ESAB Auto-Darkening Welding Helmets User manual

ESAB Auto-Darkening Welding Helmets User manual

AUTO-DARKENING

WELDING HELMETS

VARIABLE SHADE 5-8

VARIABLE SHADE 9-13

Operating

Manual

Revision: AA Issue Date: April 2, 2014 Manual No.: 89210111

Tweco.com

WE APPRECIATE YOUR BUSINESS!

Congratulations on receiving your new Tweco product. We are proud to have you as our customer and will strive to provide you with the best service and support in the industry. This product is backed by our extensive warranty and world-wide service network.

We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done.

For more than 75 years Tweco has provided quality products you can trust, when your reputation is on the line.

YOU ARE IN GOOD COMPANY!

Tweco is a Global Brand of Arc Welding Products for Victor Technologies Inc. We distinguish ourselves from our competition through market-leading innovation and truly dependable products that will stand the test of time.

We strive to enhance your productivity, efficiency and welding performance enabling you to excel in your craft. We design products with the welder in mind delivering- advanced features, durability, ease of use and ergonomic comfort.

Above all, we are committed to a safer working environment within the welding industry. Your satisfaction with this product and its safe operation is our ultimate concern. Please take the time to read the entire manual, especially the Safety

Precautions.

If you have any questions or concerns regarding your new Tweco product, please contact our friendly and knowledgeable Customer Service Team at:

1-800-462-2782 (USA) and 1-905-827-4515 (Canada), or visit us on the web at

www.Tweco.com

!

WARNING

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s judgment, the Manufacturer assumes no liability for its use.

Auto-Darkening Welding Helmets

Safety and Operating Instructions

Instruction Guide Number 89210111

Published by:

Victor Technologies Inc.

2800 Airport Rd.

Denton, TX. 76207

(940) 566-2000 www.victortechnologies.com

Copyright © 2013 by

Victor Technologies International, Inc.

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: April 2, 2014

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS....................................................1-1

1.01 Arc Welding Hazards..................................................................1-1

1.02 Principal Safety Standards.........................................................1-8

1.03 Symbol Chart.............................................................................1-9

1.04 Declaration of Conformity........................................................1-10

SECTION 2:

INTRODUCTION............................................................................................2-1

2.01 How to use this Manual.............................................................2-1

2.02 Equipment Identification............................................................2-1

2.03 Receipt Of Equipment................................................................2-1

2.04 Description: Auto-Darkening Welding Helmet............................2-2

2.05 User Responsibility....................................................................2-2

2.06 Personal protection....................................................................2-2

2.07 Specifications.............................................................................2-5

2.08 Parts List and Assembly.............................................................2-6

SECTION 3:

INSTALLATION.............................................................................................3-1

3.01 Harness Adjustment .................................................................3-1

3.02 Changing of Front Cover Lens...................................................3-2

3.03 Digital Operation Guide..............................................................3-2

SECTION 4:

SERVICE.......................................................................................................3-7

4.01 Routine Maintenance & Inspection............................................3-7

4.02 Cleaning the Auto-Darkening Welding Helmet...........................3-7

4.03 Basic Troubleshooting...............................................................3-8

LIMITED WARRANTY.............................................................................................4-1

AUTO-DARKENING WELDING HELMETS SAFETY INSTRUCTION

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

!

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP

CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.

DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE

INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting.

These practices must be learned through study and training before using this equipment.

Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN

WELDING AND CUTTING. This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE

ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED

ONLY BY QUALIFIED PEOPLE.

1.01 ARC WELDING HAZARDS

WARNING

ELECTRIC SHOCK CAN KILL.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semi-automatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live.

Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment.

Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

Manual 89210111 1-1 Safety Instruction

SAFETY INSTRUCTION AUTO-DARKENING WELDING HELMETS

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

9. Do not wrap cables around your body.

10. Ground the workpiece to a good electrical (earth) ground.

11. Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13. In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14. Wear a safety harness to prevent falling if working above floor level.

15. Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing. Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in

Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

Safety Instruction 1-2 Manual 89210111

AUTO-DARKENING WELDING HELMETS SAFETY INSTRUCTION

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death.

Be sure the breathing air is safe.

6. 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.

7. 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 if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

WARNING

WELDING can cause fire or explosion.

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

Manual 89210111 1-3 Safety Instruction

SAFETY INSTRUCTION AUTO-DARKENING WELDING HELMETS

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

Welding or Cutting

Operation

Torch soldering

Torch brazing

Oxygen Cutting

Gas welding

Light

Eye protection fi lter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Electrode Size

Metal Thickness

Under 1 in., 25 mm

Medium 1 to 6 in., 25-150 mm

Heavy Over 6 in., 150 mm

Light Under 1/8 in., 3 mm

Medium 1/8 to 1/2 in., 3-12 mm

Heavy

Shielded metal-arc welding

(stick) electrodes

Over 1/2 in., 12 mm

Under 5/32 in., 4 mm

5/32 to 1/4 in.,

4 to 6.4 mm

Over 1/4 in., 6.4 mm

Filter

Shade

2

3 or 4

3 or 4

4 or 5

5 or 6

4 or 5

5 or 6

6 or 8

10

12

14

Welding or Cutting

Operation

Gas metal-arc

welding (MIG)

Non-ferrous base metal

Non-ferrous base metal

Gas tungsten arc welding

(TIG)

Atomic hydrogen welding

Carbon arc welding

Plasma arc welding

Carbon arc air gouging

Light

Plasma arc cutting

Heavy

Electrode Size

Metal Thickness

Filter

Shade

All

All

All

All

All

All

Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

11

12

12

12

12

12

12

14

Safety Instruction 1-4 Manual 89210111

AUTO-DARKENING WELDING HELMETS SAFETY INSTRUCTION

WARNING

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.

Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

!

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

Manual 89210111 1-5 Safety Instruction

SAFETY INSTRUCTION AUTO-DARKENING WELDING HELMETS

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

Safety Instruction 1-6 Manual 89210111

AUTO-DARKENING WELDING HELMETS

4. Do not use welder to charge batteries or jump start vehicles.

SAFETY INSTRUCTION

5. Observe correct polarity (+ and –) on batteries.

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

!

WARNING

WARNING: This product contains chemicals, including lead, known to the State of California

to cause birth defects and other reproductive harm.

Wash hands after handling.

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and

Magnetic Fields

The following is a quotation from the General Conclusions Section of the U.S. Congress,

Office of Technology Assessment, Biological Effects of Power Frequency Electric &

Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government

Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

Manual 89210111 1-7 Safety Instruction

SAFETY INSTRUCTION AUTO-DARKENING WELDING HELMETS

ABOUT PACEMAKERS

The above procedures are among those also normally recommended for pacemaker wearers.

Consult your doctor for complete information.

1.02 PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society,

550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents,

U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of

Containers That Have Held Hazardous Substances, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from

Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA

22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian

Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,

Canada M9W 1R3.

Safety Instruction 1-8 Manual 89210111

AUTO-DARKENING WELDING HELMETS SAFETY INSTRUCTION

1.03 SYMBOL CHART

Note that only some of these symbols will appear on your model.

On

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Single Phase

Three Phase

Three Phase Static

Frequency Converter-

Transformer-Rectifier

Remote

X

%

Duty Cycle

Percentage

Panel/Local

Wire Feed Function

Wire Feed Towards

Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld

Mode

Spot Weld Mode

Fuse

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Shielded Metal

Arc Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

Gas Tungsten Arc

Welding (GTAW)

Air Carbon Arc

Cutting (CAC-A)

Constant Current

t1 t

Spot Time

Preflow Time

t2

Postflow Time

2 Step Trigger

Operation

Press to initiate wirefeed and welding, release to stop.

Negative

Positive

Direct Current (DC)

Constant Voltage

Or Constant Potential

High Temperature

4 Step Trigger

Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

t

Burnback Time

Protective Earth

(Ground)

Line

Fault Indication

IPM

Inches Per Minute

Line Connection

Arc Force

Touch Start (GTAW)

MPM

Meters Per Minute

S

See Note

See Note

Auxiliary Power Variable Inductance

115V 15A

Receptacle Rating-

Auxiliary Power

V

Voltage Input

Art # A-04130_AB

S when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.

Cannot be disposed with household garbage.

Manual 89210111 1-9 Safety Instruction

SAFETY INSTRUCTION AUTO-DARKENING WELDING HELMETS

This Page Intentionally Blank

Safety Instruction 1-10 Manual 89210111

AUTO-DARKENING WELDING HELMETS

1.04 DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

SAFETY INSTRUCTION

Manufacturer and Merchandiser of Quality Consumables and Equipment: Tweco

Address: Victor Technologies Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire,

England PR6 7BX

This model certified by: Colts Laboratories

702 Stephens Avenue

Oldsmar, FL 34677

Description of equipment: Tweco Auto-Darkening Welding Helmet and associated accessories.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements.

Among them are:

• EN 175: 1997 applicable to Personal Protection Equipment for eye and face protection during welding and allied processes

• EN379: 2009-07 applicable to Specification for welding filters with switchable luminous transmittance and welding filters with dual luminous transmittance (variable shade)

• ANSI/ISEA Z87.1-2010 applicable to Practice for Occupational and Educational Eye and

Face Protection – Section 10 Welding Helmets

• CAN/ CSA Z94.3 Eye and Face Protectors 7th Edition.

• Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Tweco has been manufacturing and merchandising an extensive equipment range with superior performance, ultra safe operation and world class quality for more than 30 years and will continue to achieve excellence.

Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative:

Steve Ward

Operations Director

Victor Technologies Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire,

England PR6 7BX

Manual 89210111 1-11 Safety Instruction

This Page Intentionally Blank

AUTO-DARKENING WELDING HELMETS

SECTION 2:

INTRODUCTION

INSTALLATION

2.01 HOW TO USE THIS MANUAL

This Safety and Operating Instruction Manual applies to just specification or part numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapters on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

!

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Tweco at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Tweco web site listed below and clicking on the Literature Library link: http://www.tweco.com

2.02 EQUIPMENT IDENTIFICATION

The product identification number is printed on the outer shipping carton. Record this number on page i for future reference.

2.03 RECEIPT OF EQUIPMENT

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Manual 89210111 2-1 Installation

INSTALLATION AUTO-DARKENING WELDING HELMETS

Include all equipment identification numbers as described above along with a full description of the parts in error.

2.04 DESCRIPTION: AUTO-DARKENING WELDING HELMET

The Tweco Auto-Darkening Welding Helmet is an ultra modern product manufactured specifically for welding comfort, versatility, performance and fume deflection. To ensure your complete satisfaction with your new Auto-Darkening Welding Helmet and to realize a safer work environment, we ask that you read the following Operating Manual thoroughly before use.

2.05 USER RESPONSIBILITY

This product will perform as per the information contained herein when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately.

Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Tweco. Advice in this regard can be obtained by contacting an accredited Tweco Distributor.

This product or any of its parts should not be altered from standard specification without prior written approval of Tweco. The user of this product shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specification, faulty maintenance, damage or improper repair by anyone other than appropriately qualified persons approved by Tweco.

2.06 PERSONAL PROTECTION

!

WARNING

Prior to welding check operation of the filter lens, if the lens does not darken DO NOT COMMENCE

WELDING. If during welding the filter does not darken IMMEDIATELY STOP WELDING.

The radiation from an electric arc during the welding process can seriously harm eyes and skin. It is essential that the following precautions be taken:

When electric arc welding, it is a requirement to use a welding helmet or welding handshield that complies to a relevant standard. Protective filter lenses are provided to reduce the intensity of radiation entering the eye thus filtering out harmful infra-red, ultraviolet radiation and a percentage of the visible light. Such filter lenses are incorporated into this Welding Helmet. To prevent damage to the filter lenses from molten or hard particles an additional hard clear glass or special plastic external cover lens is provided.

This cover lens should always be kept in place and replaced before the damage impairs your vision while welding.

Installation 2-2 Manual 89210111

AUTO-DARKENING WELDING HELMETS INSTALLATION

It is important to ensure that the helmet is adjusted to the correct shade level prior to the commencement of welding. The table below can be used as a guide to select the filter lens shade level for differing applications.

Welding Process Arc Current in Amps

Manual Metal Arc Welding (Stick)

Gas Metal Arc Welding (Mig) with Heavy Metals Less than 125

125 − 175

175 − 250

250 − 350

350 − 450

Gas Metal Arc Welding (Mig) with Light Alloys Less than 175

175 − 225

225 − 300

300 − 400

Gas Tungsten Arc Welding (Tig) 30 − 70

70 − 125

125 − 200

200 − 300

300 − 350

Air – Arc Gouging

60 − 100

100 − 150

150 − 200

200 − 300

300 − 450

Plasma Arc Cutting

Less than 175

175 − 200

200 − 250

250 − 350

Less than 125

125 − 150

150 − 175

175 − 250

250 − 400

Plasma Arc Welding 100 − 125

125 − 175

175 − 225

R e c o m m e n d e d

Shade

#9

#10

#11

#12

#13

#9

#10

#10

#12

#13

#10

#11

#12

#13

#9

#10

#11

#12

#13

#10

#11

#12

#13

#9

#10

#11

#12

#13

#9

#10

#11

Note: The term “Heavy Metals” applies to steels, alloy steels, copper and its alloys, etc.

Refer to standard EN 379:2009-07 for comprehensive information regarding Table 1.

!

WARNING

For machine disc cutting, scaling, grinding and machining of metals and the like, additional eyeshields or faceshields with appropriate impact rating should be used. Refer to AS/NZS1336 for full details of the appropriate protection for industrial applications.

Manual 89210111 2-3 Installation

INSTALLATION AUTO-DARKENING WELDING HELMETS

!

WARNING

The indicated filter lens shade numbers are minimum. If any discomfort is felt, higher shade numbers should be selected.

Recognized standards for recommended practices for occupational eye protection include

AS/NZS 1336 and EN 175.

Gloves should be flameproof gauntlet type to protect hands and wrists from heat burns and harmful radiations. They should be kept dry and in good repair.

Protective clothing must protect the operator from burns, spatter and harmful radiation.

Wool clothing is preferable to cotton because of its greater flame resistance. Clothing should be free from oil or grease. Wear leggings and spats to protect the lower portion of the legs and to prevent slag and molten metal from falling into boots or shoes.

Installation 2-4 Manual 89210111

AUTO-DARKENING WELDING HELMETS

2.07 SPECIFICATIONS

INSTALLATION

Optical Class

Viewing Area

Cartridge Size

Arc Sensor

Light State

Grind State

Cutting Shade

Welding Shade

Shade Control

Power On/Off

Sensitivity Control

UV/IR Protection

Power Supply

Switching Time

Oxyfuel Gas Welding

Oxygen Cutting

Grinding

Delay (Dark to Light)

L o w A m p e r a g e T I G

Rated

Operating Temp

Storing Temp

Helmet Material

Total Weight

Application Range

Approved

Technical Specifications

1 / 1 / 1 / 2

97x62mm (3.82" x 2.44")

133x114x9mm (5.24"x4.50"x0.35")

4

DIN 4

DIN 4

Shade no. from 5 to 8

Shade no. from 9 to 13

Internal, Variable Shade, Digital Display Control

Manual-on / off, Auto-off

Low - High, Digital Display Control

Up to Shade DIN16 at all times

Solar cell. Battery replaceable

2 x CR2450 lithium battery

1/25,000 s. from Light to Dark

Yes

Yes

Yes

0.1 ~ 1.0s Digital Display Control

> 2 amps (DC); > 2 amps (AC)

-10 o

C ~ +55 o

C (14 o

F ~ 131 o

F)

-20 o C ~ +70 o C (-4 o F ~ 158 o F)

High Impact Resistance Nylon

500g

Stick Welding (SMAW); TIG DC∾ TIG Pulse DC; TIG

Pulse AC; MIG/MAG/CO2; MIG/MAG Pulse; Plasma Arc

Cutting (PAC); Plasma Arc Welding (PAW); Air Carbon

Arc Cutting (CAC-A); Oxyfuel Gas Welding (OFW); Oxygen

Cutting (OC); Grinding

DIN plus, CE, ANSI Z87.1, CSA Z94.3, AS/NZS 1338.1

NOTE

Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities, measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and operation will depend upon correct installation, use, applications, maintenance and service.

Manual 89210111 2-5 Installation

INSTALLATION

2.08 PARTS LIST AND ASSEMBLY

AUTO-DARKENING WELDING HELMETS

A B C D E F

1

6

5

4

7

8

9

10

11

2

3 4

5 6

12

Part List

ITEM

A

F

G*

D

E

B

C

Part List of G*

9

10

7

8

11

12

5

6

3

4

ITEM

1

2

DESCRIPTION

Shell (Welding Mask)

Rubber Frame

Front Cover Lens

Auto-Darkening Filer (Including Batteries)

Inside Cover Lens

Lens Holder

Headgear Assembly (Including Sweatband)

DESCRIPTION

Sweatband

Washer

Washer

Fixed Washer

Rubber Washer

Block Nut

Angle Limitation Washer

Gear Washer

Right Boot Screw

Left Boot Screw

Adjustable headband

Front Headgear

G

1

1

1

1

1

1

2

2

1

2

QTY

1

1

QTY

1

1

1

1

1

1

1

Installation 2-6 Manual 89210111

AUTO-DARKENING WELDING HELMETS

SECTION 3:

INSTALLATION

3.01 HARNESS ADJUSTMENT

INSTALLATION

!

WARNING

Before using the helmet for welding, ensure that you have read and understood the safety instructions.

The helmet comes ready assembled, but before it can be used it must be adjusted to fit the user properly and set up for delay time, sensitivity and shade level.

A.

Adjusting the fit of the helmet: The overall circumference of the headband can be made larger or smaller by rotating the knob on the back of

TOP the headband (See adjustment "Y" in figure 1). This can be done whilst wearing the helmet and allows the right tension to be set to keep the helmet firmly on the head without it being too tight.

‘T’

‘T’

‘W’

B. If the headband is riding too high or too low on your head, adjust the strap which passed over the top of your head. To do this release the end of the band by pushing the locking pin out of the hole in the band. Slide the two portions of the band to a greater or lesser width as required and push the locking pin through the nearest hole (see adjustment "W" in figure 1)

‘Y’

Figure1

Test the fit of the headband by lifting up and closing down the helmet a few times while wearing it. If the headband moves while tilting, re-adjust it until it is stable.

C.

Adjusting the distance between the helmet and the face:

1. Undo the block nut (See "T" in figure 1) to adjust the distance between the helmet and your face in the down position.

TiltAdjustment

2. Re-tighten the block nut when adjustment is complete.

D. Adjusting view angle position tilt: Tilt adjustment is located on right side of helmet. Loosen the right headgear tension knob and push the top end of the adjustment lever outward until the lever's Stop Tab clear the notches. Then

Fore-Aft

Adjustment rotate the lever forward or back to the desired tilt position.

The Stop will automatically engage again when released locking the helmet into position (see figure 2).

Figure 2

Manual 89210111 3-1 Installation

INSTALLATION AUTO-DARKENING WELDING HELMETS

3.02 CHANGING OF FRONT COVER LENS

Replace Front Cover Lens

Remove lens cassette by moving locks toward center (see Figure 8) and lift up the lens cassette to remove/replace the front lens cover.

Replace Inside Clear Lens

Replace the inside clear lens if it is damaged. Place your fingernail in recess below cartridge view window and flex lens upwards until it releases from edges of cartridge view window.

Change the Shade Cartridge

Remove ADF holder assembly from helmet shell (see Figure 8 for removal). Flex top end of the ADF holder to allow for ADF cartridge to be removed from frame. Install new ADF cartridge into frame per Figure 9 below. Make sure that the ADF cartridge is inserted in

ADF holder correctly as shown. Install ADF holder assembly into helmet shell.

Figure 8

3.03 DIGITAL OPERATION GUIDE

Figure 9

On-Off

The helmet is auto on after you move it, the digital display control will be activated and the helmet will be ready for use. It is recommended that the user review helmet settings prior to use.

Sensitivity level setting >9: The welding helmet will automatically off after half an hour not being used.

Sensitivity level setting =10: The helmet will always in dark state, and will NOT automatically turn off. Please turn it off manually by long press "MODE" button.

Mode Control

Short Press MODE button to select the mode appropriate for the work activity (see Figure

3-A):

Weld Mode - used for most welding applications. Push "FUNC" button to adjust shade number, sensitivity, and delay settings properly before cutting (see Figure 3-C). In this mode the lens turns to dark immediately when you start welding.

Cutting Mode - used for cutting applications. Push "FUNC" button to adjust shade number, sensitivity, and delay settings properly before cutting (see Figure 3-C). In this mode the lens turns to dark immediately when you start cutting (see Figure 3-C).

Installation 3-2 Manual 89210111

AUTO-DARKENING WELDING HELMETS INSTALLATION

Grind Mode - used for grinding applications. In this mode the lens shade is fixed shade

No. 4 . Cannot adjust shade number, sensitivity and delay settings (see Figure 3-C)

B

A

Figure 4

C

Figure 3

Battery Indicator

The symbol " " shows the current state of the battery (see Figure 3-B). The volume of batteries has four levels symbol to appear (see Figure 4). The symbol " " appears on the display screen before 1-2 days of battery life remains, CR2450 lithium batteries should be replaced in time. The symbol of The Battery Indicator is not real-time, and should be updated after pressing "MODE" button shortly.

Variable Shade Control

After turning on the lens, short press "FUNC" button to choose "SHADE", and adjust lens shade number (see Figure 5a, 5b, 5c-A/B). Use the shade control "UP" and "DOWN" buttons to select the lens shade in the dark state (see Figure 5a, 5b, 5c-C/D). The shade range for each mode are as follows:

Weld Mode - No. 9 ~ No. 13 (see Figure 5a)

C

A

B

Figure 5a

D

Cutting Mode - No. 5 ~ No. 8 (see Figure 5b)

C

A

B

Figure 5b

D

Manual 89210111 3-3 Installation

INSTALLATION

Grind Mode - No. 4 only (see Figure 5c)

C

AUTO-DARKENING WELDING HELMETS

A

B

Figure 5c

D

Select the proper shade number for your welding/cutting process by referring to the

"Shade Guide Table" below.

Sensitivity Control

Short press "FUNC" button to choose :SENSI" (see Figure 6a, 6b-A/B).

Use Sensitivity Control "UP" and "DOWN" buttons to make the lens more or less sensitive to arc light of different welding processes (see Figure 6a, 6b-C/D). Sensitivity setting 5-10 is the normal setting for everyday use. The sensitivity ranges for each mode are as follows:

Weld Mode - No. 0 ~ No. 10 (see Figure 6a)

C

A

B

D

Figure 6a

Cutting Mode - No. 0 ~ No. 10 (see Figure 6b)

C

A

B

Figure 6b

Grind Mode - No sensitivity adjustment

D

As a simple rule for optimum performance, it is recommended to set sensitivity to the maximum at the beginning and then gradually reduce it, until the filter reacts only to the welding light flash and without annoying spurious triggering due to ambient light conditions (direct sun, intensive artificial light, neighboring welder's arcs, etc.).

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.

Installation 3-4 Manual 89210111

AUTO-DARKENING WELDING HELMETS INSTALLATION

• Press Sensitivity "DOWN" button to lower setting to 0.

• Face the helmet in the direction of use, exposing it to the surrounding light conditions.

• Press Sensitivity "UP" button repeatedly until the lens darkens, then press "DOWN" button until lens clears. Helmet is ready for use. Slight readjustment may be necessary for certain applications or if lens is flashing on and off.

• When sensitivity is set to Level 10, the filter will be darkening all the time to meet some specialty welding application under both WELD MODE and CUTTING MODE.

With this setting, the welding helmet will Not automatically turn off after half an hour of not being used.

Delay Control

Press "FUNC" button to choose "DELAY", begin lens delay adjustments (see Figure 7a,

7b-A/B). Use the Lens Delay Control "UP" and "DOWN" buttons to adjust the time for the lens to switch to the clear state after welding or cutting (see Figure 7a, 7b-C/D).

Weld Mode - No. 0 ~ No. 10 (see Figure 7a)

C

A

B D

Figure 7a

Cutting Mode - No. 0 ~ No. 10 (see Figure 7b)

C

A

B

Figure 7b

Grind Mode - No delay adjustment

D

The delay is particularly useful in eliminating bright after-rays present in higher amperage applications where the molten puddle remains bright momentarily after welding. Use the Lens Delay Control buttons to adjust delay from 0 to 10 (0.1 to 1.0 second). When welding stops, the viewing window automatically changes from dark black to light but with a pre-set delay to compensate for any bright afterglow on the workpiece. The delay time/ response can be set from Level 0 to Level 10. It is recommended to use a shorter delay with spot welding applications and a long delay with applications using higher currents.

Longer delays can also be used for lower current TIG welding and TIG / MIG / MAG pulse.

You are now ready to use the helmet. The shade number, sensitivity and delay time need to be adjusted during use according to different welding processes.

Manual 89210111 3-5 Installation

INSTALLATION AUTO-DARKENING WELDING HELMETS

OPERATION

Shielded metal arc welding

Gas metal arc welding and flux cored arc welding

SHADE GUIDE TABLE

GUIDE FOR SHADE NUMBERS

ELECTRODE SIZE

1/32 in. (mm)

ARC

CURRENT (A)

MINIMUM

PROTECTIVE

SHADE

SUGGESTED

(1)

SHADE NO.

(COMFORT)

Less than 3 (2.5)

3-5 (2.5-4)

5-8 (4-6.4)

More than 8 (6.4)

Less than 60

60 -160

160-250

250-550

Less than 60

60 -160

160-250

250-500

7

8

10

11

7

10

10

10

---

10

12

14

---

11

12

14

Gas tungsten arc welding

Air carbon

Air cutting

Plasma arc welding

(Light)

(Heavy)

Less than 50

50-150

150-500

Less than 500

500-1000

Less than 20

20-100

100-400

400-800

Plasma arc cutting (Light)

(2)

(Medium)

(2)

(Heavy)

(2)

Less than 300

300-400

400-800

8

8

10

10

11

6

8

10

11

8

9

10

10

12

14

12

14

6 to 8

10

12

14

8

12

14

Torch brazing

Torch soldering

Carbon arc welding

---

---

---

PLATE THICKNESS in.

Under 1/8

1/8 to 1/2

Over 1/2

mm.

Under 3.2

3.2 to 12.7

Over 12.7

---

---

---

3 to 4

2

14

Gas welding

Light

Medium

Heavy

Oxygen cutting

Light

Medium

Heavy

Under 1

1 to 6

Over 6

Under 25

25 to 150

Over 150

4 or 5

5 or 6

6 or 8

3 or 4

4 or 5

5 or 6

(1)

As a rule of thumb, start with a shade that is too dark, then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding or cutting where the torch produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line the visibule light of the (spectrum) operation.

(2)

These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.

Data from ANSI Z49.1-2005

Installation 3-6 Manual 89210111

AUTO-DARKENING WELDING HELMETS

SECTION 4:

SERVICE

INSTALLATION

4.01 ROUTINE MAINTENANCE & INSPECTION

This equipment must be checked periodically. Defective equipment should not be used.

Parts that are broken, missing, plainly worn, distorted or contaminated, should be replaced immediately. Should such repairs or replacements become necessary, it is recommended that such repairs be carried out by appropriately qualified persons approved by Tweco.

Advice in this regard can be obtained by contacting an accredited Tweco Distributor.

Notes:

• Inspect lenses frequently. Immediately replace any scratched, cracked, or pitted lenses as they may impair visibility and reduce protection.

• Inspect Helmet Shell and Harness Assembly frequently. Immediately replace any damaged or worn components.

4.02 CLEANING THE AUTO-DARKENING WELDING HELMET

!

WARNING

When cleaning the Welding Helmet or Filter Lens do not use solvents or abrasive cleaning agents.

In order to ensure the continued safe and reliable operation of your Auto-Darkening

Welding Helmet it should be cleaned with a soft cloth after use.

Note:

• Keep the Sensors and the Solar Cell clean at all times.

Manual 89210111 4-1 Installation

INSTALLATION

4.03 BASIC TROUBLESHOOTING

AUTO-DARKENING WELDING HELMETS

FAULT

1. The Filter Lens does not operate.

2. The Filter Lens flickers or does not darken.

3. Filter Lens stays dark after the weld is extinguished or the Filter Lens is dark when no arc is present.

CAUSE

A. The Internal Battery is discharged.

B. Filter Lens is faulty.

A. Front Cover Lens is dirty or damaged.

B. Sensors are obstructed.

A. Sensors are obstructed.

B. Sensitivity and or

Delay Switch not set correctly.

C. Ambient light level is too bright.

REMEDY

A. Check battery and verify they are in good condition and installed properly. Check battery surfaces and contacts and clean if necessary..

B. Replace the Filter Lens.

A. Clean Cover Lens with a soft cloth. Replace if necessary.

B. Clean the Sensors with a soft cloth.

A. Clean the Sensors with a soft cloth.

B. Adjust the Sensitivity and or Delay Switch accordingly.

C. Reduce the ambient light level in the area.

4. The center of the Filter

Lens viewing area appears darker than the sides of the Filter

Lens viewing area.

A. This is a normal characteristic of the LCD Lens.

A. Keep the viewing angle from the object being welded as close as possible to 90°.

5. Irregular darkening dimming.

A. Headband has been set unevenly and there is an uneven distance from the eyes to the filter lens.

A. Reset the headband to reduce the difference to the filter.

!

WARNING

When cleaning the Welding Helmet or Filter Lens,

DO NOT use solvents or abrasive cleaning agents. In order to ensure the continued safe and reliable operation of your Auto-Darkening Welding Helmet, clean with a soft, clean lint-free cloth after use.

Installation 4-2 Manual 89210111

LIMITED WARRANTY

This information applies to Tweco products that were purchased in the USA.

LIMITED WARRANTY: VICTOR TECHNOLOGIES INC

®

warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the VICTOR TECHNOLOGIES INC products as stated below, VICTOR

TECHNOLOGIES INC shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with VICTOR TECHNOLOGIES INC’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at VICTOR TECHNOLOGIES INC’s sole option, of any components or parts of the product determined by VICTOR TECHNOLOGIES INC to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE.

LIMITATION OF LIABILITY: VICTOR TECHNOLOGIES INC shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter the “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of VICTOR

TECHNOLOGIES INC with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by VICTOR TECHNOLOGIES INC whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED

WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY VICTOR TECHNOLOGIES PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

This warranty is effective for the time stated in the Warranty Schedule beginning on the date that the authorized distributor delivers the products to the Purchaser.

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized VICTOR TECHNOLOGIES INC repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous

VICTOR TECHNOLOGIES INC warranties related to this product.

No employee, agent, or representative of Tweco is authorized to change this warranty in any way or grant any other warranty, and Tweco shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of Tweco’s obligations to purchaser with respect to the product.

This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in Tweco’s sole judgment, impaired the safety or performance of any Tweco product. Purchaser’s rights under this warranty are void if the product is sold to purchaser by unauthorized persons.

THE AMERICAS

Denton, TX USA

U.S. Customer Care

Ph 1-800-426-1888 (tollfree)

Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph 1-940-381-1212

Fax: 1-940-483-8178

Miami, FL USA

Sales Office, Latin America

Ph 1-954-727-8371

Fax: 1-954-727-8376

Oakville, Ontario, Canada

Canada Customer Care

Ph 1-905-827-4515

Fax: 1-800-588-1714 (tollfree)

EUROPE

Chorley, United Kingdom

Customer Care

Ph +44 1257-261755

Fax: +44 1257-224800

Milan, Italy

Customer Care

Ph +39 0236546801

Fax: +39 0236546840

ASIA/PACIFIC

Cikarang, Indonesia

Customer Care

Ph 6221-8990-6095

Fax: 6221-8990-6096

Rawang, Malaysia

Customer Care

Ph +603 6092-2988

Fax: +603 6092-1085

Melbourne, Australia

Australia Customer Care

Ph 1300-654-674 (tollfree)

Ph 61-3-9474-7400

Fax: 61-3-9474-7391

International

Ph 61-3-9474-7508

Fax: 61-3-9474-7488

Shanghai, China

Sales Office

Ph +86 21-64072626

Fax: +86 21-64483032

Singapore

Sales Office

Ph +65 6832-8066

Fax: +65 6763-5812

I N N O V A T I O N T O S H A P E T H E W O R L D ™

U.S. Customer Care: 800-426-1888 / FAX 800-535-0557

Canada Customer Care: 905-827-4515 / FAX 800-588-1714

International Customer Care: 940-381-1212 / FAX 940-483-8178

© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in China

Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project