ESAB Variable Shade 9-13 Auto-Darkening Welding Helmets User manual

ESAB Variable Shade 9-13 Auto-Darkening Welding Helmets User manual

VARIAbLE SHADE 9-13

AUTO-DARKENING

WELDING HELMETS

English

Revision: D

SAFETY AND OPERATING

INSTRUCTIONS

Issue Date: August 20, 2013

Manual No: 89210001

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Tweco

®

product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 800-426-1888, or visit us on the web at www.tweco.

com.

This Manual has been designed to instruct you on the correct installation and use of your Tweco

®

product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore, please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Tweco

®

is a Global Brand of Welding Products for Victor Technologies Inc.

We manufacture and supply to major welding industry sectors worldwide, including: Manufacturing, Construction, Mining, Automotive, Aerospace,

Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

WARNINGS

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 89210001

Published by:

Victor Technologies Inc.

2800 Airport Rd.

Denton, TX. 76207

(940) 566-2000 www.tweco.com

U.S. Customer Care: (800) 426-1888

International Customer Care: (905) 827-9777

Copyright © 2013 Victor Technologies 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: February 28, 2010

Revision D Date: August 20, 2013

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

SectIoN 2: INtRoDuctIoN ................................................................................. 2-10

2.01 How to use this Manual .................................................. 2-10

2.02 Equipment Identification ................................................ 2-10

2.03 Receipt of Equipment ..................................................... 2-10

2.04 Description: Auto-Darkening Welding Helmet ................ 2-11

2.05 User Responsibility ........................................................ 2-11

2.06 Personal Protection ........................................................ 2-11

2.07 Specifications ................................................................. 2-13

2.08 Contents ......................................................................... 2-13

SectIoN 3: opeRatIoN ....................................................................................... 3-14

3.01 Harness Adjustment ....................................................... 3-14

3.02 Changing the Front Cover Lens ...................................... 3-15

3.03 Auto-Darkening Filter Lens Controls .............................. 3-17

SectIoN 4: SeRvIce ............................................................................................ 4-18

4.01 Routine Maintenance & Inspection ................................. 4-18

4.02 Cleaning the Auto-Darkening Welding Helmet ................ 4-18

4.03 Basic Troubleshooting .................................................... 4-19

4.04 Spare Parts ..................................................................... 4-20

lIMIteD waRRaNty global cuStoMeR SeRvIce coNtact INfoRMatIoN

AUTO-DARKENING WELDING HELMETS

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.

89210001

1-1 Safety Instructions

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 Instructions 1-2 89210001

AUTO-DARKENING WELDING HELMETS

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.

89210001

1-3 Safety Instructions

AUTO-DARKENING WELDING HELMETS

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

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

Light Under 1 in., 25 mm

Medium 1 to 6 in., 25-150 mm

Gas welding

Heavy

Light

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

Heavy

Shielded metal-arc welding

(stick) electrodes

Eye protection fi lter shade selector for welding or cutting

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

Electrode Size

Metal Thickness

Over 6 in., 150 mm

Under 1/8 in., 3 mm

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 Instructions 1-4 89210001

AUTO-DARKENING WELDING HELMETS

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.

ENGINE FUEL can cause fire or explosion.

WARNING

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

89210001

1-5 Safety Instructions

AUTO-DARKENING WELDING HELMETS

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.

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

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

Safety Instructions 1-6 89210001

AUTO-DARKENING WELDING HELMETS

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.

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

1-7 Safety Instructions

89210001

AUTO-DARKENING WELDING HELMETS

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 Instructions 1-8 89210001

AUTO-DARKENING WELDING HELMETS

1.03 SyMbol cHaRt

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

On

Off

Dangerous Voltage

Increase/Decrease

Single Phase

Three Phase

Three Phase Static

Frequency Converter-

Transformer-Rectifier

Remote

Wire Feed Function

Wire Feed Towards

Workpiece With

Output Voltage Off.

Welding Gun

Circuit Breaker

AC Auxiliary Power

X

%

Duty Cycle

Percentage

Purging Of Gas

Continuous Weld

Mode

Spot Weld Mode

Fuse

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Panel/Local

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.

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

Arc Force

IPM

Inches Per Minute

MPM

Meters Per Minute

Line Connection Touch Start (GTAW)

Auxiliary Power

115V 15A

Receptacle Rating-

Auxiliary Power

Variable Inductance

V

Voltage Input

Art # A-04130

89210001

1-9 Safety Instructions

This Page Intentionally Blank

AUTO-DARKENING WELDING HELMETS

SectIoN 2:

INtRoDuctIoN

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.

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

89210001

2-11

Introduction

AUTO-DARKENING WELDING HELMETS

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 realise 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 unauthorised 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, ultra-violet 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.

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.

Introduction 2-12 89210001

AUTO-DARKENING WELDING HELMETS

Welding Process

Manual Metal Arc Welding (Stick)

Air – Arc Gouging

Arc Current in Amps Recommended Shade

60 − 100

100 − 150

150 − 200

200 − 300

300 − 450

#9

#10

#11

#12

#13

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

#9

#10

#10

#12

#13

#10

#11

#12

#13

#9

#10

#11

#12

#13

#10

#11

#12

Plasma Arc Cutting

Plasma Arc Welding

Less than 175

175 − 200

200 − 250

250 − 350

Less than 125

125 − 150

150 − 175

175 − 250

250 − 400

100 − 125

125 − 175

175 − 225

#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.

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.

89210001

2-13

Introduction

AUTO-DARKENING WELDING HELMETS

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.

2.07 SpecIfIcatIoNS

Description

(Refer Note)

Auto-Darkening Lens

Note: Auto-Darkening Lens is fitted to

the Tweco Auto-Darkening Welding Helmet Product

Part Numbers: WHF41001, WHE41002, WHS41004,

WHDR41008.

Filter Lens Dimensions

Viewing Area Dimensions

Reaction Time

Sensors

Power Supply

Inactivated Shade and Grinding Level

Variable Shade Level

Operating Temperature

Storing Temperature

Sensitivity Range (Light to Dark)

Delay (Dark to Light)

On/Off Control

Weight

auto-Darkening filter lens

WH41001ADF

110mm x 90mm x 9mm

98mm x 43mm

1/30,000 second

4 Optical Sensors

Solar Cells

4

9 - 13

-5

0

-20

0

C to +55

C to+ 70

0

C

0

C

Low - High

0.25 sec to 0.80 sec

Automatic

450g

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.

2.08 coNteNtS of welDINg HelMet

Description

Auto-Darkening Welding Helmet

Front Cover Lens

Rear Cover Lens

Operating Manual

Quantity

1

Introduction 2-14 89210001

AUTO-DARKENING WELDING HELMETS

SectIoN 3:

INStallatIoN

3.01 HaRNeSS aDJuStMeNt

Prior to use, the Welding Helmet must be adjusted for maximum comfort and protection. The Helmet should be adjusted such that it is effectively positioned over the eyes and face to ensure adequate protection and comfort while welding. Please refer to the Harness adjustment instructions below.

1. top Head band

To adjust the top of Head Band move the Head Band in the direction of either arrow to align the center of the harness with center of the Filter Lens viewing window.

2. back of Head band

To adjust the back of Head Band push down the Knob and turn to the left or right to adjust to size.

3. Distance of Harness from filter lens

There are 3 positions possible that the Harness can be set to achieve the desired distance between the welders eyes and the Filter Lens.

4. Incline angle adjustment

There are 3 positions available for adjusting the angle from the welders eyes to the Filter lens.

5. Helmet tilt position

The Helmet is designed to be tilted and fixed into position whilst not welding. Loosen the adjustment knobs located on either side of the helmet, once in desired position tighten adjustment knobs to fix into place.

6. Hard hat attachment

Remove the head gear and install the hard hat attachment.

89210001

3-15

Installation

AUTO-DARKENING WELDING HELMETS

3.02 cHaNgINg of fRoNt coveR leNS

WARNING

Do Not Use the Welding Helmet without the Front Cover Lens installed correctly in place.

If the Front Cover Lens is broken, plainly worn, distorted or contaminated it should be replaced immediately with a genuine Tweco replacement part.

1. Removing the front cover lens

Remove the Front Cover Lens by pulling up the central part of the lens and sliding one side at a time from under the tabs.

2. Installing the front cover lens

Align the Front Cover Lens and place under the tabs on one side that secure the Front Cover

Lens in place.

Pull up the Front Cover Lens in the center and repeat for the other side.

Ensure that the Front Cover Lens is securely in place before use.

• Use only at temperatures: - 5

O

C to + 55 o

C (23

O

F to 131

O

F).

• Storing temperature: - 20

O

C to + 70

O

C (-4

O

F to 158

O

F).

• Protect filter

from contacting with liquid and dirt.

• Clean filters' surfaces regularly; do not use strong cleaning solutions. Always keep sensors and solar cells clean using a clean lint-free tissue/cloth.

• Regularly replace the cracked/scratched/pitted front cover lens.

Severe personal injury could occur If the user fails to follow the aforementioned warnings, and/or fails to follow the operating Instructions.

COMMON PROBLEMS AND REMEDY

* Irregular Darkening Dimming

• Headband has been set unevenly and there is an uneven distance from the eyes to the filter's lens (Reset headband to reduce the difference to filter).

** Auto-Darkening Filter Does Not Darken Or Flickers

• Front cover lens is soiled or damaged (change lens cover)

• Sensors are soiled (clean the sensors' surface)

• Welding current is too low (turns the switch to the "Long" position).

*** Slow response

• Operating temperature is too low (do not use at temperatures below - 5

O

C or 23

O

F).

**** Poor Vision

• Front/inside cover lens and/or filter lens are soiled (change lens)

• There is insufficient ambient light

Installation

3-16 89210001

AUTO-DARKENING WELDING HELMETS

• Shade number is incorrectly set (reset the shade number)

***** Welding Helmet Slips

• Headband is not adjusted properly (readjust headband)

WARNING ! Operator must stop using the auto - darkening filter welding helmet immediately if the above-mentioned problems cannot be corrected. Contact the dealer.

WARNING! Materials which may come into contact with the wearers skin can cause allergic reactions in some circumstances.

LENS & HELMET MAINTENANCE

Figure 3-1 Changing of front cover lens

• Replacing the front cover lens if it is damaged (cracked, scratched, soiled or pitted)

Step 1: Remove the front cover lens by pulling up the central part of the lens (figure).

Place the new cover lens into the correct position.

Step 2: Check and make sure that the frame is securely installed.

• Replacing the inside cover lens if it is damaged (cracked, scratched, soiled or pitted).

• Cleaning The Filter's Lens with a clean lint-free tissue or cotton cloth.

• Don't immerse the lens in water or any other liquid. Never use abrasives, solvents or oil based cleaners.

• Don't remove the auto-darkening filter from the helmet. Never try to open the filter.

TECHNICAL SPECIFICATIONS

• Viewing Area: 98 x 43 mm ( 3.86" x 1.69"), two or four optical sensors

• Size of Cartridge: 110 x 90 x 9mm (4.33" x 3.54" x 0.35")

• UV/IR Protection: Up To Shade DIN16 at all time

• Light State: Shade DIN 4

• Variable Shade: From DlN 9 to DlN 13

• Power Supply: Solar cells, with built in replaceable battery.

• Power On/Off: Fully Automatic

• Sensitivity: Outside Can be adjusted.

• Function: "WELDING"/"GRINDING" can be selective.

89210001

3-17

Installation

AUTO-DARKENING WELDING HELMETS

• Switching Time: a) b)

Light to Dark: 1/30000 s (0.000033 sec). (-5

O

C, 0.0008 sec).

Dark to Light: 0.25- 0.8 s (short -middle- long).

• Operating Temperature: -5

O

C to+55

O

C (23

O

F to 131

O

F)

• Storing Temperature: -20

O

C to +70

O

C (-4

O

F to 158

O

F)

3.03 auto-DaRKeNINg fIlteR leNS coNtRolS

VARIABLE SHADE 9-13 AUTO-DARKENING FILTER LENS CONTROLS

Long

Middle

Short

Delay time

Welding

Wa rning: Additiona l e ye & fa c e p rote c tion re c om m e nd e d whe n grinding

Mode

Grinding

1

2

3

Operating Instructions

4

Figure 3-2 Variable Shade 9-13 Auto-Darkening Filter Lens Controls

1. Mode Switch:

2. Delay Switch:

The Mode Switch is used to change the Filter Lens between Welding and Grinding modes. Note that additional eye and face protection is recommended when Grinding.

The Delay Switch is used to adjust the hold time of the Filter lens after welding is completed. Manually adjust Delay time to desired level as required for application.

3. Sensitivity Control:

The Sensitivity Control is used to make the Filter Lens more responsive to different light levels. Manually adjust the sensitivity level as required for the application.

4. Va r i a b l e S h a d e

Control:

The Variable Shade Control is used to adjust the Shade level between

9-13. Manually adjust shade to desired level as required for the application.

Installation

3-18 89210001

AUTO-DARKENING WELDING HELMETS

SectIoN 4:

SeRvIce

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.

89210001

4-19

Service

AUTO-DARKENING WELDING HELMETS

4.03 baSIc tRoubleSHootINg

fault cauSe

1. The Filter Lens does not operate.

2. The Filter Lens flickers or does not darken.

A. The Internal Battery is discharged.

B. Filter Lens is faulty.

A. Front Cover Lens is dirty or damaged.

B. Sensors are obstructed.

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

A. Sensors are obstructed.

B. Sensitivity and or Delay

Switch not set correctly.

C. Ambient light level is too bright.

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.

ReMeDy

A. The Internal Battery is not replaceable. Do not attempt to open the filter lens. Replace.

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.

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

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.

Service

4-20 89210001

AUTO-DARKENING WELDING HELMETS

4.04 SpaRe paRtS

Item

No.

1

2

3

4

5

6

7

NS

NS

Part No./

Stock No.

WH41001-FL

2089-1010

WH41001-IL4

2089-1026

WH41001-KB

2089-1013

WH41001-BN

1089-1017

WH41001-FF

2089-1018

WH41001-HB

2089-1020

WH41001-HG

2089-1023

WH41001-HH

2089-1024

WH41001-ML

2089-1025

Description

Front Cover Lens

Inside Cover Lens

Shade / Sensitivity knob

Headgear Knob

Filter Frame w/Screws

Headband

Headgear Assembly

Hard Hat Fixtures

Magnifying Lens Kit (2X Magnification)

Qty/Pkg

2

2

1

2

2

1

1

1

1

Figure 4-1 Spare Parts- Tweco welding helmet

89210001

4-21

Service

AUTO-DARKENING WELDING HELMETS

1. REMOVE THE STANDARD FILTER FRAME FROM INSIDE

OF HELMET BY REMOVING (4) SCREWS WITH PHILLIPS

HEAD SCREWDRIVER.

2. INSTALL MAGNIFYING LENS FROM THE BOTTOM INTO

THE RETAINING BRACKETS OF NEW FRAME WITH

FLAT SIDE FACING THE AUTO-DARKENING LENS.

3. INSALL NEW FRAME INSIDE HELMET USING (4) SCREWS

WITH PHILLIPS HEAD SCREWDRIVER.

4. LEAVE LENS IN DOWN POSITION FOR MAGNIFICATION, OR

SLIDE UP TO TOP POSITION WHEN NOT IN USE.

Figure 4-2 Installation of frame for magnifying lens

4-22 89210001

AUTO-DARKENING WELDING HELMETS

DeclaRatIoN of coNfoRMIty

Manufacturer and Merchandiser of Quality Consumables and Equipment: Tweco

Building

Chorley

Lancashire,

England

This model certified by:ECS GMBH

OBERE BAHNSTRAßE 74

GERMANY

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

89210001

4-23

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

lIMIteD waRRaNty

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 nonconformities, 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.

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This Page Intentionally Blank

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 Canada Customer Care: 905-827-4515

International Customer Care: 940-381-1212

©2013 Victor Technologies International, Inc.

www.victortechnologies.com

Printed in China

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