mode Control Button Use the LTR and DKR adjustment buttons to adjust the lens shade in the darkened state. Use the table in Section 1-4 to select proper shade control setting based on your welding process. The shade ranges for each mode are as follows: Weld − No. 8 − No. 13 Cut − No. 5 − No. 8 2 Grind − No. 3 only X-Mode − No. 8 − No.
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3-5. Lens Delay Control Digital Elite Lens Shown 1 1 Lens Delay Adjustment Buttons 2 Mode Control Button Use the Lens Delay Short and Long 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).
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3-6. Sensitivity Control Digital Elite Lens Shown 2 1 1 Sensitivity Adjustment Buttons 2 Mode Control Button Use control to make the lens more responsive to different light levels in various welding processes. Use a MidRange 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.
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3-7. Typical Lens Adjustment Procedure 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. X-Mode is not present on Pro-Hobby and Performance helmets. Cut mode is not present on Pro-Hobby helmets. Adjusting Lens Assembly: OM-256 476 Page 12 Turn lens On. Display screen appears. Select mode (Weld, Cut, Grind, X-Mode).
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SECTION 4 − ADJUSTING HEADGEAR There are four headgear adjustments: headgear top, tightness, angle adjustment, and distance adjustment. 1 Headgear Top Straps Adjusts headgear for proper depth on the head to ensure correct balance and stability. 1 3 2 Headgear Tightness To adjust, turn the adjusting knob located on the back of the headgear left or right to desired tightness.
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SECTION 5 − REPLACING THE LENS COVERS 5-1. Replacing Outside Lens Cover − Digital Pro-Hobby Series 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. 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.
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5-2. Replacing Inside Lens Cover − Pro-Hobby Series 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. 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.
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5-3. Replacing Outside Lens Covers On Digital Elite And Performance Quick-Release Helmets 2 1 ! 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 Holder 2 Release Points 3 Lens Cover 4 Gasket 2 Remove front lens holder by pressing release points and pulling the holder away from the helmet. Remove lens cover and gasket from the holder.
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5-4. Replacing Inside Lens Cover − Performance Series 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. 1 Lens Assembly 2 inside Lens Cover Remove the lens cover holder (see Section 5-3). Remove lens assembly. Remove the inside lens cover by prying the cover up at either thumbnail opening at each side of the cover. Slide cover it out of either side of frame.
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5-5. Replacing The Lens Covers On Digital Elite Standard Helmets Be sure wide edge of gasket faces helmet shell. Be sure flat side of gasket faces helmet shell. 6 5 4 3 2 1 Ref. 805 012 ! Never use the autodarkening lens without the inside and outside lens covers properly installed. Welding spatter will damage the auto-darkening lens and void the warranty.
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SECTION 6 − REPLACING THE BATTERY To replace the batteries, remove the auto-darkening lens assembly (see Section 5). 1 1 Battery Tray After removing the lens assembly, slide the battery holding trays out and remove the old batteries. Be sure Positive (+) side of battery faces up. 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.
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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. SECTION 8 − MAINTENANCE NOTICE − Never use solvents or abrasive cleaning detergents. NOTICE − Do not immerse the lens assembly in water.
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SECTION 9 − TROUBLESHOOTING Trouble Remedy Auto lens not On – autolens does not darken momentarily when the On button is pressed. Check batteries and verify they are in good condition and installed properly. Not switching – auto-lens stays light and does not darken when welding or cutting. Stop welding or cutting immediately: Make sure the lens is turned On. Check battery surfaces and contacts, and clean if necessary. Check battery for proper contact and gently adjust contact points if necessary.
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SECTION 10 − PARTS LIST 7 Miller 9 8 10 11 1 2 3 4 5 6 804 796 Figure 10-1.
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Item No. Part No. Description Quantity Figure 10-1 Digital Pro-Hobby Auto-Darkening Welding Helmet 1 . . . . . . . . . . . . . . 231 415 . . . . . . Helmet Shell, Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 250 367 . . . . . . Helmet Shell, Blue Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 231 416 . . . . . . Helmet Shell, American Eagle II . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . .
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7 9 8 Miller 11 10 1 2 3 4 5 6 Figure 10-2.
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Item No. Part No. Description Quantity Figure 10-2. Digital Performance Auto-Darkening Welding Helmet 1 . . . . . . . . . . . . . . 250 533 . . . . . . Helmet Shell, ’64 Custom . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 232 021 . . . . . . Helmet Shell, America’s Eagle . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 232 020 . . . . . . Helmet Shell, Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . .
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8 10 9 11 Miller 7 2 3 5 12 6 4 1 804 111 Figure 10-3.
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Item No. Part No. Description Quantity Figure 10-3. Digital Elite Auto-Darkening Welding Helmet − Standard Models 1 . . . . . . . . . . . . . . 216 331 1 . . . . . . . . . . . . . . 223 454 1 . . . . . . . . . . . . . . 237 872 1 . . . . . . . . . . . . . . 234 066 1 . . . . . . . . . . . . . . 247 058 1 . . . . . . . . . . . . . . 247 059 1 . . . . . . . . . . . . . . 256 172 1 . . . . . . . . . . . . . . 227 190 1 . . . . . . . . . . . . . . 250 089 2 . . . . . . . . . . . . . . 216 327 3 . . . . . .
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Miller 7 11 9 8 12 10 6 5 4 1 2 3 242 385 / Ref. 804 111 Figure 10-4.
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Item No. Part No. Description Quantity Figure 10-4. Digital Elite Auto-Darkening Welding Helmet − Quick Release Models 1 . . . . . . . . . . . . . . 241 976 2 . . . . . . . . . . . . . . 216 327 3 . . . . . . . . . . . . . . 256 469 4 . . . . . . . . . . . . . . 241 977 5 . . . . . . . . . . . . . . 216 326 6 . . . . . . . . . . . . . . 241 978 7 . . . . . . . . . . . . . . 256 174 8 . . . . . . . . . . . . . *256 178 9 . . . . . . . . . . . . . . 770 249 . . . . . . . . . . . . . . . . 079 975 10 . . .
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Visit our website at www.MillerWelds.com ® Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA ORIGINAL INSTRUCTIONS © 2012 Miller Electric Mfg. Co.