Miller Electric Bicycle Accessories Digital Elitet User Manual

OM-234 388B  
200708  
®
Auto-Darkening Helmets  
Model: Digital Elitet  
 
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  
. Indicates special instructions.  
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.  
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.  
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 (ultravio-  
let 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  
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-234 388 Page 1  
 
 
SECTION 2 SPECIFICATIONS  
Viewing Field  
97 x 60mm/3.81 x 2.62 in  
Reaction Time  
Operating Modes  
Available Shades  
0.0000500sec (1/20,000)  
4 Modes: Weld, Cutting, Grind, X Mode  
Weld Mode:  
Darkened State: No. 8 No. 13  
Light State: No. 3  
All shades provide continu-  
ous UV and IR protection.  
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  
Sensitivity Settings  
Delay Settings  
Adjusts for varying ambient light and welding/cutting arc  
Weld Mode: No. 0 No. 10  
Cutting Mode: No. 0 No. 10  
Grind Mode: Not Applicable  
X Mode: No. 0 No. 10  
Slows lens dark-to-light state  
Weld Mode: No. 0 No. 10  
Cutting Mode: No. 0 No. 10  
Grind Mode: Not Applicable  
X Mode: No. 0 No. 10  
Automatic Power Off  
Low Battery Indicator  
Power Supply  
Shuts lens Off 1520 minutes after last arc is struck  
Display indicates 23 days remaining battery life  
CR2450 Lithium Batteries (Miller Part No. 217 043)  
Independent/Redundant (Four)  
Sensors  
Operating Temperature  
14_F to 131_F / 10_C to +55_C  
. 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  
Standards  
Warranty  
510.3 g (1 lb 2oz.)  
ANSI Z87.1 and CSA/TUV  
. 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  
OM-234 388 Page 2  
 
 
SECTION 3 OPERATING INSTRUCTIONS  
3-1. Helmet Controls  
1
2
On-Off Button (See Section  
3-2)  
Mode Control Button  
3
4
Display Screen  
Variable Shade Control  
5
6
Sensitivity Control Buttons  
Lens Delay Control Buttons  
. The lens assembly saves the  
shade, sensitivity, and delay  
settings when the lens turns  
off.  
4
5
6
1
2
3
805 010  
OM-234 388 Page 3  
 
 
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 be-  
gin 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 hel-  
met if the lens does not function as  
described. (See Section 9, Trouble-  
shooting.)  
2
Low Battery Indicator  
The message “Low Battery” ap-  
pears on the display screen when  
23 days of battery life remains.  
If battery power is low, replace with  
CR2450 lithium batteries (2 re-  
quired Miller Part No. 217 043)  
See Section 6.  
1
2
805 010  
OM-234 388 Page 4  
 
 
3-3. Mode Control  
1
Mode Control Button  
Press button to select the mode ap-  
propriatefor 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 adjust-  
ments 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  
OM-234 388 Page 5  
 
 
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 ad-  
just lighter to suit the application  
and your personal preference.  
1
Use the table below to select prop-  
er shade control setting based on  
your welding process.  
805 010  
Application Welding  
Arc Current in Amperes  
Protective Shade No.  
Stick Electrodes  
Less than 40  
4080  
9
10  
11  
12  
13  
80175  
175300  
300500  
MIG  
Less than 100  
100175  
10  
11  
12  
13  
175300  
300500  
Gas Tungsten Arc Welding  
(TIG)  
Less than 50  
50100  
100200  
200400  
10  
11  
12  
13  
Air Carbon  
Less than 500  
500700  
12  
13  
Plasma Arc Cutting  
60150  
150250  
250400  
11  
12  
13  
Plasma Arc Welding  
OM-234 388 Page 6  
Less than 50  
50200  
9
10  
12  
200400  
 
 
3-5. Sensitivity Control  
1
Sensitivity Control Buttons  
Use Sensitivity Control Low and Hi buttons  
to make the lens more responsive to differ-  
ent light levels in various welding pro-  
cesses. 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 sensi-  
tivity to accommodate different lighting con-  
ditions or if lens is flashing On and Off. Ad-  
just helmet sensitivity as follows:  
1
. Adjust helmet sensitivity in lighting con-  
ditions helmet will be used in.  
S
S
Press Sensitivity Low button to lower  
setting to 0.  
Face the helmet in the direction of use,  
exposing it to the surrounding light con-  
ditions.  
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.  
805 010  
Recommended Sensitivity Settings  
Mid-Range  
Stick Electrode  
Short Circuiting (MIG)  
Low/Mid-Range  
Pulsed & Spray (MIG)  
Gas Tungsten Arc (TIG)  
Plasma Arc Cutting/Welding  
Grinding  
Mid-Range  
Mid/High-Range  
Low/Mid-Range  
No sensitivity setting; use Grind mode  
OM-234 388 Page 7  
 
 
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 pres-  
ent in higher amperage applica-  
tions where the molten puddle re-  
mains bright momentarily after  
welding. Use the Lens Delay Con-  
trol 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
805 010  
OM-234 388 Page 8  
 
 
3-7. Lens Adjustment Procedure  
. Lens assembly displays prior  
settings when turned On. Re-  
tained settings are not shown  
in example.  
MODE  
SHADE  
. In the Grind mode the lens is a  
fixed shade No. 3. No lens ad-  
justments are possible.  
SENSITIVITY  
DELAY  
Adjusting Lens Assembly:  
S
S
S
S
S
S
Turn lens On. Display screen  
appears.  
Select mode (Weld, Cutting,  
Grind, X-Mode)  
MODE  
WELD  
SHADE  
Select Shade By Pressing  
Down/Up Buttons.  
SENSITIVITY  
DELAY  
Select Sensitivity By Pressing  
Low/Hi Buttons.  
Select Delay by Pressing  
Fast/Slow Buttons.  
Begin work.  
MODE  
WELD  
SHADE  
12  
SENSITIVITY  
DELAY  
MODE  
WELD  
SHADE  
12  
6
SENSITIVITY  
DELAY  
MODE  
WELD  
SHADE  
12  
6
SENSITIVITY  
DELAY  
5
805 010  
OM-234 388 Page 9  
 
 
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-  
ance and stability.  
1
2
Headgear Tightness  
3
To adjust, push in the adjusting knob  
located on the back of the headgear  
and turn left or right to desired tight-  
ness.  
. If adjustment is limited, it may be  
necessary to remove the com-  
fort 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 de-  
sired 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 ten-  
sion adjustment knob then lift on the  
control arm tab and move it to the de-  
sired position. Retighten tension ad-  
justment knob.  
2
4
. When using the back distance  
adjustment positions, only the  
back three angle adjustment  
pins can be used.  
804 118  
OM-234 388 Page 10  
 
 
SECTION 5 REPLACING THE LENS COVERS  
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  
Remove the lens assembly  
to remove either lens cover.  
!
Never use the auto-  
darkening lens with-  
out the inside and out-  
side lens covers prop-  
erly installed. Welding  
spatter will damage  
. Be sure the flat side of  
lens cover gasket faces  
the helmet shell.  
To remove the lens assem-  
bly, push down on the helmet  
bottom retaining arms and  
push the retaining clips to-  
ward the outside of the hel-  
met. Lift up on the assembly  
and pull free of the helmet.  
Inside Lens Cover  
the  
auto-darkening  
To replace the inside lens  
cover, remove the lens as-  
sembly from the lens frame  
by pushing up on the top two  
retaining tabs while gently  
pushing the lens free.  
lens and void the  
warranty.  
1
2
3
4
5
6
Front Lens Gasket  
Outside Lens Cover  
Lens Assembly Gasket  
Lens Assembly  
Outside Lens Cover  
Remove the outside lens  
cover by pushing cover into  
the helmet. Remove the rub-  
ber lens gasket and install on  
the new lens cover. Reinstall  
the lens assembly.  
Remove the lens cover by  
sliding it out of either side.  
Replace with the new cover  
lens and reinstall the assem-  
bly in the helmet.  
Inside Lens Cover  
Lens Frame  
OM-234 388 Page 11  
 
 
SECTION 6 REPLACING THE BATTERY  
To replace the batteries, re-  
move the auto-darkening lens  
1
Battery Tray  
After removing the lens as-  
sembly, slide the battery hold-  
ing trays out and remove the  
old batteries.  
1
Replace with CR2450 lithium  
type batteries (2 required) or  
equivalent (Miller Part No.  
217043).  
+
+
. Be sure Positive (+) side  
of the battery faces up (to-  
ward inside of helmet).  
Be sure Positive  
(+) side of battery  
faces up.  
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 hel-  
met will not work if battery  
trays are installed on the  
wrong sides.  
805 010  
OM-234 388 Page 12  
 
 
SECTION 7 INSTALLING OPTIONAL MAGNIFYING LENS  
1
Optional Magnifying Lens  
Starting at the top, slide magnifying  
lens into the helmet retaining brack-  
ets. Align the magnifying lens with  
the auto-darkening lens assembly.  
1
Reverse procedure to remove  
magnifyinglens.  
. To prevent lens fogging, install  
flat side of magnifying lens to-  
ward 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.  
OM-234 388 Page 13  
 
 
SECTION 9 TROUBLESHOOTING  
Trouble  
Remedy  
Auto lens not ON – auto-  
lens does not darken mo-  
mentarily when the On  
button is pressed.  
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.  
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.  
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.  
Not Switching – auto-lens Reduce Sensitivity setting (see Section 3-5). In extreme light con-  
stays dark after the arc is  
extinguished, or the auto-  
lens stays dark when no  
arc is present.  
ditions, 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.  
Sections of the auto-lens  
Stop welding or cutting immediately: The auto-lens may be  
are not going dark, distinct cracked which can be caused by the impact of dropping the hel-  
lines separate the light and met.  
dark areas.  
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).  
Switching or Flickering –  
Review the sensitivity setting recommendations and increase the  
the auto-lens darkens then sensitivity if possible. Be sure the arc sensors are not being  
lightens while the welding  
or cutting arc is present.  
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 cor-  
ners.  
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-234 388 Page 14  
 
 
SECTION 10 PARTS LIST  
11  
8
10  
12  
9
Miller  
7
2
3
5
13  
6
4
1
804 111  
Figure 10-1. Digital Elite Auto-Darkening Welding Helmet  
OM-234 388 Page 15  
 
 
Item  
No.  
Part  
No.  
Description  
Quantity  
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.  
OM-234 388 Page 16  
 
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 pur-  
chaser 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.  
OM-234 388 Page 17  
 
 
Visit our website at  
®
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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