Miller Electric Digital Elitet User manual

®
Auto-Darkening Helmets
Models: XLi, XLix and Elitet
OM-217 741C
May 2006
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 1
SECTION 1 −SAFETY PRECAUTIONS −
READ BEFORE USING
Warning! Watch Out! There are possible hazards as shown
in the adjoining symbols.
DRead 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 (ultravio-
let and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
DWear 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.
DWear approved safety glasses with side shields under your helmet.
DUse protective screens or barriers to protect others from flash and glare;
warn others not to watch the arc.
DWear 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.
DUse impact resistant safety spectacles or goggles and ear protection at all
times when using this welding helmet.
DDo not use this helmet while working with or around explosives or
corrosive liquids.
DDo not weld in the overhead position while using this helmet.
DInspect 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.
DWear approved ear protection if noise level is high.

Page 2
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
provides continuous UV and IR protection
Sensitivity/Grind Mode Control Adjusts for varying ambient light and welding arc
Delay Control Slows lens dark-to-light state between 0.1 and
1.0 seconds
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
remaining battery life
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
.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 3
SECTION 3 −OPERATION INSTRUCTIONS
Auto-Darkening Lens
Controls
.Two different lens assemblies
are shown. Refer to the illustra-
tion 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
1234
5
123 4 5
804 090

Page 4
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
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

Page 5
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 neces-
sary 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 sensitiv-
ity 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 6
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 re-
mains bright momentarily after welding. Adjusts from 0.10 second (Min) to 1.0 sec-
ond (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 7
Adjusting Headgear
XLi Models
.There are four headgear ad-
justments: headgear top, tight-
ness, angle adjustment, and
distance adjustment.
1 Headgear Top
Adjusts headgear for proper depth
on the head to ensure correct bal-
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 de-
sired tightness.
.If adjustment is limited, it may
be necessary to remove the
comfort cushion.
3 Angle Adjustment
Three slots on the right side of the
helmet position the forward tilt of
the helmet. To adjust, loosen the
right outside tension adjustment
knob then lift up on the inside tab
and slide to the desired hole. Re-
tighten tension adjustment knob.
4 Distance Adjustment
Adjusts the distance between the
face and the lens. To adjust, loosen
both outside tension knobs and
slide forward or back to desired
position and retighten. (Both sides
must be equally positioned for
proper vision.)
804 119
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Page 8
Adjusting Headgear
(Continued)
Xlix and Elite Models−
.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.
2 Headgear Tightness
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.
.When using either the front or
back distance adjustment posi-
tions, only the center three
angle adjustment pins can be
used.
804 118
1
2
3
4