Miller Ultra HDV Manuel utilisateur

Ultra HDV

Auto-Darkening Helmet w/

Clearlight Lens

OM-288717B 2023-02

OWNER’S MANUAL

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2 Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-3 California Proposition 65 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-4 Lens Shade Selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-5 Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-1 Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-2 Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 4 – OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4-1 Helmet Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4-2 Helmet Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4-3 Mode Control And Grind/Memo/Low Battery Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4-4 Mode Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4-5 Variable Shade Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4-6 Lens Delay Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-7 Sensitivity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-8 Typical Lens Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4-9 Arc Time And Arc Count Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-10 Memo Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 5 – ADJUSTING HEADGEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5-1 Adjusting Headgear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 6 – REPLACING LENS COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6-1 Replacing The Lens Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION 7 – REPLACING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7-1 Replacing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 8 – INSTALLING OPTIONAL MAGNIFYING LENS AND SLIDING SIDE

COVERS.................................................................. 19

8-1 Installing Optional Magnifying Lens And Sliding Side Covers . . . . . . . . . . . . . . . . . . . . 19

SECTION 9 – MAINTENANCE AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 10 – TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

10-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

SECTION 12 – LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

OM-288717 Page 1

SECTION 1 – SAFETY PRECAUTIONS –

READ BEFORE USING

Protect yourself and others from injury—read, follow, and save these important safety

precautions and operating instructions.

1-1. Symbol Usage

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 ex-

plained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or seri-

ous injury. The possible hazards are shown in the adjoining symbols or explained in

the text.

NOTICE – Indicates statements not related to personal injury.

Indicates special instructions.

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 these hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and

identify possible hazards. When you see the symbol, watch out, and follow the related

instructions to avoid the hazard. The safety information given below is only a sum-

mary of the more complete safety information found in the Principal Safety Standards.

Read and follow all Safety Standards.

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, certifi-

cate, or professional standing, or who by extensive knowledge, training and experi-

ence, has successfully demonstrated the ability to solve or resolve problems relating

to the subject matter, the work, or the project and has received safety training to rec-

ognize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultra-

violet and infrared) rays that can burn eyes and skin. Sparks fly off from the

weld.

lWear 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 Principal Safety

Standards). Refer to Lens Shade Selection table in Section 1-4.

lWear approved safety glasses with side shields under your helmet.

lUse protective screens or barriers to protect others from flash, glare, and sparks; warn others

not to watch the arc.

lWear body protection made from leather or flame-resistant clothing (FRC). Body protection in-

cludes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and

a cap.

OM-288717 Page 2

lBefore welding, adjust the auto-darkening lens sensitivity setting to meet the application.

lStop welding immediately if the auto-darkening lens does not darken when the arc is struck.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

lWear approved ear protection if noise level is high.

WELDING HELMETS do not provide unlimited eye, ear,

and face protection.

Arc rays from the welding process produce intense visible and invisible (ultra-

violet and infrared) rays that can burn eyes and skin. Sparks fly off from the

weld.

lUse helmet for welding/cutting applications only. Do not use helmet for laser welding/cutting.

lUse impact resistant safety spectacles or goggles and ear protection at all times when using

this welding helmet.

lDo not use this helmet while working with or around explosives or corrosive liquids.

lThis 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.

lInspect the auto-lens frequently. Immediately replace any scratched, cracked, or pitted cover

lenses or auto-lenses.

lLens and retention components must be installed as instructed in this manual to ensure com-

pliance with ANSI Z87.1 protection standards.

lThis helmet provides protection from projectiles associated with grinding, chipping, and re-

lated activities; it is not a hard hat and does not provide protection from falling objects.

READ INSTRUCTIONS.

lRead 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.

lUse only genuine replacement parts from the manufacturer.

lPerform 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.

lKeep your head out of the fumes. Do not breathe the fumes.

lVentilate 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

composition and quantity of fumes and gases to which personnel are exposed.

lIf ventilation is poor, wear an approved air-supplied respirator.

lRead and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for

adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

lWork 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.

OM-288717 Page 3

lDo 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.

lDo 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. California Proposition 65 Warnings

WARNING – Cancer and Reproductive Harm — www.P65Warnings.ca.gov.

1-4. Lens Shade Selection Table

Process Electrode Size

in. (mm)

Arc Current in

Amperes

Minimum Pro-

tective Shade

No.

Suggested

Shade No.

(Comfort)*

Shielded Metal

Arc

Welding

(SMAW)

Less than 3/32 (2.4) Less than 60 7 - -

3/32-5/32 (2.4-4.0) 60–160 8 10

5/32-1/4 (4.0-6.4) 160–250 10 12

More than 1/4 (6.4) 250–550 11 14

Gas Metal Arc

Welding

(GMAW)

Flux Cored Arc

Welding (FCAW)

Less than 60 7 - -

60–160 10 11

160–250 10 12

250–500 10 14

Gas Tungsten

Arc

Welding (TIG)

Less than 50 8 10

50–150 8 12

150–500 10 14

Air Carbon Arc

Cutting (CAC-A)

Light Less than 500 10 12

Heavy 500–1000 11 14

Plasma Arc Cut-

ting (PAC)

Less than 20 4 4

20–40 5 5

40–60 6 6

60–80 8 8

80–300 8 9

300–400 9 12

400–800 10 14

Plasma Arc

Welding (PAW)

Less than 20 6 6–8

20–100 8 10

100–400 10 12

400–800 11 14

Reference: ANSI Z49.1:2021

*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.

OM-288717 Page 4

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding Society standard ANSI

Standard Z49.1. Website: http://www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1,

from American National Standards Institute. Website: www.ansi.org.

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2 from Canadian Stand-

ards Association. Website: www.csagroup.org.

Industrial Head Protection, ANSI/ISEA Standard Z89.1 from American National Standards Insti-

tute. Website: www.ansi.org.

Australian National Work Health Safety Policy from Safe Work Australia. Website: www.safewor-

kaustralia.com.

Safety in Welding and Allied Processes, AS1674.1 and AS1674.2 part 1 and 2 from SAI Global.

Website: www.saiglobal.com.

Helmet 2022–01

OM-288717 Page 5

SECTION 2 – DEFINITIONS

2-1. Additional Safety Symbol Definitions

Warning! Watch Out! There are possible haz-

ards as shown by the symbols.

Accidental ingestion prevention. Keep battery

away from children. Battery is harmful if

swallowed.

2-2. Miscellaneous Symbols And Definitions

Positive

Negative

Power On/

Off

OM-288717 Page 6

SECTION 3 – SPECIFICATIONS

INJURY due to impact. Falling objects can be hazardous.

Head covering by the helmet provides protection from projectile particles, associated

with grinding and chipping. For Australia & New Zealand, rating is "High Impact" in

accordance with AS/NZS1337.1

WARNING: The helmet is not to be considered a hard hat, and will not provide protec-

tion from falling object. If head protection is required consult your safety officer. For

Australia & New Zealand the helmet does not meet the requirements of AS/NZS 1801.

Specification Ultra HDV

Viewing Field 3.81 x 2.62 in. (97 x 60 mm)

Reaction Time 0.0000400 sec (1/25,000)

Available Shades

All Shades Provide Continuous UV And IR

Protection.

Weld Mode Darkened State: No. 8 – No. 12.5

Light State: No. 2.5

Cut Mode Darkened State: No. 5 – No. 8

Light State: No. 2.5

Grind Mode Light State: No. 2.5

X-Mode Darkened State: No. 8 – No. 12.5

Light State: No. 2.5

Sensitivity Control Adjustable For Varying Ambient Light And Weld-

ing/Cutting Arc.

Delay Control Slows Lens Dark-To-Light State Between 0.1 And

1.0 Seconds

Automatic Power Off Shuts Lens Off 45 Minutes After Last Arc Is

Struck

Low Battery Light Red LED Illuminates To Indicate 2−3 Days Re-

maining Battery Life

Power Supply CR2450 Lithium Battery

Sensors Independent/Redundant (Four)

Operating Temperature 14 F to 131° F / −10 C to +55° C

When Stored In Extremely Cold Tempera-

tures, Warm Helmet to Ambient Tempera-

ture Before Welding.

Storage Temperature −4 F to 158° F / −20 C to +70° C

When Stored In Extremely Cold Tempera-

tures, Warm Helmet to Ambient Tempera-

ture Before Welding.

Total Weight 709 g (25 oz)

Standards EN 379 Optical Class 1/1/1/2 Australian and New

Zealand AS/NZS 1337.1 High Impact AS/NZS

1338.1

Impact Rating High Impact AS/NZS 1337.1 B

Warranty Three Years From Date Of Purchase (Section 12)

OM-288717 Page 7

SECTION 4 – OPERATING INSTRUCTIONS

4-1. Helmet Configurations

The Ultra HDV helmet fea-

tures a flip-up auto-darkening

lens and a separate, clear

grinding shield. Flip the lens

up when grinding and per-

forming other non-welding

work. Flip the lens down when

welding or cutting.

OM-288717 Page 8

4-2. Helmet Controls

3 4 5

After One-Touch system

is activated (Section 4-

3), the auto-darkening

lens turns on (darkens)

automatically when

welding begins and

turns off when welding

stops.

1 Mode (On/Off) Button (On/

Off) (Section 4-3)

2 Grind/Memo Low Battery

Light (Section 4-3)

3 Variable Shade Control

Buttons (See Section 4-5)

4 Lens Delay Control But-

tons (See Section 4-6

5 Sensitivity Control Buttons

(Section 4-7)

6 Grind Button

7 Arc Time Button

8 Arc Count Button

9 Memo Buttons

The lens assembly

saves the shade, sensi-

tivity, and delay settings.

Activate lens by pressing

the Mode (On/Off) but-

ton longer than one sec-

ond (Section 4-3).

The Memo 1 and Memo

2 buttons save the cur-

rent mode, shade, sen-

sitivity, and delay

settings (Section 4-10).

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