Miller Classic Series User manual

Classic Series
Welding Helmets
OM-252052G 2019−07
To help us serve you better, go to www.MillerWelds.Com/Register

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 2....................................................
1-4. Lens Shade Selection Table 3.................................................
1-5. Principal Safety Standards 3..................................................
SECTION 2 −SPECIFICATIONS 4.....................................................
SECTION 3 −OPERATING INSTRUCTIONS 5..........................................
3-1. Helmet Controls 5...........................................................
3-2. Reset Button And Low Battery Indicator 7.......................................
3-3. Mode Control (Vsi Helmet Only) 8..............................................
3-4. Lens Delay Control 9.........................................................
3-5. Variable Shade Control 10.....................................................
3-6. Sensitivity Control 11..........................................................
SECTION 4 −ADJUSTING HEADGEAR 12.............................................
SECTION 5 −REPLACING THE LENS COVERS 13.....................................
5-1. Replacing Outside Lens Cover On Variable Shade And Standard Fixed Shade Helmets 13
5-2. Replacing Inside Lens Cover On Variable Shade and Standard Fixed Shade Helmets 14.
5-3. Replacing Lens Covers On VSi Helmet 15........................................
5-4. Replacing Grinding Shield On VSi Helmet 16......................................
5-5. Replacing Lens Covers And Grinding Shield On Fixed Shade Flip-Up Helmets 17.......
SECTION 6 −REPLACING THE BATTERY 18..........................................
6-1. Replacing Battery On Variable Shade Helmets 18..................................
6-2. Replacing Battery On Vsi Helmet 18.............................................
6-3. Solar Cell On Fixed Shade Helmets 19...........................................
SECTION 7 −INSTALLING OPTIONAL MAGNIFYING LENS 20...........................
SECTION 8 −MAINTENANCE AND STORAGE 21......................................
SECTION 9 −TROUBLESHOOTING 22................................................
SECTION 10 −PARTS LIST 24.......................................................
SECTION 11 −LIMITED WARRANTY 29...............................................

OM-252052 Page 1
SECTION 1 −WELDING HELMET SAFETY PRECAUTIONS −
READ BEFORE USING
helmet 2018-08
Protect yourself and others from injury — read, follow, and save these important safety
precautions and operating instructions.
1-1. Symbol Usage
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.
Indicates special instructions.
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. Arc Welding Hazards
Only qualified persons should install, operate, maintain, and repair this equipment. A
qualified person is defined as one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge, training and experience, has
successfully demonstrated ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety training to recognize and avoid
the hazards involved.
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.
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 Lens
Shade Selection table in Section 1-4.
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash, glare, and sparks; warn
others not to watch the arc.
Wear body protection made from durable, flame−resistant material (leather, heavy cotton,
wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
•Before welding, adjust the auto-darkening lens sensitivity setting to meet the application.
•Stop welding immediately if the auto-darkening lens does not darken when the arc is struck.
ARC RAYS can burn eyes and skin.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
 Wear approved ear protection if noise level is high.

OM-252052 Page 2
WELDING HELMETS do not provide unlimited eye, ear, and
face protection.
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.
Use helmet for welding/cutting applications only. Do not use helmet for laser welding/cutting.
Use impact resistant safety spectacles or goggles and ear protection at all times when using
this welding helmet.
Do not use this helmet while working with or around explosives or corrosive liquids.
This helmet is not rated for overhead welding. Do not weld in the direct overhead position
while using this helmet unless additional precautions are taken to protect yourself from arc
rays, spatter, and other hazards.
Inspect the auto-lens frequently. Immediately replace any scratched, cracked, or pitted cover
lenses or auto-lenses.
Lens and retention components must be installed as instructed in this manual to ensure
compliance with ANSI Z87.1 protection standards.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s Manual carefully before in-
stalling, operating, or servicing unit. Read the safety information at the be-
ginning of the manual and in each section.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the Owner’s Manuals, industry
standards, and national, state, and local codes.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be
hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
Ventilate the work area and/or use local forced ventilation at the arc to remove welding fumes
and gases. The recommended way to determine adequate ventilation is to sample for the com-
position and quantity of fumes and gases to which personnel are exposed.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for
adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator.
Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays
of the arc can react with vapors to form highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the
coating is removed from the weld area, the area is well ventilated, and while wearing an air-
supplied respirator. The coatings and any metals containing these elements can give off toxic
fumes if welded.
1-3. Proposition 65 Warnings
WARNING: Cancer and Reproductive Harm −www.P65W arnings.ca.gov

OM-252052 Page 3
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 (6.4)
Less than 60
60−160
160−250
250−550
7
8
10
11
−−
10
12
14
Gas Metal
Arc Welding
(GMAW)
Flux Cored
Arc Welding
(FCAW)
Less than 60
60−160
160−250
250−500
7
10
10
10
−−
11
12
14
Gas Tungsten Arc
Welding (TIG)
Less than 50
50−150
150−500
8
8
10
10
12
14
Air Carbon
Arc Cutting (CAC-A)
Light
Heavy
Less than 500
500−1000
10
11
12
14
Plasma Arc
Cutting (PAC)
Less than 20
20−40
40−60
60−80
80−300
300−400
400−800
4
5
6
8
8
9
10
4
5
6
8
9
12
14
Plasma Arc Welding
(PAW)
Less than 20
20−100
100−400
400−800
6
8
10
11
6−8
10
12
14
Reference: ANSI Z49.1:2012
* Start with a shade that is too dark to see the weld zone. Then, go to a lighter shade which gives a
sufficient view of the weld zone without going below the minimum.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free down-
load from the American Welding Society at http://www.aws.org or purchased from Global Engineering
Documents (phone: [phone], website: www .global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone:
212-642-4900, website: www.ansi.org).
Industrial Head Protection, ANSI/ISEA Standard Z89.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: [phone], website: www.ansi.org).

OM-252052 Page 4
SECTION 2 −SPECIFICATIONS
Specification Variable Shade
Helmet VSi Helmet
Standard
Fixed Shade
No. 10 Helmet
Fixed Shade
2 x 4 No. 10
Flip-Up Helmet
Viewing Field 95 x 34 mm
(3.75 x 1.375 in.)
95 x 40 mm
(3.75 x 1.57 in.)
95 x 35 mm
(3.75 x 1.375 in.)
Reaction Time 0.0000833 sec
(1/12,000)
0.00005 sec
(1/20,000)
0.000277 sec (1/3,600)
Available
Shades
Darkened State:
No. 8 −No. 12
Light State: No. 3
Provides Continu-
ous UV And IR
Protection
Darkened State:
No. 8 −No. 13
Light State: No. 3
Provides Continu-
ous UV And IR
Protection
Darkened State: No. 10
Light State: No. 3
Provides Continuous UV And
IR Protection
Sensitivity
Control
Adjusts For Varying
Ambient Light And
Welding Arc
Adjusts For Varying
Ambient Light And
Welding Arc;
X-Mode
Not Applicable
Delay Control Slows Lens Dark-
To-Light State
(Slow −Fast)
Slows Lens Dark-
To-Light State
(Between 0.1 And 1
Second)
Not Applicable
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
Not Applicable
Power Supply AAA Alkaline
Batteries Only
(Two)
Panasonic CR2450
Lithium Battery
(Part No. 217043)
Rechargeable,
Non-Replaceable Solar Cell
Sensors Independent/
Redundant (Two)
Independent/
Redundant (Three)
Independent/
Redundant (Two)
Operating
T emperature
14F to 131F / −10C to +55C
When stored in extremely cold temperatures, warm helmet to ambient
temperature before welding.
Storage
T emperature
−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 453.6g (16oz.) 640.2g (22.58oz.) 453.6g (16 oz.) 396g (13.96oz.)
Standards Meets ANSI Z87.1+ (2015) and CSA Z94.3 (2015) Standards
Warranty 2 Years From Date Of Purchase (See Section 11)

OM-252052 Page 5
SECTION 3 −OPERATING INSTRUCTIONS
3-1. Helmet Controls
Four different lens assemblies are
shown. Refer to the illustration that
matches the lens on your helmet.
Variable Shade Helmet
1 Reset Button
(See Section 3-2)
2 Low Battery Indicator
(See Section 3-2)
3 Lens Delay Control (See Section
3-4)
4 Variable Shade Control
(No. 8 −12) (See Section 3-5)
5 Sensitivity Control
(See Section 3-6)
123 45
Variable Shade
Lens Assembly
VSi Lens Assembly
67 8 9 10 11
VSi Helmet
6 Reset Button
(See Section 3-2)
7 Low Battery Indicator
(See Section 3-2)
8 Variable Shade Control
(No. 8 −13) (See Section 3-5)
9 Sensitivity Control
(See Section 3-6)
10 Mode Control (See Section
3-3)
11 Lens Delay Control (See
Section 3-4)

OM-252052 Page 6
3-1. Helmet Controls −Continued
Fixed Shade No. 10 Helmets
The fixed shade models have no
buttons or controls. The lens turns
on (darkens) automatically when
welding begins and turns off when
welding stops.
To ensure proper function, charge
lens internal battery prior to first
use or after extended storage
(about 30 days). Charge battery by
either of these methods:
Expose lens to direct sunlight
for 10 seconds.
Expose lens to light bulb for 20
minutes.
After initial charging, the welding
arc will maintain the charge in the
battery.
Notes

OM-252052 Page 7
3-2. Reset Button And Low Battery Indicator
The auto-darkening lens turns
on (darkens) automatically
when welding begins and turns
off when welding stops.
1 Reset Button
Press Reset button to check if the
lens is working properly.
When the Reset button is pressed,
the lens should darken twice and re-
turn to the clear state. Do not use the
helmet if the lens does not function
as described. (See Section 9, Trou-
bleshooting.)
2 Low Battery Indicator
The low battery indicator lights when
2−3 days of battery life remain.
If battery power is low, install new
AAA Alkaline batteries (Variable
Shade helmet) or Panasonic
CR2450 Lithium battery (VSi helmet)
(see Section 6).
12
1
2
Variable Shade Lens Assembly
VSi Lens Assembly

OM-252052 Page 8
3-3. Mode Control (VSi Helmet Only)
1 Mode Control Button
Slide Mode Control switch to select
the mode appropriate for the work
activity.
Slide switch away from the de-
sired mode (Weld or X-Mode).
When the switch is moved, “On” is
revealed next to the active mode.
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.
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 helmet
operation when lens is in X-Mode.
Stay at least 12 ft (3.7 m) away
from other welding activity.
1

OM-252052 Page 9
3-4. Lens Delay Control
1 Lens Delay Control
The lens delay control is used to
adjust the time for the lens to switch
to the clear state after welding.
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.
Variable Shade helmet adjusts
from Slow to Fast and VSi helmet
adjusts from Min to Max (0.1 to 1.0
second).
1
Variable Shade Lens Assembly
VSi Lens Assembly
1

OM-252052 Page 10
3-5. Variable Shade Control
1 Variable Shade
Control
Lens shade can be adjusted
from No. 8 −12 on Variable
Shade helmet, and from No.
8 −13 on VSi helmet.
Use the control to adjust the
lens shade in the darkened
state. Use the table below to
select proper shade control
setting based on your weld-
ing process.
Start at darkest shade and
adjust lighter to suit the
welding application and
your personal preference.
1
VSi Lens Assembly
1
Variable Shade Lens Assembly
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

OM-252052 Page 11
3-6. Sensitivity Control
1 Sensitivity Control
Use control to make the lens more re-
sponsive to different light levels in vari-
ous welding processes. Use a Mid-
Range 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. Adjust helmet sensitivity as
follows:
Adjust helmet sensitivity in lighting
conditions helmet will be used in.
Turn sensitivity control to lowest
setting.
Press On button to turn helmet On.
Helmet lens will darken twice and
then clear.
Face the helmet in the direction of
use, exposing it to the surrounding
light conditions.
Gradually turn sensitivity setting
clockwise until the lens darkens,
then turn sensitivity control coun-
terclockwise until slightly past set-
ting where lens clears. Helmet is
ready for use. Slight readjustment
may be necessary for certain ap-
plications or if lens is flashing on
and off.
804 792
1
Variable Shade Lens Assembly
VSi Lens Assembly
1
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

OM-252052 Page 12
SECTION 4 −ADJUSTING HEADGEAR
There are four headgear ad-
justments: headgear top,
tightness, distance adjust-
ment, and angle adjustment.
1 Headgear Top Adjustment
Adjusts headgear for proper
depth on the head to ensure cor-
rect balance and stability.
2 Headgear Tightness
Adjustment
Adjusts headgear for a secure fit.
To adjust, push in the adjusting
knob located on the back of the
headgear. Turn knob left or right
to obtain 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, loos-
en both outside tension knobs
and press inward to free from ad-
justment slots. Move forward or
back to desired position and re-
tighten. (Both sides must be
equally positioned for proper vi-
sion.)
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
tension adjustment knob then lift
on the control arm tab and move
it to the desired position. Retigh-
ten tension adjustment knob.
When using the back dis-
tance adjustment position,
only the back three angle ad-
justment pins can be used.
804 793
1
2
3
4

OM-252052 Page 13
SECTION 5 −REPLACING THE LENS COVERS
5-1. Replacing Outside Lens Cover On Variable Shade And Standard Fixed
Shade 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.
See Section 5-5 for information
on replacing lens covers and
grinding shield on Fixed Shade
Flip-Up Helmets.
1 Outside Lens Cover Frame
2 Lens Cover
3 Gasket
Remove lens cover frame by grasp-
ing the outside corners and pulling
the frame away from the helmet.
Remove lens cover and gasket from
the six-prong lens frame. Replace
lens cover and reinstall gasket and
lens in frame. Reinstall frame in hel-
met.
Be sure the flat side of lens gas-
ket faces the six-prong lens
frame.
Be sure all six prongs of lens
frame are securely fastened in
slots in helmet.
1
804 794
1
2
3
Be sure flat side of gasket
faces lens frame.

OM-252052 Page 14
5-2. Replacing Inside Lens Cover On Variable Shade and Standard Fixed
Shade Helmets
!Never use the auto-darkening
lens without the inside and out-
side lens covers properly
installed. Welding spatter will
damage the auto-darkening
lens and void the warranty.
See Section 5-5 for information
on replacing lens covers and
grinding shield on Fixed Shade
Flip-Up Helmets.
1 inside Lens Cover
Remove the inside lens cover by pry-
ing the lens up at the thumbnail open-
ing located at the top center of the lens
cover.
Replace the lens cover by gently bow-
ing it in the center and inserting it, one
end at a time, into the retaining clips
located on the outside of the auto-
darkening lens assembly.
Be sure the cover lens is seated
properly (flat) to prevent fogging.
804 793 / 804 794
1

OM-252052 Page 15
5-3. Replacing Lens Covers On VSi Helmet
!Never use the auto-dark-
ening lens without the in-
side and outside lens
covers properly instal-
led. Welding spatter will
damage the auto-darken-
ing lens and void the war-
ranty.
Outside Lens Cover
1 Lens Holder
2 Release Points
3 Outside Lens Cover
Remove lens holder by press-
ing release points and pulling
the holder away from the hel-
met.
Remove lens cover from hold-
er. Replace lens cover in lens
holder. Reinstall lens holder in
helmet.
Inside Lens Cover
4 Gasket
5 Lens
6 Inside Lens Cover
Remove the inside lens cover
by prying cover from groove in
gasket.
Replace the lens cover by gent-
ly bowing it in the center and in-
serting it, one end at a time, into
the gasket.
Be sure the cover lens is
seated properly (flat) to
prevent fogging.
12
2
3
456

OM-252052 Page 16
5-4. Replacing Grinding Shield On VSi Helmet
Ref. 804 109
!Never use the auto-dark-
ening lens without the in-
side and outside lens
covers properly installed.
Welding spatter will dam-
age the auto-darkening
lens and void the
warranty.
1 Grinding Shield
2 Retaining Clip
3 Tab
Rotate both retaining clips to the
Open position.
Gently push shield toward bot-
tom tab and remove shield from
helmet.
Remove retaining clips from
shield. Install clips in same loca-
tion on new shield. (Retaining
clips are not interchangeable.)
Install new shield in helmet and
rotate clips to the Lock position.
Tear-Away Protective Sheets
Tear-away sheets are available
to prolong the life of the griding
shield (see Parts List).
To install tear-away sheets, pull
backing from both sides of the
tear-away, remove white ad-
hesive backing strips, and
place on clear shield.
12
3

OM-252052 Page 17
5-5. Replacing Lens Covers And Grinding Shield On Fixed Shade Flip-Up
Helmets
!Never use the auto-
darkening lens with-
out the inside and
outside lens covers
properly installed.
Welding spatter will
damage the auto-
darkening lens and
void the warranty.
See Sections 5-1 and
5-2 for lens cover re-
placement informa-
tion on standard Fixed
Shade Helmets.
1 Outside Lens Cover
2 Lens
3 Inside Lens Cover
Lift flip-up frame and slide
lens and covers together
out of the open side of the
frame. Replace lens cov-
ers. Slide lens and covers
together back into frame.
4 Grinding Shield
Remove grinding shield
from front of helmet by
pushing shield from the in-
side. Reinstall shield by
placing one edge of shield
in track. Using both hands,
bend shield outward until
the loose end of the shield
can be installed in the open
track.
1
2
3
4
Notes

OM-252052 Page 18
SECTION 6 −REPLACING THE BATTERY
6-1. Replacing Battery On Variable Shade Helmets
1 Battery Cover
Slide cover to left and remove batter-
ies. Install two AAA alkaline batteries
and replace cover.
1
LOCKOPEN AAA BATTERY
6-2. Replacing Battery On VSi Helmet
OTOS / 804 847
1 Battery Cover
Insert a coin into the slot on the bat-
tery cover. Rotate cover counter-
clockwise to remove battery.
Install Panasonic CR2450 lithium
battery or equivalent (Miller Part No.
217043).
Be sure Positive (+) side of the
battery faces up (toward inside
of helmet).
To reinstall battery cover, position
cover with arrows at 6 and 12
o’clock positions, then turn cap 1/4
turn clockwise.
1