Hobart HELMET: AUTO ARC EXPLORER AUTO-DARKENING User guide

OM-261 661B
2013−06

Explorer Series

Auto-Darkening Welding Helmets

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...............................................

SECTION 1 − WELDING HELMET SAFETY PRECAUTIONS −

2

t

d

READ BEFORE USING

helmet 2012−0

Protect yourself and others from injury — read, follow, and save these important safety
precautions and operating instructions.

1-1. Symbol Usage

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 o r serious injury. The possible
hazards are shown in the adjoining
symbols or explained in the text.

NOTICE − Indicates statements not related to

personal injury.

 Indicates special instructions.

This group of symbols means Warning! W atch
Out! ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols
and related instructions below for necessary
actions to avoid the hazards.

1-2. Arc Welding Hazards

Only qualified persons should install, operate, maintain, and repair this unit.

ARC RAYS can burn eyes and skin.

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.

WELDING HELMETS do not provide unlimited eye, ear, an
face protection.

Arc rays from the welding process produce intense visible and invisible (ultraviole
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.

OM-261 661 Page 1

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.
 W ear approved ear protection if noise level is high.

READ INSTRUCTIONS.

 Read and 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.
 Perform maintenance 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
hazardous t o 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

instructions for 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 air­supplied respirator. 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 2

1-4. Lens Shade Selection Table

Process

Shielded Metal Arc

Welding (SMAW)

Gas Metal

Arc Welding

(GMAW)

Flux Cored

Arc Welding

(FCAW)

Gas Tungsten Arc

Welding (TIG)

Air Carbon

Arc Cutting (CAC-A)

Plasma Arc

Cutting (PAC)

Plasma Arc Welding

(PAW)

Electrode Size

in. (mm)

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)

Light

Heavy

Arc Current

in

Amperes

Less than 60

60−160
160−250
250−550

Less than 60

60−160
160−250
250−500

Less than 50

50−150
150−500

Less than 500

500−1000

Less than 20

20−40
40−60
60−80

80−300
300−400
400−800

Less than 20

20−100
100−400
400−800

Minimum
Protective
Shade No.

7

8
10
11

7
10
10
10

8

8
10

10
11

4

5

6

8

8

9
10

6

8
10
11

Suggested

Shade No.
(Comfort)*

−−
10
12
14

−−
11
12
14

10
12
14

12
14

4
5
6
8

9
12
14

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 down­load f r o m the American W elding Society at http://www.aws.org or purchased from Global Engineering
Documents (phone: [phone], 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 3

SECTION 2 − SPECIFICATIONS

Notes

Cartridge Dimensions 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 23F to 131F / −5C to +55C

 When stored in extremely cold temperatures, warm

helmet t o ambient temperature before welding.

Storage Temperature 14F to 158F / −10C to +70C

 When stored in extremely cold temperatures, warm

helmet t o 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 Y ear From Date Of Purchase (See Section 11)
Sensitivity Control Light Levels Adjusts For Varying Ambient Light And W elding Arc
Delay Control Slows Lens Dark-To-Light State Between 0.1 And

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

1.0 Seconds (Infinite Dial Control)

OM-261 661 Page 4

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

SECTION 3 − OPERATING INSTRUCTIONS

3-1. Helmet Controls

2345

1

6

3-2. Low Battery Indicator

 The auto-darkening lens turns on

(darkens) automatically when
welding begins 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)

 The auto-darkening lens turns on

(darkens) automatically when
welding begins and turns off 15 −
20 minutes after welding stops.

1

1 Low Battery Indicator
The low battery indicator lights when

2−3 days of battery life remain.
If battery power is low, install new

CR2450 lithium battery.

OM-261 661 Page 5

3-3. Weld On/Grind On Switch

1

3-4. Lens Delay Control

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) posi­tion.

OM-261 661 Page 6

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.

1

The delay is particularly useful in
eliminating bright after-rays present
in higher amperage applications
where the molten puddle remains
bright momentarily after welding.

Lens delay adjusts from min (0.10
second) to max (1.0 second).

3-5. Variable Shade Control (No. 9 − 13)

Notes

1

1 Variable Shade 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
lighter to suit the welding applica­tion and your personal preference.

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-261 661 Page 7

3-6. Sensitivity Control

1

1 Sensitivity Control
Use control to make the

lens more responsive to dif­ferent light levels in various
welding processes. Use a

Mid-Range or 30−50%
sensitivity setting for
most applications.

It may be necessary to ad­just helmet sensitivity to ac­commodate different light­ing conditions or if lens is
flashing On and Off. Adjust

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

OM-261 661 Page 8

helmet sensitivity as fol­lows:

 Adjust helmet sensitiv-

ity in lighting conditions
helmet will be used in.

 Turn sensitivity control

to lowest setting.

 Face the helmet in the

direction o f use, expos­ing it to the surrounding
light conditions.

Recommended Sensitivity Settings

 Gradually turn sensitiv-

ity setting clockwise
until the lens darkens,
then turn sensitivity
control counterclock­wise until slightly past
setting where lens
clears. Helmet is ready
for use. Slight readjust­ment may be neces­sary for certain ap­plications or if lens is
flashing o n and off.

SECTION 4 − ADJUSTING HEADGEAR

 The helmet view is typical of all

 There are four headgear adjust-

1

3

1 Headgear Top
Adjusts headgear for proper depth

on the head to ensure correct bal­ance and stability.

2 Headgear Tightness
T o adjust, turn knob left or right to de-

sired tightness.

 If adjustment is limited, it may be

3 Distance Adjustment
Adjusts the distance between the

face and the lens. To adjust, loosen
both outside tension knobs and
press inward to free from adjustment

2

4

slots. Move forward or back to de­sired position and retighten. (Both
sides must be equally positioned for
proper vision.)

4 Angle Adjustment
Five pins on the right side of the

headband top provide adjustment
for the forward tilt of the helmet. To
adjust, loosen the right outside ten­sion adjustment knob then lift on the
control arm tab and move it to the de­sired position. Retighten tension ad­justment knob.

units. Your helmet may differ
slightly from that shown.

ments: headgear top, tightness,
angle adjustment, and distance
adjustment.

necessary to remove the com­fort cushion.

 When using the back distance

adjustment positions, only the
back three angle adjustment
pins can be used.

OM-261 661 Page 9

SECTION 5 − REPLACING THE LENS COVERS

-

.

r

l

-

f

-

5-1. Replacing Outside Lens Cover

Never use the auto-darkening lens without the inside and outside lens covers properly
installed. Welding spatter will damage the auto-darkening lens and void the warranty

Place helmet on a flat surface. Grasp the front lens holder with one hand while pushing the inside re­taining clips of the lens holder outward. Do one side at a time, gently pulling the front lens holder away
from the helmet as each tab is released from its retaining clip. Once released, the outside cover lens
can be replaced.

5-2. Replacing Inside Lens Cover

! Never use the auto-darkening lens

without the inside and outside lens
covers properly installed. Welding
spatter will damage the auto-dark
ening lens and void the warranty.

1 inside Lens Cover
Remove the auto-darkening lens assembly

by following the procedure in Section 5-1
With the auto-darkening lens removed

from the helmet, remove the inside cove
lens by prying the lens up at the thumbnai
opening located at the top center of the cov
er lens.

Replace the lens by gently bowing it in the
center and inserting it, one end a time, into
the retaining clips located on the outside o
the auto-darkening lens assembly.

OM-261 661 Page 10

 Be sure the cover lens is seated prop

erly (flat) to prevent fogging.

1

SECTION 6 − REPLACING THE BATTERY

1 Battery Cover
Remove battery by turning battery

cover counterclockwise.
Replace with CR2450 lithium battery.

1

 Be sure Positive (+) side of the

battery faces up (toward inside of
helmet).

SECTION 7 − INSTALLING OPTIONAL MAGNIFYING LENS

1 Optional Magnifying Lens
Release lower lens retainer clip.

Starting a t the bottom, slide magni­fying lens into the helmet retaining
brackets. Align the magnifying lens
with the auto-darkening lens as­sembly.

Reverse procedure to remove
magnifying lens.

 T o prevent lens fogging, install

flat side of magnifying lens to-

1

ward auto-darkening lens.

SECTION 8 − MAINTENANCE

NOTICE − Never use solvents or abrasive cleaning detergents. Do not immerse the lens assembly
in water.

The helmet requires little maintenance. However, for best performance clean after each use. Using
a soft cloth dampened with a mild soap and water solution, wipe the cover lenses clean. Allow to air
dry. Occasionally, the filter lens and sensors should be cleaned by gently wiping with a soft, dry cloth.

OM-261 661 Page 11

SECTION 9 − TROUBLESHOOTING

Trouble Remedy

Auto lens not On – auto­lens will not darken mo­mentarily when exposed to
welding arc.

Auto-lens not switching –
auto-lens stays light and
will not darken when
welding or cutting.

Auto-lens not switching –
auto-lens stays dark after
the weld arc is extin­guished, or the auto-lens
stays dark when no arc is
present.

Sections of the auto-lens
are not going dark, distinct
lines separate the light and
dark areas.

Switching or Flickering –
the auto-lens darkens then
lightens while the welding
arc is present.

Check batteries and verify they are in good condition and installed
properly. Also, check battery surfaces and contacts and clean if
necessary. Check battery for proper contact and gently adjust
contact points if necessary. This is particularly important if the
helmet has been dropped.

Stop welding immediately.
Make sure the lens is in the Weld On mode. When in the Weld On

mode the lens will darken for welding applications. Do not weld in
the Grind On mode; the lens will not darken.

Make sure the lens is turned On. If power is on, review the sensi­tivity recommendations and adjust sensitivity. Clean lens cover
and sensors of any obstructions. Make sure the sensors are fac­ing the arc; angles of 45 or more may not allow the arc light to
reach the sensors.

Fine-tune the sensitivity setting by making small adjustments to
the control by turning it toward the “min” setting. In extreme light
conditions, it may be necessary to reduce the surrounding light
levels.

Stop welding immediately.
The auto-lens may be cracked which can be caused by the im-

pact of dropping the helmet. Weld spatter on the auto lens may
also cause cracking. (The lens may need to be replaced; most
cracked lenses are not covered by warranty).

Review the sensitivity setting recommendations and increase the
sensitivity if possible. Be sure the arc sensors are not being
blocked from direct access to the arc light. Check the lens cover
for dirt and spatter that may be blocking the arc sensors. Increas­ing Lens Delay 0.1–0.3 second may also reduce switching.

Inconsistent or lighter
auto-lens shading in the
dark-state, noticeable on
the outside edges and cor­ners.

OM-261 661 Page 12

Referred to as an angle of view effect, auto-darkening lenses
have an optimum viewing angle. The optimum viewing angle is
perpendicular or 90 to the surface of the auto-lens. When that
angle of view varies in the dark-state, welders may notice slightly
lighter areas at the outside edges and the corners of the lens. This
is normal and does not represent any health or safety hazard.
This effect may also be more noticeable in applications where
magnifying lenses are used.

SECTION 10 − PARTS LIST

3

1

2

4

Ref. 803 935

Figure 10-1. Explorer Series Auto-Darkening Welding Helmets

Item

No. Quantity

Part

No.

Description

Figure 10-1. Explorer Series Auto-Darkening Welding Helmets

1 *770 425 Kit, Lens Cover Flat Black 1............. ...... .........................

1 *770 426 Kit, Lens Cover Gloss Black 1............. ...... .......................

1 *770 493 Kit, Clear Lens (Bezel Not Included) 1............. ...... ................

2 770 769 Lens, Helmet Auto Darkening 1.............. ...... ......................

3 770 433 Ratchet Headgear Assy. 1.............. ...... ..........................

4 ♦770 274 Lens, 1.50 Magnification (Not Shown) 1............ ...... ...............

4 ♦770 275 Lens, 1.75 Magnification (Not Shown) 1............ ...... ...............

4 ♦770 276 Lens, 2.00 Magnification (Not Shown) 1............ ...... ...............

4 ♦770 277 Lens, 2.25 Magnification (Not Shown) 1............ ...... ...............

* Includes bezel, front lens cover gasket, 5 front lens covers, 2 inside lens covers.

(5 Outside Lenses, 5 Inside Lenses).............................. ................

Battery, Lithium CR2450 (Not Shown) 1.............................. ...............

♦ Optional

SECTION 11 − LIMITED WARRANTY

LIMITED WARRANTY – Subject to the terms and conditions below. Hobart Brothers

Co., T roy, Ohio, warrants to its original retail purchaser that the new Auto Arc equip­ment sold after the effective date of this limited warranty is free of defects in material
and workmanship at the time it is purchased at the retailer. THIS W ARRANTY IS EX­PRESSL Y IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, IN­CLUDING THE WARRANTIES OR MERCHANTABILITY AND FITNESS.

Auto Arc auto-darkening lens helmets are warranted for one (1) year from the date
of purchase. Proof of purchase is required for warranty transactions so it is

imperative that a copy of the original invoice or sales receipt be retained.
For warranty transactions, contact your original Auto Arc retailer or call

1−800−332−3281

AutArc Helm 2013-01

Effective January 1, 2013

OM-261 661 Page 13

Hobart Brothers Co.

2200 Corporate Drive

Troy, OH 45373 USA

Phone: [phone] (Warranty Service)

or 800−626−9420 (Product Information)

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ORIGINAL INSTRUCTIONS © 2013 Hobart Welding Products