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OM-217 741C
May 2006
®
Auto-Darkening Helmets
Models: XLi, XLix and Elite
XLi
XLix
Elite
To help us serve you better, go to www.MillerWelds.Com/HelmetReg/
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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 . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Warning! Watch Out! There are possible hazards as shown in the adjoining symbols. Read 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. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching
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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 Po
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SECTION 3 − OPERATION INSTRUCTIONS Auto-Darkening Lens Controls Two different lens assemblies 1 23 4 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 5 Low Battery Indicator 1 23 4 5 Manual-On Lens Assembly 1 On/Auto-Off Button 2 Low Battery Indicator 3 Variable Shade Control 4 Sensitivity Control 5 Lens Delay Control 804 090 Page 3
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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 st
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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 lighti
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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
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Adjusting Headgear XLi Models There are four headgear ad- justments: headgear top, tight- ness, angle adjustment, and distance adjustment. 1 1 Headgear Top Adjusts headgear for proper depth 4 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 slot
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Adjusting Headgear (Continued) Xlix and Elite Models − There are four headgear adjust- ments: headgear top, tightness, angle adjustment, and distance adjustment. 1 1 Headgear Top 3 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 Dis
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Replacement of the Front and Inside Lens Covers Warning! 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. XLi – 1 Outside − Remove the outside lens cover frame by grasping the outside corners and pulling gently away from the helmet. Remove the clear lens cover by pulling the retaining tabs away from the lens. Install the lens cover replacement by reversing this procedure.
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SECTION 4 − BATTERY REPLACEMENT XLi and Xlix – Remove the battery by inserting a coin into the slot on the battery cover and turn to the left to release the cover. Replace with a CR2450 lithium type battery or equivalent, Miller Part No. 217043. (Note: make certain that the positive, (+) side of the battery faces up when reinstalling). To rein- stall battery cap, position cap with arrows at 6 and 12 o’clock positions then turn cap 1/4 turn clockwise. Elite − To replace the batteries on the Elit
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SECTION 5 − MAINTENANCE Cleaning The helmet requires little maintenance. However, for best performance we rec- ommend cleaning after 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. (Never use solvents or abrasive cleaning detergents. Do not immerse the lens assembly in water). SECTION 6 − TROUBLESHOOTING Symptom Solution Not ON
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SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS To prevent lens fogging, install flat side of magnifying lens toward auto-darkening lens. XLi – Magnifying lenses can be adapted to the XLi helmet as follows: 1 Pull outside lens cover/holder free from helmet. 2 Position magnifying lens over auto-darkening lens between the four center- ing tabs. 3 Reinstall outside lens cover/holder over top of magnifying lens. 4 Reverse procedure to remove magnifying lens. Xlix – Installation: 1 Locate magnifyi
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SECTION 8 − REPLACEMENT PARTS XLi Series Item XLi Description No. Series 1 Helmet shell, Black 217 606 1 Helmet shell, American Eagle II 223 645 1 Helmet shell, Black Flame 217 604 1 Helmet shell, Red Flame 217 603 1 Helmet shell, Millermatic 770 233 1 Helmet shell, Dale Earnhardt Sr. 770 253 1 Helmet shell, Dale Earnhardt Jr. 770 234 1 Helmet shell, Jeff Gordon 212 243 1 Helmet shell, Camouflage 227 423 1 Mexican Flag 229 365 1 Helmet shell, Stars and Stripes 1 Helmet, shell, Boyd Coddington 1
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Lense, 1.00 magnification (not shown) 212 236 Lense, 1.25 magnification (not shown) 212 237 Lense, 1.50 magnification (not shown) 212 238 Lense, 1.75 magnification (not shown) 212 239 Lense, 2.00 magnification (not shown) 212 240 Lense, 2.25 magnification (not shown) 212 241 Lense, 2.50 magnification (not shown) 212 242 * Kit includes front lens holder, 2 inside lens covers, and 5 front lens covers. XLi Series 9 6 Miller 8 10 7 5 1 2 3 4 804 110 Page 14
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XLix Series Item XLix Description No. Series 1 Helmet shell, Black 770 236 1 Helmet shell, American Eagle II 1 Helmet shell, Black Flame 1 Helmet shell, Red Flame 1 Helmet shell, Millermatic 1 Helmet shell, Dale Earnhardt Sr. 1 Helmet shell, Dale Earnhardt Jr. 1 Helmet shell, Jeff Gordon 1 Helmet shell, Maple Leaf 223 458 1 Helmet shell, OCC Paul Jr. 223 459 1 Helmet shell, Stars and Stripes 770 235 1 Helmet, shell, Boyd Coddington 1 Helmet shell, Inferno 2 Inside lens cover (4-1/2 x 2) (5 per
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Lense, 0.75 magnification (not shown) 212 235 Lense, 1.00 magnification (not shown) 212 236 Lense, 1.25 magnification (not shown) 212 237 Lense, 1.50 magnification (not shown) 212 238 Lense, 1.75 magnification (not shown) 212 239 Lense, 2.00 magnification (not shown) 212 240 Lense, 2.25 magnification (not shown) 212 241 Lense, 2.50 magnification (not shown) 212 242 * Kit includes front lens holder, 2 inside lens covers, and 5 front lens covers. ** Adjustment hardware kit with O-rings. XLix Serie
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Elite Series Item Elite Description No. Series 1 Helmet shell, Black 216 331 1 Helmet shell, American Eagle II 1 Helmet shell, Black Flame 217 602 1 Helmet shell, Red Flame 216 332 1 Helmet shell, Camouflage 227 190 1 Helmet shell, Mexican Flag 229 587 1 Helmet shell, The Joker 227 189 1 Helmet shell, UA-Series 1 229 366 1 Helmet shell, Maple Leaf 223 455 1 Helmet shell, OCC Paul Jr. 223 456 1 Helmet shell, Stars and Stripes 216 329 1 Helmet, shell, Boyd Coddington 223 457 1 Helmet shell, Infern
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Lense, 0.75 magnification (not shown) 212 235 Lense, 1.00 magnification (not shown) 212 236 Lense, 1.25 magnification (not shown) 212 237 Lense, 1.50 magnification (not shown) 212 238 Lense, 1.75 magnification (not shown) 212 239 Lense, 2.00 magnification (not shown) 212 240 Lense, 2.25 magnification (not shown) 212 241 Lense, 2.50 magnification (not shown) 212 242 ** Adjustment hardware kit with O-rings. Elite Series 10 7 Miller 12 9 8 6 2 3 11 5 4 1 804 111 Page 18
