AUTO ARC Explorer Series User manual
Explorer Series
Auto-Darkening Welding Helmets
OM-261 661B
2013−06
TABLE OF CONTENTS
SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −READ BEFORE USING 1
1-1. Symbol Usage 1.............................................................
1-2. Arc Welding Hazards 1........................................................
1-3. Proposition 65 Warnings 2.....................................................
1-4. Lens Shade Selection Table 3..................................................
1-5. Principal Safety Standards 3...................................................
SECTION 2 − SPECIFICATIONS 4.....................................................
SECTION 3 − OPERATING INSTRUCTIONS 5..........................................
3-1. Helmet Controls 5............................................................
3-2. Low Battery Indicator 5........................................................
3-3. Weld On/Grind On Switch 6....................................................
3-4. Lens Delay Control 6..........................................................
3-5. Variable Shade Control (No. 9 − 13) 7............................................
3-6. Sensitivity Control 8...........................................................
SECTION 4 − ADJUSTING HEADGEAR 9..............................................
SECTION 5 − REPLACING THE LENS COVERS 10.....................................
5-1. Replacing Outside Lens Cover 10...............................................
5-2. Replacing Inside Lens Cover 10................................................
SECTION 6 − REPLACING THE BATTERY 11..........................................
SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS 11..........................
SECTION 8 − MAINTENANCE 11.....................................................
SECTION 9 − TROUBLESHOOTING 12................................................
SECTION 10 − PARTS LIST 13.......................................................
SECTION 11 − LIMITED WARRANTY 13...............................................
OM-261 661 Page 1
SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −
READ BEFORE USING
helmet 2012−0
2
Protect yourself and others from injury — read, follow, and save these important safety
precautions and operating instructions.
1-1. Symbol Usage
This group of symbols means Warning! Watch
Out! ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols
and related instructions below for necessary
actions to avoid the hazards.
Indicates special instructions.
DANGER! − Indicates a hazardous
situation which, if not avoided, will
result in death or serious injury. The
possible hazards are shown in the
adjoining symbols or explained in
the text.
Indicates a hazardous situation
which, if not avoided, could result in
death or serious injury. The possible
hazards are shown in the adjoining
symbols or explained in the text.
NOTICE − Indicates statements not related to
personalinjury.
1-2. Arc Welding Hazards
Only qualified persons should install, operate, maintain, and repair this unit.
Arc rays from the welding process produce intense visible and invisible (ultraviolet
and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when
welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Refer to Lens
Shade Selection table in Section 1-4.
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash, glare, and sparks; warn
others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton,
and wool) and foot protection.
•Before welding, adjust the auto-darkening lens sensitivity setting to meet the application.
•Stop welding immediately if the auto-darkening lens does not darken when the arc is struck.
See the Owner’s Manual for more information.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviole
t
and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
Use impact resistant safety spectacles or goggles and ear protection at all times when using
this welding helmet.
Do not use this helmet while working with or around explosives or corrosive liquids.
Do not weld in the overhead position while using this helmet.
Inspect the auto-lens frequently. Immediately replace any scratched, cracked, or pitted cover
lenses or auto-lenses.
WELDING HELMETS do not provide unlimited eye, ear, an
d
face protection.
OM-261 661 Page 2
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
NOISE can damage hearing.
READ INSTRUCTIONS.
Readand follow all labels and the Owner’s Manual carefully before installing,
operating,or servicing unit. Read the safety information at the beginning of
the manual and in each section.
Use only genuine replacement parts from the manufacturer.
Performmaintenance and service according to the Owner’s Manuals, industry standards,
and national, state, and local codes.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be
hazardousto your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding
fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instructionsfor metals, consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator.
Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
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.
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 while wearing an air-
suppliedrespirator. The coatings and any metals containing these elements can give off toxic
fumes if welded.
1-3. Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known
to the State of California to cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to the state of California to cause
cancer, birth defects, or other reproductive harm. Wash hands after use.
OM-261 661 Page 3
1-4. Lens Shade Selection Table
Process ElectrodeSize
in. (mm) Arc Current
in
Amperes
Minimum
Protective
Shade No.
Suggested
Shade No.
(Comfort)*
Shielded Metal Arc
Welding (SMAW) Less than 3/32 (2.4)
3/32−5/32 (2.4−4.0)
5/32−1/4 (4.0−6.4)
More than 1/4 (6.4)
Less than 60
60−160
160−250
250−550
7
8
10
11
−−
10
12
14
Gas Metal
Arc Welding
(GMAW)
Flux Cored
Arc Welding
(FCAW)
Less than 60
60−160
160−250
250−500
7
10
10
10
−−
11
12
14
Gas Tungsten Arc
Welding (TIG) Less than 50
50−150
150−500
8
8
10
10
12
14
Air Carbon
Arc Cutting (CAC-A) Light
Heavy Less than 500
500−1000 10
11 12
14
Plasma Arc
Cutting (PAC) Less than 20
20−40
40−60
60−80
80−300
300−400
400−800
4
5
6
8
8
9
10
4
5
6
8
9
12
14
Plasma Arc Welding
(PAW) Less than 20
20−100
100−400
400−800
6
8
10
11
6−8
10
12
14
Reference: ANSI Z49.1:2005
* Start with a shade that is too dark to see the weld zone. Then, go to a lighter shade which gives a
sufficient view of the weld zone without going below the minimum.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free down-
load from the American Welding Society at http://www.aws.org or purchased from Global Engineering
Documents(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone:
212-642-4900, website: www.ansi.org).
OM-261 661 Page 4
SECTION 2 − SPECIFICATIONS
CartridgeDimensions 4.33 x 3.54 x 0.39 in. (110 x 90 x 10 mm)
Viewing Field 3.82 x 1.81 in. (97 x 46 mm)
Reaction Time 0.000083 Second (1/12,000 Second)
Available Shades Darkened State: No. 9 − No. 13 / Light State: No. 4
Sensors Independent/Redundant (Two)
Operating Temperature 23F to 131F / −5C to +55C
Whenstored in extremely cold temperatures, warm
helmetto ambient temperature before welding.
Storage Temperature 14F to 158F / −10C to +70C
Whenstored in extremely cold temperatures, warm
helmetto ambient temperature before welding.
Power Supply CR2450 Lithium Battery (1)
Total Weight 16.7 oz (475 g)
Standards ANSI Z87.1-2010 and DIN/CE/TUV/CSA
Warranty One Year From Date Of Purchase (See Section 11)
Sensitivity Control Light Levels Adjusts For Varying Ambient Light And Welding Arc
Delay Control Slows Lens Dark-To-Light State Between 0.1 And
1.0 Seconds (Infinite Dial Control)
Automatic Power Off Shuts Lens Off 15−20 Minutes After Welding Stops
Low Battery Indicator Red Led Light Goes On To Indicate Low Battery
Grind mode Yes
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-261 661 Page 5
SECTION 3 − OPERATING INSTRUCTIONS
3-1. Helmet Controls
The auto-darkening lens turns on
(darkens) automatically when
weldingbegins and turns off 15 −
20 minutes after welding stops.
1 Weld On/Grind On Switch (See
Section 3-3)
2 Variable Shade Control (See
Section 3-5)
3 Sensitivity Control
(See Section 3-6)
4 Delay Control
(See Section 3-4)
5 Battery Compartment (See
Section 6)
6 Low Battery Indicator
(See Section 3-2)
12345
6
3-2. Low Battery Indicator
The auto-darkening lens turns on
(darkens) automatically when
weldingbegins and turns off 15 −
20 minutes after welding stops.
1 Low Battery Indicator
The low battery indicator lights when
2−3 days of battery life remain.
If battery power is low, install new
CR2450lithium battery.
1
OM-261 661 Page 6
3-3. Weld On/Grind On Switch
1 Weld On/Grind On Switch
Do not weld in the Grind On mode;
the lens will not darken.
For Welding applications, move the
switch to the Weld On (up) position.
For grinding applications, move the
switch to the Grind On (down) posi-
tion.
1
3-4. Lens Delay Control
1 Lens Delay Control
The lens delay control is used to ad-
just the time for the lens to switch to
the clear state after welding.
The delay is particularly useful in
eliminatingbright after-rays present
in higher amperage applications
where the molten puddle remains
brightmomentarily after welding.
Lens delay adjusts from min (0.10
second) to max (1.0 second).
1
OM-261 661 Page 7
3-5. Variable Shade Control (No. 9 − 13)
1 VariableShade Control
(No. 9 − 13)
Use the control to adjust the lens
shade in the darkened state. Use
the table in Section 1-4 to select
proper shade control setting
based on your welding process.
Start at shade 12 or 13 and adjust
lighterto suit the welding applica-
tionand your personal preference.
1
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-261 661 Page 8
3-6. Sensitivity Control
1 Sensitivity Control
Use control to make the
lens more responsive to dif-
ferent light levels in various
welding processes. Use a
Mid-Range or 30−50%
sensitivity setting for
most applications.
It may be necessary to ad-
just helmet sensitivity to ac-
commodate different light-
ing conditions or if lens is
flashingOn and Off. Adjust
helmet sensitivity as fol-
lows:
Adjust helmet sensitiv-
ity in lighting conditions
helmetwill be used in.
Turn sensitivity control
to lowest setting.
Face the helmet in the
directionof use, expos-
ing it to the surrounding
light conditions.
Graduallyturn sensitiv-
ity setting clockwise
until the lens darkens,
then turn sensitivity
control counterclock-
wise until slightly past
setting where lens
clears. Helmet is ready
for use. Slight readjust-
ment may be neces-
sary for certain ap-
plications or if lens is
flashingon and off.
1
Recommended Sensitivity Settings
Stick Electrode Mid-Range
Short Circuiting (MIG) Low/Mid-Range
Pulsed & Spray (MIG) Mid-Range
Gas Tungsten Arc (TIG) Mid/High-Range
Plasma Arc Cutting/Welding Low/Mid-Range
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