Miller Classic Series User manual

Classic Series
Welding Helmets
OM-252 052B 2011−04
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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 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