Miller Classic Series User manual

Classic Series
Welding Helmets
OM-252 052B 2011−04
To help us serve you better, go to www.MillerWelds.Com/Helmet/Reg/

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. .....................................................
SECTION 2 −SPECIFICATIONS 3.....................................................
SECTION 3 −OPERATING INSTRUCTIONS 4..........................................
3-1. Helmet Controls 4. ............................................................
3-2. On Button And Low Battery Indicator 5. ...........................................
3-3. Lens Delay Control 5. ..........................................................
3-4. Variable Shade Control (No. 8 −12) 6. ............................................
3-5. Sensitivity Control 7. ...........................................................
SECTION 4 −ADJUSTING HEADGEAR 8..............................................
SECTION 5 −REPLACING THE LENS COVERS 9......................................
5-1. Replacing Outside Lens Cover 9. ................................................
5-2. Replacing Inside Lens Cover 10. ................................................
SECTION 6 −REPLACING THE BATTERY 11..........................................
6-1. Variable Shade Helmets 11. ....................................................
6-2. Fixed Shade No. 10 Helmets 11. ................................................
SECTION 7 −INSTALLING OPTIONAL MAGNIFYING LENS 12..........................
SECTION 8 −MAINTENANCE 13.....................................................
SECTION 9 −TROUBLESHOOTING 13................................................
SECTION 10 −PARTS LIST 14.......................................................
SECTION 11 −LIMITED WARRANTY 15...............................................

OM-252 052 Page 1
SECTION 1 −WELDING HELMET SAFETY PRECAUTIONS −
READ BEFORE USING
helmet 2010−03
Protect yourself and others from injury — read and follow these precautions.
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 unit.
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.
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.
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 protective clothing made from durable, flame-resistant material (leather, heavy cotton,
and wool) and foot protection.
•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.
See the Owner’s Manual for more information.
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.
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.
Do not weld in the overhead position while using this helmet.
Inspect the auto-lens frequently. Immediately replace any scratched, cracked, or pitted cover
lenses or auto-lenses.
WELDING HELMETS do not provide unlimited eye, ear and
face protection.

OM-252 052 Page 2
Noise from some processes or equipment can damage hearing.
 Wear approved ear protection if noise level is high.
NOISE can damage hearing.
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.
Perform 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.
If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding
fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
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
Welding or cutting equipment produces fumes or gases which contain chemicals known
to the State of California to cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to the state of California to cause
cancer, birth defects, or other reproductive harm. Wash hands after use.

OM-252 052 Page 3
SECTION 2 −SPECIFICATIONS
Specification Variable Shade Helmet Fixed Shade No. 10 Helmet
Viewing Field 95 x 34 mm (3.75 x 1.375 in.) 95 x 35 mm (3.75 x 1.375 in.)
Reaction Time 0.0001 sec (1/10,000) 0.000277 sec (1/3,600)
Available Shades Darkened State:
No. 8 −No. 12
Light State: No. 3
Provides continuous 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
Not Applicable
Delay Control Slows lens dark-to-light state
(slow −fast) 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) Rechargeable, non-replaceable solar cell
Sensors Independent/Redundant (Two)
Operating
Temperature 14F to 131F / −10C to +55C
When stored in extremely cold temperatures, warm helmet to am-
bient temperature before welding.
Storage
Temperature −4F to 158F / −20C to +70C
When stored in extremely cold temperatures, warm helmet to am-
bient temperature before welding.
Total Weight 453.6g (16oz.)
Standards ANSI Z87.1+(2003) and CSA
Warranty 2 years from date of purchase (see Section 11)

OM-252 052 Page 4
SECTION 3 −OPERATING INSTRUCTIONS
3-1. Helmet Controls
Two different lens assemblies are
shown. Refer to the illustration
that matches the lens on your
helmet.
Variable Shade Model
1 Reset Button
(See Section 3-2)
2 Low Battery Indicator
(See Section 3-2)
3 Lens Delay Control (See
Section 3-3)
4 Variable Shade Control
(No. 8 −12) (See Section 3-4)
5 Sensitivity Control
(See Section 3-5)
Fixed Shade No. 10 Model
The fixed shade model has no buttons
or controls. The lens turns on (dark-
ens) automatically when welding be-
gins and turns off when welding stops.
Always make sure the lens is fully
charged before welding. Place
helmet in direct sunlight for 20
minutes to charge the lens as-
sembly solar cell.
123 45
804 792
Variable Shade Lens Assembly
Fixed Shade No. 10 Lens Assembly

OM-252 052 Page 5
3-2. On 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 func-
tion as described. (See Section 9,
Troubleshooting.)
2 Low Battery Indicator
The low battery indicator lights
when 2−3 days of battery life re-
main.
If battery power is low, replace with
AAA Alkaline Batteries only (see
Section 6).
12
3-3. 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. Adjusts from slow to fast.
1

OM-252 052 Page 6
3-4. Variable Shade Control (No. 8 −12)
1 Variable Shade Control
(No. 8 −12)
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 welding process.
Start at shade 12 and adjust lighter
to suit the welding application and
your personal preference.
1
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-252 052 Page 7
3-5. 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
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-252 052 Page 8
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
headbandtop 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-252 052 Page 9
SECTION 5 −REPLACING THE LENS COVERS
5-1. Replacing Outside Lens Cover
!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 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-252 052 Page 10
5-2. Replacing Inside Lens Cover
!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.
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-252 052 Page 11
SECTION 6 −REPLACING THE BATTERY
6-1. 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. Fixed Shade No. 10 Helmets
804 792
1 Solar Cell (Internal)
Fixed shade models are powered by
a rechargeable, non-replaceable so-
lar cell. No service is required.
Always make sure the lens is fully
charged before welding. Place
helmet in direct sunlight for 20
minutes to charge lens solar cell.
1

OM-252 052 Page 12
SECTION 7 −INSTALLING OPTIONAL MAGNIFYING LENS
1 Outside Lens Cover Frame
2 Optional Magnifying Lens
Remove lens cover frame by
grasping the outside corners and
pullingthe frame away from the hel-
met.
Remove the auto-darkening lens
assembly by gently lifting the hel-
met lip above the assembly and
pushing assembly free of the re-
taining brackets.
Starting at the top, slide magnifying
lens into the helmet retaining brack-
ets. Position the lens tightly against
the bottom holding pins.
Reinstall auto-darkening lens as-
sembly and lens cover frame.
Lift helmet lip with thumb
and push lens out.
804 794 / 804 795
1
2

OM-252 052 Page 13
SECTION 8 −MAINTENANCE
Never use solvents or abrasive cleaning detergents. 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.
SECTION 9 −TROUBLESHOOTING
Trouble Remedy
Auto lens not On; lens
does not darken momen-
tarily when the Reset but-
ton is pressed.
Check batteries and verify they are in good condition and installed
properly. Also, check battery surfaces and contacts and clean if
necessary.
Auto lens not switching;
lens stays light and does
not darken when welding.
Stop welding immediately. Press the Reset button on variable
shade helmets. On fixed-shade helmets, make sure the lens solar
cell is properly charged by placing the helmet in direct sunlight for
20 minutes. If power is on, review the sensitivity recommenda-
tions and adjust sensitivity. 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.
Auto lens not Switching;
lens stays dark after the
weld arc is extinguished,
or the lens stays dark
when no arc is present.
Fine-tune the sensitivity setting by making small adjustments to
the control by turning it toward the “min” setting. In extreme light
conditions, it may be necessary to reduce the surrounding light
levels.
Sections of the auto-lens
are not going dark; distinct
lines separate the light and
dark areas.
Stop welding immediately. The auto-lens may be cracked which
can be caused by the impact of dropping the helmet. 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).
Auto lens switching or
Flickering; lens darkens
then lightens while the
welding arc is present.
Review the sensitivity setting recommendations and increase the
sensitivity if possible. Be sure the arc sensors are not being
blocked from direct access to the arc light. Check the lens cover
for dirt and spatter that may be blocking the arc sensors. Increas-
ing Lens Delay to Fast position may also reduce switching.
Inconsistent or lighter
auto-lens shading in the
dark-state, noticeable on
the outside edges and
corners.
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-252 052 Page 14
SECTION 10 −PARTS LIST
10
8
7
9
4
3
2
1
5
6
11
Miller
804 796
12
Figure 10-1. Classic Series Auto-Darkening Welding Helmet

OM-252 052 Page 15
Description
Part
No.
Item
No. Quantity
Figure 10-1. Classic Series Auto-Darkening Welding Helmet
1 231 415 Helmet Shell, Black 1............ ........ ..............................
2 231 410 Lens Cover, Inside (4.25 −1.75 in.) (5 Per Pkg.) 1............ ........ ......
3 231 571 Auto-Darkening Lens Assy. (Fixed Shade) 1............ ........ ...........
3 251 293 Auto-Darkening Lens Assy. (Variable Shade) 1............ ........ .........
231 413 Cover, Battery (Variable Shade) 1.............. ........ ....................
4 231 412 Gasket, Front Lens 1............ ........ ...............................
5 231 411 Lens, Front Cover (4.5 x 3.6875 in) (5 Per Pkg.) 1............ ........ ......
6 231 572 Holder, Front Lens (Black) 1............ ........ .........................
7 770 246 Ratchet Headgear Assy. 1............ ........ ..........................
8 770 248 Adjustment Angle/Stop Hardware Kit 1............ .......... ..............
9 770 249 Headband, Fabric 1............ .......... ..............................
10 216 336♦Comfort Cushion, Foam Rubber 1........... ....... ....................
11 770 250♦Bag Helmet, Miller 1........... ....... ...............................
079 975♦O-Rings, Replacement (For Item 8) (5 Per Pkg.) 1.............. ....... ......
222 003♦Adapters, Hard Hat (Not Shown) 1.............. ....... ...................
12 212 235♦Lens, 0.75 Magnification (Not Shown) 1........... ....... ...............
12 212 236♦Lens, 1.00 Magnification (Not Shown) 1........... ....... ...............
12 212 237♦Lens, 1.25 Magnification (Not Shown) 1........... ....... ...............
12 212 238♦Lens, 1.50 Magnification (Not Shown) 1........... ....... ...............
12 212 239♦Lens, 1.75 Magnification (Not Shown) 1........... ....... ...............
12 212 240♦Lens, 2.00 Magnification (Not Shown) 1........... ....... ...............
12 212 241♦Lens, 2.25 Magnification (Not Shown) 1........... ....... ...............
12 212 242♦Lens, 2.50 Magnification (Not Shown) 1........... ....... ............... ....
♦Optional
SECTION 11 −LIMITED WARRANTY
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 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.
Effective January 1, 2011

Notes

Notes

ORIGINAL INSTRUCTIONS −PRINTED IN USA ©2011 Miller Electric Mfg. Co.
Visit our website at
www.MillerWelds.com
®
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA