AUTO-DARKENING WELDING HELMET Operating Manual

AUTO-DARKENING WELDING HELMET Operating Manual
AUTO-DARKENING
WELDING HELMET
Art # A-08587
Operating Manual
Revision: AG
Date: May 26,2009 Manual No.: 0-5045
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc 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
1-800-752-7621, or visit us on the web at www.Thermalarc.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Arc 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.
Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne
Industries 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 marketleading, 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 best judgement,
the Manufacturer assumes no liability for its use.
Power-Master Inverter Welding Power Supply
Instruction Manual Number 0-5045 for:
Black USA Canada Claret Auto-Darkening Welding Helmet Auto-Darkening Welding Helmet Auto-Darkening Welding Helmet Auto-Darkening Welding Helmet Part Number W4012000
Part Number W4011700
Part Number W4011800
Part Number W4011900
Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright 2007, 2008 by
Thermadyne Industries 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:
Revision AG Date:
November 21, 2007
May 26, 2009
Record the following information for Warranty purposes:
Where Purchased:
_____________________________________
Purchase Date:
_____________________________________
Equipment Serial #:
_____________________________________
i
TABLE OF CONTENTS
SECTION 1:SAFETY INSTRUCTIONS AND WARNINGS.......................................................... 1
1.01
1.02
1.03
1.04
1.05
1.06
1.07
Arc Welding Hazards...................................................................................... 1
Principal Safety Standards............................................................................. 4
Symbol Chart.................................................................................................. 5
Precautions De Securite En Soudage A L’arc................................................ 6
Dangers relatifs au soudage à l’arc................................................................ 6
Principales Normes De Securite..................................................................... 9
Graphique de Symbole................................................................................. 10
SECTION 2:INTRODUCTION ..................................................................................................2-1
2.01
2.02
2.04
2.05
2.06
2.07
2.08
How To Use This Manual............................................................................2-1
Equipment Identification..............................................................................2-1
Description: Auto-Darkening Welding Helmet.............................................2-2
User Responsibility......................................................................................2-2
Personal Protection.....................................................................................2-3
Specifications...............................................................................................2-4
Contents......................................................................................................2-5
SECTION 3:OPERATION ........................................................................................................3-1
3.01
3.02
3.03
3.04
3.05
Harness Adjustment....................................................................................3-1
Auto-Darkening Filter Lens Controls............................................................3-2
Changing the Front Cover Lens...................................................................3-3
Removing the Auto-Darkening Filter Lens...................................................3-4
Changing the Rear Cover Lens...................................................................3-5
SECTION 4:SERVICE . ............................................................................................................4-1
4.01
4.02
4.03
4.04
Routine Maintenance & Inspection..............................................................4-1
Cleaning the Auto-Darkening Welding Helmet............................................4-1
Basic Troubleshooting.................................................................................4-2
Spare Parts..................................................................................................4-3
LIMITED WARRANTY.................................................................................................................. 6
WARRANTY SCHEDULE
Declaration Of Conformity
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
TABLE OF CONTENTS
SAFETY INSTRUCTIONS AUTO-DARKENING WELDING HELMET
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
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.
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.
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.
1. Do not touch live electrical parts.
WARNING
2. Wear dry, hole-free insulating gloves and body protection.
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.
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.
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.
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.
8. Do not use worn, damaged, undersized, or poorly spliced
cables.
1-
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AUTO-DARKENING WELDING HELMET
SAFETY INSTRUCTIONS
WARNING
WARNING
WELDING can cause fire or explosion.
FUMES AND GASES can be hazardous to your health.
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.
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.
1. Protect yourself and others from flying sparks and hot metal.
3. If ventilation is poor, use an approved air-supplied respirator.
2. Do not weld where flying sparks can strike flammable material.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
and cleaners.
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.
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.
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.
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.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or cutting
Operation
Electrode Size
Metal Thickness
Filter
Shade
Welding or cutting
Operation
Torch soldering
2
Gas metal-arc
welding (MIG)
Torch brazing
3 or 4
Non-ferrous base metal
All
11
Non-ferrous base metal
All
12
Gas tungsten arc welding
All
12
Oxygen Cutting
Light
Medium
Heavy
Under 1 in., 25 mm
3 or 4
1 to 6 in., 25-150 mm
4 or 5
(TIG)
All
12
Over 6 in., 150 mm
5 or 6
Atomic hydrogen welding
All
12
Carbon arc welding
All
12
Gas welding
Light
Under 1/8 in., 3 mm
4 or 5
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6
Heavy
Over 1/2 in., 12 mm
6 or 8
Shielded metal-arc
welding
(stick) electrodes
Under 5/32 in., 4 mm
10
Manual 0-5045
Electrode Size Filter
Metal
Shade
Plasma arc welding
Carbon arc air gouging
1-
Light
12
Heavy
14
SAFETY INSTRUCTIONS AUTO-DARKENING WELDING HELMET
WARNING
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
ENGINE FUEL can cause fire or explosion.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
Engine fuel is highly flammable.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
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.
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.
3. Keep cylinders away from any welding or other electrical
circuits.
2. Stop engine before installing or connecting unit.
4. Never allow a welding electrode to touch any cylinder.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
6. Turn face away from valve outlet when opening cylinder valve.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
!
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
WARNING
Engines can be dangerous.
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.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
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.
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.
1-
Manual 0-5045
AUTO-DARKENING WELDING HELMET
SAFETY INSTRUCTIONS
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
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
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the
State of California to cause birth defects and, in some
cases, cancer. (California Health & Safety code Sec.
25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
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.
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 0-5045
1-
SAFETY INSTRUCTIONS AUTO-DARKENING WELDING HELMET
1.03 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
115V 15A
X
%
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
Line Connection
Touch Start (GTAW)
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
t
Spot Time
Preflow Time
t1
t2
Postflow Time
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
t
Burnback Time
IPM
Inches Per Minute
MPM
Meters Per Minute
Voltage Input
Art # A-04130
1-
Manual 0-5045
AUTO-DARKENING WELDING HELMET
SAFETY INSTRUCTIONS
1.04 Precautions De Securite En Soudage A L’arc
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS
S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES
INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la
propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par
étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait
pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux
groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre.
Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions
de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.05 Dangers relatifs au soudage à l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension dès
la mise en circuit. Le circuit d’alimentation et les circuits
internes de l’équipement sont aussi sous tension dès
la mise en marche. En soudage automatique ou semiautomatique avec fil, ce dernier, le rouleau ou la bobine
de fil, le logement des galets d’entrainement et toutes les
pièces métalliques en contact avec le fil de soudage sont
sous tension. Un équipement inadéquatement installé ou
inadéquatement mis à la terre est dangereux.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de
la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
1. Ne touchez pas à des pièces sous tension.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
2. Portez des gants et des vêtements isolants, secs et non troués.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
3 Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
15. Fermez solidement tous les panneaux et les capots.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation
afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
Manual 0-5045
1-
SAFETY INSTRUCTIONS AUTO-DARKENING WELDING HELMET
AVERTISSEMENT
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux
et la peau. Le bruit causé par certains procédés peut
endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour
vous protéger le visage et les yeux lorsque vous soudez ou que
vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
Le soudage dégage des vapeurs et des fumées dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée
ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives
aux métaux, aux produits consummables, aux revêtements et aux
produits nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz protecteurs
de soudage peuvent déplacer l’oxygène de l’air et ainsi causer
des malaises ou la mort. Assurez-vous que l’air est propre à la
respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent
réagir avec des vapeurs et former des gaz hautement toxiques et
irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que
si l’espace est bien ventilé; si nécessaire portez un respirateur à
adduction d’air. Car ces revêtements et tout métal qui contient
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de
filtre oculaire
Brassage tendre
au chalumeau
toutes conditions
2
Brassage fort
au chalumeau
toutes conditions
3 ou 4
Opération de coupage
ou soudage
moins de 1 po. (25 mm)
moyen de 1 á 6 po. (25 á 150 mm)
épais
plus de 6 po. (150 mm)
moins de 1/8 po. (3 mm)
moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais
plus de 1/2 po. (12 mm)
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
2 ou 3
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
toutes conditions
12
4 ou 5
Soudage á l'hydrogène
atomique (AHW)
toutes conditions
12
5 ou 6
Soudage á l'arc avec
électrode de carbone (CAW)
toutes conditions
12
Soudage á l'arc Plasma (PAW)
toutes dimensions
12
Soudage aux gaz
mince
Nuance
de
filtre
oculaire
Soudage á l'arc sous gaz
avec fil plein (GMAW)
Oxycoupage
mince
Dimension d'électrode
ou
Epiasseur de métal ou
Intensité de courant
Opération de coupage
ou soudage
4 ou 5
Gougeage Air-Arc avec
électrode de carbone
5 ou 6
mince
12
6 ou 8
épais
14
1-
Manual 0-5045
AUTO-DARKENING WELDING HELMET
SAFETY INSTRUCTIONS
ces éléments peuvent dégager des fumées toxiques au moment
du soudage.
AVERTISSEMENT
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure
et l’équipement surchauffé peuvent causer un incendie
et des brûlures. Le contact accidentel de l’électrode ou
du fil-électrode avec un objet métallique peut provoquer
des étincelles, un échauffement ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et
d’incendie.
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou
lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication
P-1 de la CGA, identifiée dans la liste de documents ci-dessous.
AVERTISSEMENT
9. Ne dégelez pas les tuyaux avec un source de courant.
LES MOTEURS PEUVENT ETRE DANGEREUX
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact
lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en
cuir, une chemise épaisse, un pantalon revers, des bottines de
sécurité et un casque.
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
Manual 0-5045
Le carburant est hautement inflammable.
1. A r r ê t e z l e m o t e u r a v a n t d e v é r i f i e r l e n i v e a u e
carburant ou de faire le plein.
1-
SAFETY INSTRUCTIONS AUTO-DARKENING WELDING HELMET
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier le niveau au début du soudage.
AVERTISSEMENT
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des
outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour
l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
1.06 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, 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, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami,
FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR
PEUT BRULER LA PEAU ET LES YEUX.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association
canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430
Broadway, New York, NY 10018.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un
accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1-
Manual 0-5045
AUTO-DARKENING WELDING HELMET
SAFETY INSTRUCTIONS
1.07 Graphique de Symbole
Seulement certains de ces symboles apparaîtront sur votre modèle.
Sous Tension
Mono Phasé
Déroulement du Fil
Hors Tension
Trois Phasé
Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension
Tri-Phase Statique
Torch de Soudage
Tension dangereuse
Fréquence Convertisseur
Transformateur-Redresseur
Augmentez/Diminuer
Distant
Purge Du Gaz
Facteur de Marche
Mode Continu de
Soudure
Pourcentage
Soudure Par Point
Disjoncteur
Source AC Auxiliaire
X
%
Fusible
Panneau/Local
Intensité de Courant
Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)
Tension
Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)
Hertz (cycles/sec)
Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)
Fréquence
Decoupe Arc Carbone
(CAC-A)
t
Duréc du Pulse
Durée de Pré-Dèbit
t1
t2
Durée de Post-Dèbit
Détente à 2-Temps
Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.
Détente à 4-Temps
Négatif
Positif
Tension Constante
Ou Potentiel Constant
Courant Continue (DC)
Haute Température
Terre de Protection
Force d'Arc
Ligne
Amorçage de L’arc au
Contact (GTAW)
Connexion de la Ligne
Inductance Variable
Source Auxiliaire
115V 15A
Manual 0-5045
Courant Constant
V
Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.
t
Probléme de Terre
IPM
Pouces Par Minute
MPM
Mètres Par Minute
Tension
Classement de PriseSource Auxiliaire
Art # A-07639
1-10
INTRODUCTION AUTO-DARKENING WELDING HELMET
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
2.02 Equipment Identification
This Owner’s Manual applies to just specification or part
numbers listed on page i.
The product identification number is printed on the outer
shipping carton. Record this number on page i for future
reference.
To ensure safe operation, read the entire manual, including
the chapter 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.
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.
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 Thermal Arc 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
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
2-1
Manual 0-5045
AUTO-DARKENING WELDING HELMET
INTRODUCTION
2.04 Description: Auto-Darkening Welding Helmet
The Thermal Arc 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 AutoDarkening 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 Thermal Arc. Advice in this regard can be obtained by contacting
an accredited Thermal Arc Distributor.
This product or any of its parts should not be altered from standard specification without prior written approval of
Thermal Arc. 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 Thermal Arc.
Manual 0-5045
2-2
INTRODUCTION AUTO-DARKENING WELDING HELMET
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.
Welding Process
Manual Metal Arc Welding (Stick)
Gas Metal Arc Welding (Mig) with Heavy Metals
Gas Metal Arc Welding (Mig) with Light Alloys
Gas Tungsten Arc Welding (Tig)
Air – Arc Gouging
Plasma Arc Cutting
Plasma Arc Welding
Arc Current in Amps
60 − 100
100 − 150
150 − 200
200 − 300
300 − 450
Less than 125
125 − 175
175 − 250
250 − 350
350 − 450
Less than 175
175 − 225
225 − 300
300 − 400
30 − 70
70 − 125
125 − 200
200 − 300
300 − 350
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
Recommended Shade
#9
#10
#11
#12
#13
#9
#10
#10
#12
#13
#10
#11
#12
#13
#9
#10
#11
v#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 379:2003 for comprehensive information regarding Table 1.
2-3
Manual 0-5045
AUTO-DARKENING WELDING HELMET
!
INTRODUCTION
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 and EN 175 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.
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 1)
Auto-Darkening Filter Lens
Auto-Darkening Lens Part Number 454320
Note: Auto-Darkening Lens Part Number 454320 is fitted to the Thermal Arc Auto-Darkening Welding Helmet Product Part Numbers: W4012000, W4011700, W4011800 & W4011900. 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 Low Battery Indicator Weight 110mm x 90mm x 10mm
98mm x 46mm
1/20,000 second
2 Optical Sensors
3V Battery plus Solar Cell
3.5
9 - 13
-10C – 600C
-200C – 700C
Low - High
Min (0.1 sec) – Max (1 sec)
Automatic
Flashing LED
110g
NOTE 1
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 0-5045
2-4
INTRODUCTION AUTO-DARKENING WELDING HELMET
2.08 Contents
CONTENTS
Description
Quantity
Auto-Darkening Welding Helmet
1
Draw String Product Bag
1
Front Cover Lens
2
Rear Cover Lens
2
Operating Manual
1
2-5
Manual 0-5045
AUTO-DARKENING WELDING HELMET
Manual 0-5045
2-6
INTRODUCTION
OPERATION AUTO-DARKENING WELDING HELMET
SECTION 3:
OPERATION
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 whilst welding.
Please refer to the Harness adjustment instructions below.
4. Stop Angle Adjustment
1. Top Head Band
Art # A-08591_AB
Art # A-08588
To adjust the top of Head Band move the Head Band in
the direction of either arrow (as pictured) to align the
centre of the harness with centre of the Filter Lens viewing
window.
There are 3 stop positions available (as pictured) to adjust
the angle from the welders eyes to the Filter lens.
2. Back of Head Band
5. Helmet Tilt Position
Loosen Before Adjusting
Art # A-08589
To adjust the back of Head Band push down the Knob and
turn to the left or right to adjust to desired size.
3. Distance of Harness from Filter Lens
Art # A-08592
Art # A-08590
There are 3 positions possible that the Harness can be set
upon to achieve the desired distance between the welders
eyes and the Filter Lens.
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.
3-1
Manual 0-5045
AUTO-DARKENING WELDING HELMET
OPERATION
3.02 Auto-Darkening Filter Lens Controls
For your protection and maximum efficiency of your product, please study this information carefully before use.
1
2
3
4
5
6
Art # A-08595_AB
WELDING
GRINDING
7
1.00
Pro Auto-Darkening Filter Lens Controls
1. Battery Compartment: In order to remove the Auto-Darkening Filter Lens Battery the lens must be removed from
the Welding Helmet Shell. Refer to section 3.04. Once the Lens is removed, slide the Battery cover to the left and
replace with Battery type CR-2032.
2. Welding / Grinding Switch: This switch is used to select either welding or grinding mode.
3. Variable Shade Control: The shade control is used to adjust the shade level between 9-13. Manually adjust shade
to desired level as required for application. Please refer to SECTION 4: of this manual for recommended shade
levels for your application.
4. Sensitivity Control: The Sensitivity Control is designed to make the filter lens more responsive to different light
levels. Welding applications and processes produce differing light levels which in turn necessitate varying filter
lens sensitivity adjustments. Manually adjust the sensitivity level as required for application.
5. Delay Control: The delay control is used to adjust the hold time of the Filter Lens after welding is completed (i.e.
it is used to adjust the time taken for the Filter Lens to transition from dark to light state after the completion of
welding). Manually adjust delay time to desired level as required by application.
6. Low Battery Indicator: LED will flash when the Battery requires replacement. It is recommended that batteries be
replaced immediately when the low battery indicator is flashing. Refer to point 1 for battery replacement details.
7. Magnification Amount: This number indicates the magnification power provided by the Rear Cover Lens.
Manual 0-5045
3-2
OPERATION AUTO-DARKENING WELDING HELMET
3.03 Changing the 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 Thermal Arc replacement part.
1. Removing the Front Cover Lens
2. Installing the Front Cover Lens
Push and Hold down the Front Cover Lens holder button
one side at a time (as shown in Removal Step 1) and pull
out the Front Cover Lens toward the front (as shown in
Removal Step 2).
Align the Front Cover Lens within the slot of the Front
Cover Lens holder (as shown in Installation Step 1) one
side at a time. Then slide in the Front Cover Lens until it
firmly locks into place (as shown in picture D).
Repeat this step for the other side.
Repeat this step for the other side.
Installation Step 1
Removal Step 1
Art # A-08594
Art # A-08593
Removal Step 2
Installation Step 2
Ensure that the Front Cover Lens is securely in place
before use.
3-3
Manual 0-5045
AUTO-DARKENING WELDING HELMET
OPERATION
3.04 Removing the Auto-Darkening Filter Lens
The Auto-Darkening Filter Lens can be removed for service, adjustments, replacement and to change the battery.
1. Remove the Front Cover Lens. Refer to Section 3.03.
2. Locate the two locking tabs inside the helmet that secure the Auto-Darkening Filter Lens and push them firmly
downward until they clear the bottom corners of the lens. Refer to the image below (Rear Cover Lens removed for
clarity).
Auto Darkening Lens
Locking Tabs
3. Gently push the bottom of the Auto-Darkening Filter Lens inward from the outside of the helmet taking care not
to scratch or mar the front lens surface. Pull the lens out of its mounting slot from within the helmet and handle
it carefully. Refer to the image below (Rear Cover Lens removed for clarity).
Manual 0-5045
3-4
OPERATION AUTO-DARKENING WELDING HELMET
3.05 Changing the Rear Cover Lens
The Rear Cover Lens can be replaced if damaged or to change it to a different magnification level. The Auto-Darkening Welding Helmet comes with three different Rear Cover Lenses to accommodate various welding applications and
user's eyesight. Refer to the Spare Parts List in Section 4.04 for more details.
Rear Cover Lens Removal
1. Remove the Auto-Darkening Filter Lens from the helmet. Refer to Section 3.04.
2. Insert a thumbnail or a small flat-blade screwdriver into either clearance slot and gently pry the Rear Cover Lens
up very slightly to clear the retaining frame. At the same time, push the lens from the other side to slide it out of the retaining frame. Refer to the image below.
WELDING
GRINDING
1.00
Clearance Slot
WELDING
GRINDING
1.00
3-5
Manual 0-5045
AUTO-DARKENING WELDING HELMET
OPERATION
Rear Cover Lens Replacement
1. Position the replacement Rear Cover Lens with its magnification number up and facing out.
2. Tilt the lens downward to clear the retaining frame and engage its end into the start of the two mounting tabs at
either end of the frame.
3. Slide the lens all the way over until if goes under the other pair of mounting tabs and snaps into position. Refer to
the image below.
WELDING
GRINDING
Magnification
Number
2.00
A-09185_AB
Mounting Tab
Manual 0-5045
3-6
SERVICE AUTO-DARKENING WELDING HELMET
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 Thermal
Arc. Advice in this regard can be obtained by contacting an accredited Thermal Arc 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.
4-1
Manual 0-5045
AUTO-DARKENING WELDING HELMET
SERVICE
4.03 Basic Troubleshooting
FAULT
1.
2.
3.
4.
The Filter Lens does not operate.
The Filter Lens flickers or does
not darken.
Filter Lens stays dark after the
weld is extinguished or the Filter
Lens is dark when no arc is
present.
The center of the Filter Lens
viewing area appears darker
than the sides of the Filter Lens
viewing area.
CAUSE
REMEDY
A.
The Battery is discharged.
A.
Replace Battery with Type CR2032.
B
The Battery is not contacting
properly with battery contacts
points.
Front Cover Lens is dirty or
damaged.
Sensors are obstructed.
Sensors are obstructed.
Sensitivity Control not adjusted
correctly.
Ambient light level is too
bright.
This is a normal characteristic
of the LCD Lens.
B.
Adjust Battery contact points.
A.
Clean Cover Lens a soft cloth.
Replace if necessary.
Clean the Sensors with a soft cloth.
Clean the Sensors with a soft
cloth. Adjust the Sensitivity Control
accordingly.
Reduce the ambient light level in
the area.
Keep the viewing angle from the
object being welded as close as
possible to 90 degrees.
A.
B.
A.
B.
C.
A.
!
B.
A.
B.
C.
A.
WARNING
If the above troubleshooting recommendations do not resolve the problem, do not use the Auto-Darkening
Welding Helmet. Contact Thermal Arc for further information.
Manual 0-5045
4-2
SERVICE AUTO-DARKENING WELDING HELMET
4.04 Spare Parts
!
WARNING
Thermal Arc cannot be held responsible for the continuing performance of this Welding Helmet if nongenuine spare parts are used.
SPARE PARTS
Item No
Part Number
Description
Qty
1A
454332
Helmet Shell, USA
1
1B
454333
Helmet Shell, Canada
1
1C
454334
Helmet Shell, Claret
1
1D
454335
Helmet Shell, Black
1
2
454298TA
Front Cover Lens
1
3
454320
Auto-Darkening Filter Lens
1
4
454299
Rear Cover Lens
1
5
454330
2
6
454300
7
454301
Cover Lens Holder Button
Harness Assembly Complete
(Available as assembly only
Sweat Band
-
454302TA
-
454321
Magnifying Lens - 1.00 (not pictured)
-
454322
Magnifying Lens - 1.50 (not pictured)
-
454323
Magnifying Lens - 2.00 (not pictured)
-
454331
Battery - Type CR2032 (not pictured)
1
Product Bag - Welding Helmet (not pictured)
1
1
1
6
3
4
5
7
Art # A-08596
2
1
4-3
Manual 0-5045
AUTO-DARKENING WELDING HELMET
Manual 0-5045
4-4
SERVICE
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
November 2007
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company (“Thermal Arc”), warrants
to customers of authorized distributors (“Purchaser”) that its products will be free of defects
in workmanship or material. Should any failure to conform to this warranty appear within the
warranty period stated below, Thermal Arc shall, upon notification thereof and substantiation that
the product has been stored, installed, operated, and maintained in accordance with Thermal
Arc’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or damage, correct such defects by suitable
repair or replacement, at Thermal Arc’s sole option, of any components or parts of the product
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty of merchantability,
fitness for any particular purpose, or other warranty of quality, whether
express, implied, or statutory.
Limitation of liability: Thermal Arc shall not under any circumstances be liable for special, indirect,
incidental, or consequential damages, including but not limited to lost profits and business
interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of
Thermal Arc 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 Thermal Arc, whether arising out of contract, tort, including
negligence or strict liability, or under any warranty, or otherwise, shall not exceed the price of the
goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this warranty in
any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt.
Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment
of thermal’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 Thermal Arc’s sole judgment, impaired the safety or performance
of any Thermal Arc product. Purchaser’s rights under this warranty are void if the product is sold
to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the authorized
distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event
shall the warranty period extend more than the time stated plus one year from the date Thermal
Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Thermal Arc repair facility within thirty (30) days of purchaser’s
discovery of any defect. Thermal Arc shall pay no transportation costs of any kind 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 dated July 1st 2007 supersedes all previous Thermal Arc
warranties. Thermal Arc® is a Registered Trademark of Thermal Arc, Inc.
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
November 2007
SAFETY EQUIPMENT
Auto-Darkening Welding Helmet (Electronic Lens)
Harness Assembly
ENGINE DRIVEN WELDERS
Scout, Raider, Explorer
Original Main Power Stators and Inductors
Original Main Power Rectifiers, Control P.C. Boards
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors
Engines and associated components are NOT warranted by Thermal Arc,
although most are warranted by the engine manufacturer
GMAW/FCAW (MIG) WELDING EQUIPMENT
Fabricator 131, 181; 140; 180; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor
Original Main Power Rectifiers, Control PC Boards, power switch semi-conductors
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors.
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors.
PLASMA WELDING EQUIPMENT
Ultima 150
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors
Welding Console, Weld Controller, Weld Timer
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator.
SMAW (Stick) WELDING EQUIPMENT
Dragster 85
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors
160S, 300S, 400S
Original Main Power Magnetics
Original Main Power Rectifiers, Control P.C. Boards
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors
GENERAL ARC EQUIPMENT
Water Recirculators
Plasma Welding Torches
Gas Regulators (Supplied with power sources)
MIG and TIG Torches (Supplied with power sources)
Replacement repair parts
MIG, TIG and Plasma welding torch consumable items
Warranty Period
2 year
1 month
Warranty Period
Labor
2 year
1 month
Labor
3 years
3 years
3 years
3 years
1 year
1 year
See the Engine Manufactures’ Warranty for Details
Warranty Period
Labor
5 years
3 years
3 years
3 years
1 year
1 year
Warranty Period
Labor
5 years
3 years
3 years
3 years
1 year
Warranty Period
1 year
Labor
5 years
3 years
3 years
3 years
3 years
3 years
1 year
1 year
Warranty Period
Labor
1 year
1 year
1 year
1 year
1 year
1 year
5 years
3 years
3 years
3 years
1 year
1 year
Warranty Period
1 year
180 days
180 days
90 days
90 days
Nil
Labor
1 year
180 days
Nil
Nil
Nil
Nil
Declaration Of Conformity
Manufacturer and Merchandiser of Quality Consumables and Equipment: Thermal Arc
Address:
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
This model certified by: CERTOTTICA Scarl, Zona industriale Villnova
32013 Longaraone (BL), Italy – Notified Body Number: 0530
Description of equipment: Thermal Arc 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: 2003 applicable to Specification for welding filters with switchable luminous transmittance and welding
filters with dual luminous transmittance (variable shade)
• IEC/EN 60974-1 (EN50192) (EN50078) Arc Welding Equipment Part 1: Welding Power Supplies
• CSA Z94.3 applicable to Eye and Face Protectors
• ANSI Z87.1 applicable to Practice for Occupational and Educational Eye and Face Protection – Section 10
Welding Helmets
• 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.
Thermal Arc 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. Thermadyne 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
Thermadyne Europe
Europa Building
Chorley N Industrial Park
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: [email protected]
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
FAX:
(636) 728-3010
Email: [email protected]
www.thermalarc.com
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