Clarke PG4 Operation & Maintenance Instructions Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0518 iss 2

ARC ACTIVATED HEADSHIELD

MODEL NO: PG4

PART NO: 6000716

2

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

INTRODUCTION

Thank you for purchasing this CLARKE Headshield.

Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.

This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.

Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.

This guarantee does not effect your statutory rights.

TECHNICAL DATA

Viewing field (W x H) 98 X 43 mm

Shade available in Light State DIN 4

Shade available in Dark State DIN 9-13 Outside Adjustment

UV/IR protection Max shade DIN16 at all times

Operating temperature range

-5

o

C to +55oC

Weight 0.54 kg

Switching time from light to dark 1/30,000 second or 0.033ms

Delay time from dark to light 0.1 - 1.0 second

Light Filter power control Automatic

Power supply Solar Cells / Lithium Battery CR2450

Construction material Polyamide (flame retardant)

3

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

SAFETY PRECAUTIONS

This headshield is not suitable for laser welding, laser cutting or overhead
welding applications or for oxy-acetylene.

• The protective plate in this headshield is breakable and will not protect
against impact hazards. Never use the headshield without the protective
cover plate installed.

• This headshield is designed for use in grinding, arc welding or cutting
applications such as MIG/MAG, TIG, MMA, Plasma Arc and Carbon Arc.

• Use this headshield for face and eye protection against harmful rays,
sparks and spatter from welding and cutting.

• Never place this product on a hot surface.

• Stop using the headshield if the filter fails to change from light to dark.
Contact your Clarke dealer.

• Do not make any modifications to this product. Protection can be seriously
impaired if modifications are made.

• When necessary, use identical replacement parts. This will ensure that the
safety of the product is maintained.

• Do not use without the protective plate installed. Do not use if any part of
the headshield is cracked or broken.

• Do not use this headshield for welding outside the range of DIN 9-13. Harm
to the eyes and impaired eyesight may result. Always select the correct
setting before use.

INVENTORY

1 x Arc-activated solar/lithium powered welding headshield

2 x Spare outside lens covers 124 x 99 mm

1 x Spare inside lens cover 108 x 59 mm

4

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

PREPARATION & USE

ADJUSTING THE HEADBAND TO FIT

1. The headband should be
adjusted both in diameter and
height to fit the wearer’s head. To
do this, turn the adjustment knob
on the back of the headband
either left or right to expand or
contract the headband.

2. The top headband can be
adjusted by bending the strap
and positioning the peg in the
appropriate hole.

3. The working position of the
headshield and its raised position
can be pre-set.

4. Loosen the adjusting nuts until you
can lift the adjusting tab and
position it against the backing
plate to set the headband range
of movement. Tighten the
adjusting nut when satisfied.

5. You can remove the headband
completely from the headshield by squeezing the side clips together and
sliding it away from the adjusting knob assembly.

PREPARATION AND TESTING

1. Remove the protective film from the outer lens cover.

2. Unfasten the top and bottom
retaining clips and lift the filter
cartridge away while remaining
connected to the control devices
by the cable at each side.

5

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

3. Remove the outer lens cover from
the headshield and peel away
the protective film.

4. Clip the outer lens cover gently
back into position.

5. Clip the filter cartridge back into
position.

6. Lift and slide the inside lens cover
(on the operators side of the filter
cartridge) free from the filter
cartridge and peel away the
protective film. Re-fit the inside
lens cover.

7. When refitting the cartridge,
carefully seat it in position and
fold back the retaining clips to
secure.

8. Test to see that the Auto
Darkening Filter (ADF) is working,
set the shade to any setting and
press the TEST button inside the
headshield. The display should
change from light to dark and
then back to light when the
button is released. Confirm that
the LOW BATTERY light does not
light up.

9. You can also test the filter by
presenting any light source of greater than 400 lumens to the light sensor.
Check that the display becomes dark and automatically returns to a light
state when the light source is removed.

10. The lens will be set to Light DIN 4 state & you will be able to see the
workpiece. The lens will automatically darken when an arc is struck.

• If using at very low temperatures, the reaction time of the filter may

slow down but will still afford full protection.

11. Check also that the outer screen and lens are clean and clear at all times.

12. Change the shade setting as required using the shade adjustment knob as
described on page 5 and referring to the table on page 7.

6

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

SELECTING WELD OR GRIND SETTING

The headshield has a ‘GRIND’ setting,
on the selector knob. When set to
‘GRIND’ the auto darkening function
is disabled. The headshield then
provides eye and face protection for
sparks and airborne particles created
during grinding operations.

SELECTING THE SHADE SETTING

On striking an arc, the light created will activate the solar cell and the window
will automatically darken to a preset level. The lithium batteries will provide the
necessary energy to operate the headshield when there is no arc light.

You can adjust this shade level using the shade adjustment knob on the side of
the headshield, corresponding to the type of welding process.

• There are five levels available; 9, 10, 11, 12 and 13. Check the table

on page 7 to determine which you should select.

1. Set the helmet to WELD mode
using the switch on the left side of
the headshield.

2. Turn the shade selector to the
required setting.

• During the welding operation

the lens will automatically
darken to the pre-set shade.
On removal of the arc, the lens
will return to the light state.

WARNING: IT IS ESSENTIAL THAT AFTER USING THE HEADSHIELD IN
GRINDING MODE, IT SHOULD BE RETURNED TO THE WELD SETTING BEFORE
WELDING. FAILURE TO DO THIS COULD LEAD TO EYE INJURY. MAKE A
HABIT OF RETURNING THE SWITCH TO THE WELD SETTING.

WARNING: DO NOT USE FOR WELDING OUTSIDE THE RANGE OF DIN 9-13.
INJURY TO THE EYES & LOSS OF EYESIGHT MAY BE CAUSED. MAKE SURE
THAT WELDING MODE IS SELECTED BEFORE STRIKING AN ARC.

7

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

SHADE REFERENCE TABLE

The shade number can be manually set from 9-13 using the adjusting knob on
the left side of the headshield. Adjust the headshield to the correct shade
shown in the table above.

Shade numbers according to BS 379, DIN 4647-1 and EN 169.

DELAY TIME ADJUSTMENT

The delay time is the time taken to
switch back from fully dark to fully
light and is selected using the switch
on the right hand side of the
headshield.

1. Set the minimum (0.1-0.25 sec)
when spot welding, or doing short
or seam welding work.

2. Set the delay to medium for most
welding operations.

3. Set the maximum (0.85-1.0 sec) when doing high current welding.

SENSITIVITY

The sensitivity can be adjusted using the knob on the right hand side of the
headshield according to the type of welding and the background light. The
mid range selection is suitable for most indoor and outdoor welding.

1. Select maximum for low current welding or when working in low light
conditions, especially when welding argon arc with a low current.

2. Select minimum for high current welding or working in a brightly lit
environment.

8

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

CARE & MAINTENANCE

Damaged components must be replaced immediately to avoid risk of eye
and face injuries. Periodically inspect the filter cartridge and lens covers.
Cracked, pitted or scratched lenses reduce vision and seriously reduce the
level of protection and should be replaced with genuine, certified spare parts.

Never use sharp tools to remove foreign material sticking to the outer lens
cover. This may cause damage which may cause incorrect function and
invalidate the warranty.

The outer lens cover can be removed for replacement if damaged as
described on page 4 and may need replacing regularly.

• Two replacement outer lens covers are supplied with the

headshield.

The inner lens cover may also require cleaning. Lift and slide the inside lens
cover (on the operators side of the filter cartridge) free from the filter cartridge
as shown on page 5.

• A single replacement is supplied with this headshield.

Clean the filter surface, sensors and solar cells regularly by wiping with a
household glass cleaner. Apply the cleaner with a clean cloth or paper towel.
DO NOT USE ALCOHOL TO CLEAN. DO NOT APPLY CLEANER DIRECTLY TO THE
CARTRIDGE.

Clean the headshield shell and sweat bands with detergent if necessary.

BATTERY REPLACEMENT

The batteries should last
approximately 5000 hours of normal
use. If the LOW BATTERY lamp comes
on, (Low Volume Alarm), the battery
should be replaced.

9

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

The batteries are located in the back
of the welding and shade control
housings and can be removed after
pressing firmly on the cover plate and
sliding it away. Use a small blade to
lift the battery from its retaining clips.

• The headshield uses CR2450

Lithium batteries obtainable
from most electrical retailers.

STORAGE

Store the headshield in its box or similar safe place.

ENVIRONMENTAL PROTECTION

If broken, do not dispose of this product with general household waste. This
product contains valuable raw materials and should be disposed of
appropriately at a recognised disposal facility.

Through purchase of this product, the customer is taking on the obligation to
deal with the WEEE in accordance with the WEEE regulations in relation to the
treatment, recycling & recovery and environmentally sound disposal of the
WEEE.

This means that this product must not be disposed of with general household
waste. It must be disposed of according to the laws governing Waste
Electrical and Electronic Equipment (WEEE) at a recognised disposal facility.

10

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

COMPONENT PARTS

1 Headshield Shell 8 Sensitivity Control

2 Adjustable Headband 9 Filter Cartridge

3 Headband Adjustment parts 10 LCD

4. Angle/Distance Adjusting parts 11 Welding/Grinding Switch

5 Outside Lens Cover 12 Variable Shade Control

6 Battery Compartment 13 Inside Lens Cover

7 Time Delay Switch 14 Filter Cartridge Retaining Clip

11

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

DECLARATION OF CONFORMITY